Gear Designer

Gear geometry, ratios, contact stress and module selection.

⚙️ Spur Gear DesignerDesign and analyze spur gear pairs with geometry, stress, and efficiency calculations (AGMA methods)
Gear ParametersModule
Pressure Angle
Pinion Teeth 
Gear Teeth 
Face Width (mm)
Operating ConditionsInput Speed (RPM)
Input Torque (Nm)
Material
Gear GeometryGear Ratio
3.000
Center Distance
72.00mm
Pinion PD
36.00mm
Gear PD
108.00mm
Pinion OD
40.00mm
Gear OD
112.00mm
Contact Ratio
1.65
Circular Pitch
6.28mm
Stress Analysis & Safety FactorsBending Stress
295.06MPa
Contact Stress
716.05MPa
Tangential Force
555.56N
Radial Force
202.21N
Bending SF
1.36
Contact SF
1.96
Pitch Line Vel
2.83m/s
Dynamic Factor
1.46
Power TransmissionInput Power
1570.80W
Output Power
1535.83W
Output Speed
500.00RPM
Output Torque
29.33Nm
Efficiency
97.8%
Power Loss
34.96W
Mass EstimatePinion Mass
147.97g
Gear Mass
1160.08g
Total Mass
1308.05g
Material
AISI 4140 Steel
Safety Factor vs ModuleBending safety factor for different module sizes at current torque
Speed ReductionInput vs output speed comparison
Design Notes• Contact Ratio: Should be ≥1.2 for smooth operation. Current: 1.65
• Minimum Pinion Teeth: 17 teeth for 20° pressure angle to avoid undercutting (12 with profile shift)
• Face Width: Typically 8-16× module for proper load distribution
• Safety Factors: Bending SF ≥1.5, Contact SF ≥1.2 recommended for industrial applications
• Calculations: Based on AGMA 2001 simplified methods with Lewis bending stress and Hertzian contact stress

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⚙️ Spur Gear DesignerDesign and analyze spur gear pairs with geometry, stress, and efficiency calculations (AGMA methods)
Gear ParametersModule
Pressure Angle
Pinion Teeth 
Gear Teeth 
Face Width (mm)
Operating ConditionsInput Speed (RPM)
Input Torque (Nm)
Material
Gear GeometryGear Ratio
3.000
Center Distance
72.00mm
Pinion PD
36.00mm
Gear PD
108.00mm
Pinion OD
40.00mm
Gear OD
112.00mm
Contact Ratio
1.65
Circular Pitch
6.28mm
Stress Analysis & Safety FactorsBending Stress
295.06MPa
Contact Stress
716.05MPa
Tangential Force
555.56N
Radial Force
202.21N
Bending SF
1.36
Contact SF
1.96
Pitch Line Vel
2.83m/s
Dynamic Factor
1.46
Power TransmissionInput Power
1570.80W
Output Power
1535.83W
Output Speed
500.00RPM
Output Torque
29.33Nm
Efficiency
97.8%
Power Loss
34.96W
Mass EstimatePinion Mass
147.97g
Gear Mass
1160.08g
Total Mass
1308.05g
Material
AISI 4140 Steel
Safety Factor vs ModuleBending safety factor for different module sizes at current torque
Speed ReductionInput vs output speed comparison
Design Notes• Contact Ratio: Should be ≥1.2 for smooth operation. Current: 1.65
• Minimum Pinion Teeth: 17 teeth for 20° pressure angle to avoid undercutting (12 with profile shift)
• Face Width: Typically 8-16× module for proper load distribution
• Safety Factors: Bending SF ≥1.5, Contact SF ≥1.2 recommended for industrial applications
• Calculations: Based on AGMA 2001 simplified methods with Lewis bending stress and Hertzian contact stress