Comparative Strength Analysis of Helical Gears with Different Tooth Profiles Using FEM

This paper presents a strength analysis of helical gears for several selected tooth profiles. Four analogous gear design solutions with identical geometry and functional features were compared, with differences limited solely to the parameters of the gear rim. The primary focus of the research was on gears featuring convex–concave profiles based on Novikov and sinusoidal tooth profiles, which were compared against the standard involute profile. Solid models of the investigated gears were prepared using a CAD (Computer-Aided Design) method developed by the authors. The modelling process, which replicates the generating gear cutting method, allowed for highly accurate gear models to be obtained. The computational models of circular-arc tooth profile gears prepared in this manner were subsequently used for numerical FEM (Finite Element Method) analyses in ANSYS 2025 R2 software. As part of the numerical computations, instantaneous contact patterns and total contact patterns for the loaded gear drive were determined. Furthermore, the stress state at the tooth root and the surface stresses on the contacting tooth flanks were specified. Stress plots in these critical areas, which are essential for gear strength, were generated alongside distribution maps of regions prone to failure. Finally, an evaluation and comparative analysis of the results obtained for all considered gear models were conducted. The conclusions derived from the study provide insights into the stress distribution within critical regions of gears with different circular-arc tooth profiles.