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Machine Theory
Mechanism and Machine Theory 43 (2008) 829–858
ate/mechmt
Optimization of asymmetric spur gear drives to improve
the bending load capacity
V. Senthil Kumar, . Muni, G. Muthuveerappan *
Indian Institute of Technology Madras, Department of Mechanical Engineering, Chennai, Tamilnadu 600 036, India
Received 10 October 2006; received in revised form 30 May 2007; accepted 27 June 2007
Available online 13 August 2007
Abstract
In a given size of symmetric involute gear designed through conventional approach, as the load carrying capacity is
restricted at the higher pressure angle due to tipping formation, the use of the asymmetric toothed gear to improve the
fillet capacity in bending is examined in this study. Non-standard asymmetric rack cutters with required pressure angles
and module are developed to generate the required pinion and gear of a drive with asymmetric involute surfaces and tro-
choidal fillet profiles. The respective profiles thus generated are optimized for balanced fillet stresses that are equal and
possibly the lowest also. For this study of optimization, several non-standard asymmetric rack cutters are designed to
modate binations in the values of pressure angle, top land thickness ratio, profile shift, speed ratio
and the asymmetric factors. However for any drive with a given center distance and a speed ratio, only two non-standard
asymmetric rack cutters, one for the pinion and other for the gear are used to generate a required numbers of pinion and
gear with different cutter shift values for the purpose of optimization. The influence of these parameters on the maximum
fillet stress has been analyzed to suggest the optimum values of these parameters that improve the fillet capacity in bending.
The optimization of the asymmetric spur gear drive is carried out using an iterative procedure on the calculated maximum
fillet stresses through FEM for different rack cutter shifts and final