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Tooth root form and fillet radius have a great influence on gear tooth root strength that is one of the primary subjects of this paper. Special attention is given to analysis on impact of gear tooth fillet radius at the critical cross section on stress value and distribution. A first initial crack appears at the gear tooth and it is affected, the most, by root stress concentration. Hence, this paper's research topic is focused on finding the optimal fillet tooth root radius to minimize the tooth root stress intensity. This paper provides results achieved by application of numerical methods - finite element method (FEM) and real working conditions simulation. The results of this analysis are presented as figures and tables of Von Mises and normal stresses as well as charts against different values of tooth root fillet radius ρF in two case: with one tooth root fillet radius ρF and with two fillet radii ρF1 and ρF2 ('two level approach' in a root).

Gear tooth rooth stress and fillet radii dependence