A gear tooth profile optimization study is performed with the target being defined as the maximization of tooth bending fatigue life for a selected operational range, where the operating torque and speed ranges are defined along with their corresponding durations. For this purpose, a nonlinear lumped gear dynamics model is combined with the S/N curve of the gear material in order to estimate tooth bending fatigue life of the spur gear pair. The differences between the predicted lives of the optimally modified and non-modified gear pairs are presented based on example spur gear pairs. The proposed tooth bending fatigue life estimation is compared with the standard AGMA procedure.

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