Numerical study of rim thickness effects on tooth root stress in metal-composite gears

Hybrid metal-composite gears, which combine the strengths of traditional metal gears with advanced composite materials, have become a promising solution for various industrial applications. This study presents a comprehensive numerical analysis of the influence of rim thickness on tooth root stress in metal-composite gears. In the process of manufacturing composite gears, the gear body is replaced with a composite, excluding the hub and rim, which remain metallic. This analysis includes proportional scaling of the rim thickness while keeping other parameters constant to assess its impact on root stress distribution. Six different cases are examined. In each case, various gear configurations are considered, starting from a fully metal gear and moving to hybrid metal-composite gears with varying rim thicknesses. Ansys Workbench is used for the analysis, and the results are verified with analytical calculations according to ISO 6336-3. This study establishes a deeper understanding of the compromise between rim thickness and stress distribution. The conclusions gained from this study can guide gear engineers in optimizing the design of hybrid metal-composite gears.