Abstract: Simplest type of gear is well known as spur gear. Spur gears have a wide variety of applications. These are most commonly applicable in auto motives. The failure of gears occurs when the working stress exceeds the maximum permissible stress. Contact stress analysis between two spur gear teeth was considered in different contact positions representing a pair of mating gears during rotation. These stresses are proportional to the amount of power transmitted while the design could offer favorable or adverse conditions for generation of the same. This project intends to identify the magnitude of the stresses for a given configuration of a two wheeler gear transmitting power while trying to find ways for reducing weight of the gear. The philosophy for driving this work is the lightness of the gear for a given purpose while keeping intact its functionality. The process constraints for manufacturing the gear also needs to be considered while recommending alternative/s. Ease of incorporating the new feature for weight reduction over the existing process of manufacturing and the magnitude of volume of mass (or weight) reduced could be considered as the key parameters for assessment for this work. This study will focus on the weight optimization of the two wheeler gear set, keeping the torque transmitting capacity intact, thus reducing the material cost of the gear.
Keywords: GFRP, Composite Material, Weight Reduction, Vibration Frequencies.