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Static Structural Analysis of a Spur gear pair for contact stress and bending stress

Author(s) Rajendra Wasnik, Prof. Dr. Manish Joshi, Prof. Dr. Suraj Prasad
Country India
Abstract Gear tooth failure attributable to surface pitting and root fracture remains a persistent challenge in mechanical power transmission design. This work investigates the static structural response of a 20MnCr5 steel involute spur gear pair through a parametric finite element study conducted within an ANSYS Workbench environment. A three-factor full-factorial experiment encompassing module (3, 4, 5 mm), face width (20, 25, 30 mm), and tangential load (500–2000 N) was executed over 36 simulation runs. For each run, the solver extracted maximum Hertzian contact pressure, peak root bending stress, equivalent von Mises stress, total elastic deformation, and the corresponding bending safety factor. Statistical processing through descriptive analysis, log-linear regression (R² = 0.999 and 1.000), and hypothesis testing demonstrated that both module and face width are significant stress-mitigating parameters, while tangential load drives stress upward. Transitioning from the smallest to the largest tested geometry at maximum load achieved a 37.2 % contact-pressure reduction and a 61.2 % bending-stress reduction. The study provides a replicable, data-driven framework for gear design screening that substantially reduces reliance on physical prototyping at the early engineering stage.
Keywords ANSYS Workbench; bending stress; contact pressure; design of experiments; finite element analysis; spur gear; static structural analysis; 20MnCr5 steel.
Field Engineering
Published In Volume 7, Issue 9, September 2026
Published On 2026-09-28
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IJLRP's Crossref DOI prefix is
10.70528/IJLRP

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