Background: Generally, gears are used without material removal or weight reduction. An
appropriate design can be modeled to dissipate stresses imparted on the gear through material reduction.
In this study, an innovative design is proposed and modeled for reducing the weight.
Objective: Designing a gear with high strength-to-weight ratio achieved through innovative designing.
Method: A standard involute teeth profile has been used. Innovation lies in removing material depending
upon the stresses imparted to the gear. Additionally, with appropriate variation in the weight reduction
features, the design can be universally used in gears of any size.
Result: The proposed design can reduce the weight of gear train systems by approximately 50% as
compared to gears without any weight reduction by reducing weight in between the hub and the rim of
the gear. The modeled spur gear dissipates the stresses generated during vehicle movement and withstands
tangential and radial forces imparted due to torque transfer.
Conclusion: The gear can be installed in gearboxes and other high torque gear assemblies. A patent has
been filed for this original gear design with the application number-201641035146 under Intellectual
Property India, Chennai.