Abstract
Gears are most critical components in mechanical power transmission systems. Helical gear is used to transmit power or torque at high speed, heavy loads with smooth and silent operation. It involves many variables including specific materials with consideration of force/stress analysis and its mechanical properties. The optimal design and its lead curve is the primary objective of the present work. The bending and surface strength of the gear tooth is considered to be the main contributors to gear failure. Thus, stress analysis on gear is vital to reduce the failures for optimal design. Analytical design for helical gear has been done with five different sets of parameters and then 3D modelling and FEM carried out with 30 cases and optimization was carried out to derive the best selection so that the fillet stress can be reduced and the life can be improved. The optimum lead curve is determined by the design of the experiment, transmission error calculation and response surface method. The results obtained in analytical design and FEM have been validated and it has been observed that by means of life it’s clear that Nickel alloy MP35N is more valuable and better material for manufacturing helical gear.