Design and Computational Analysis of Hybrid Carbon Fiber-Enhanced Metal Matrix Composite Spur Gears

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 158 172
    By

    Rishikesh Hanmant Tike,

  • Nitish Kumar Gautam,

  • Prasanna C. Kattimani,

  • Narendra Bhople,

  • Ritesh Fegade,

  • Rupendra Nehete,

  • Vithoba Tale,

  • Ramakant Chaudhari,

  1. Assistant Professor, Department of Mechanical Engineering, Progressive Education Society’s Modern College of Engineering, Shivajinagar, Pune, Maharashtra, India
  2. Associate Professor and HOD, Department of Mechanical Engineering, Shri Jagdishprasad Jhabarmal Tibrewala University, Vidyanagri, Jhunjhunu, Rajasthan, India
  3. Assistant Professor, Department of Automation & Robotics Engineering, Army Institute of Technology, Dighi Hills, Pune, Maharashtra, India
  4. Associate Professor, Department of Mechanical Engineering, College of Military Engineering Dapodi, Pune, Maharashtra, India
  5. Associate Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitribai Phule Pune University, Wagholi, Pune, Maharashtra, India
  6. Professor, Department of Mechanical Engineering, SIES Graduate School of Technology, Navi Mumbai, Maharashtra, India
  7. Associate Professor, Department of Mechanical Engineering, Rajarshi Shahu College of Engineering, Tathawade, Pune, Maharashtra, India
  8. Assistant Professor, Department of Mechanical Engineering, Padmashri Dr. V. B. Kolte College of Engineering, Malkapur, Maharashtra, India

Abstract

The automobile industry has to find the alternative solution for steel grade gears to overcome the weight to high strength ratio and thermal consideration with high damping properties. This study describes the design, FEM analysis, and performance evaluation of three new hybrid composite spur gears: a monolithic carbon fiber/epoxy (80/20 weight percent) composite (A), and two hybrids with steel (B) and aluminum (C) matrices (64% CF, 21% Epoxy, 15% metal). Composite A, with a density of 1710 kg/m³, achieved a superior yield strength of 1096 MPa and a Young’s modulus of 323 GPa using Taguchi optimization. Finite Element Analysis (FEA) evaluated theoretical models under a static load of 303.75 N and found that all composites superior to SCM420 steel by significantly. Composite A showed a 38.2% reduction in deformation (0.00134 mm as opposed to steel’s 0.00217 mm) while maintaining a controllable von Mises stress of 45.06 MPa. Composite A’s specific stiffness (E/ρ) was roughly 5.8 times higher than steel’s. Strong agreement in deformation trends is found in a comparative analysis with recent literature on fiber-reinforced gears; however, the unique contribution of our metal-matrix hybridization approach in customizing stress distribution is also highlighted. With FEA results offering a high-confidence predictive model for future manufacturing, this work unequivocally shows that carbon fiber composites, especially the monolithic design, offer a revolutionary solution for lightweight, high-stiffness automotive gearing.

Keywords: Static analysis, Taguchi method, Optimization, Reinforcement, Composite gear.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Rishikesh Hanmant Tike, Nitish Kumar Gautam, Prasanna C. Kattimani, Narendra Bhople, Ritesh Fegade, Rupendra Nehete, Vithoba Tale, Ramakant Chaudhari. Design and Computational Analysis of Hybrid Carbon Fiber-Enhanced Metal Matrix Composite Spur Gears. Journal of Polymer & Composites. 2026; 14(01):158-172.
How to cite this URL:
Rishikesh Hanmant Tike, Nitish Kumar Gautam, Prasanna C. Kattimani, Narendra Bhople, Ritesh Fegade, Rupendra Nehete, Vithoba Tale, Ramakant Chaudhari. Design and Computational Analysis of Hybrid Carbon Fiber-Enhanced Metal Matrix Composite Spur Gears. Journal of Polymer & Composites. 2026; 14(01):158-172. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236381


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Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 10/09/2025
Accepted 22/11/2025
Published 27/01/2026
Publication Time 139 Days
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