Anushka Mukherjee,
- Student, Department of Mechanical Engineering, United College of Engineering and Research, Prayagaraj, Uttar Pradesh, India
Abstract
Helical gears are widely used in modern power‐transmission systems because of their high load‐carrying capacity, smooth meshing action, and increased overlapping of gear teeth. However, the design of helical gear pairs is constrained by contact stresses generated at the mating tooth surfaces, which can lead to surface fatigue (pitting), micro-cracking, and ultimately gear failure. Traditional analytical methods, such as those of the American Gear Manufacturers Association (AGMA) or International Organization for Standardization (ISO 6336) standards, provide simplified estimates of Hertzian contact stress but fail to capture the full complexity of three-dimensional geometry, helix angle effects, surface curvature changes, material non-uniformities, and frictional sliding. In this research work, a three-dimensional finite element modelling (FEM) methodology is developed for helical gear pairs to compute contact stress distributions throughout the meshing cycle. The model accounts for accurate involute geometry generation, helical cutting, proper contact definitions (including frictional effects), and elastic deformation of both pinion and gear. Parametric studies are carried out to explore the effects of helix angle, face width, module, material elastic modulus, and coefficient of friction on peak contact stresses. The results show that increasing helix angle and face width tend to reduce peak contact stresses, though friction may offset these benefits since sliding in the contact region modifies stress concentration. Validation against analytical Hertz/AGMA results shows close agreement under simple conditions, but the FEM model reveals local stress peaks that exceed analytical predictions, especially for larger helix angles or when material deflection is significant. The findings suggest that FEM is a valuable complement to standard design methods for optimizing gear geometry, material selection, and life prediction in high‐performance helical gear systems
Keywords: Finite element analysis (FEA), contact stress, helical gears, gear tooth contact, stress distribution
[This article belongs to Trends in Machine design ]
Anushka Mukherjee. Finite Element Modelling of Contact Stresses in Helical Gear Systems. Trends in Machine design. 2025; 12(03):35-39.
Anushka Mukherjee. Finite Element Modelling of Contact Stresses in Helical Gear Systems. Trends in Machine design. 2025; 12(03):35-39. Available from: https://journals.stmjournals.com/tmd/article=2025/view=235063
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Trends in Machine design
| Volume | 12 |
| Issue | 03 |
| Received | 31/10/2025 |
| Accepted | 11/11/2025 |
| Published | 25/11/2025 |
| Publication Time | 25 Days |
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