![]() Various fillet design parameters and tooth numbers are examined. The design method is conducted for involute gear and, for the first time, non-involute gears. The second aim of this work is to examine if increasing the order of the proposed GFTC can enhance the fillet strength of the gear tooth further. ![]() The mathematical model employed a general fillet transition curve (GFTC) to ensure smooth transition surfaces in the fillet zone and an improved radius of curvature as well as tooth form factor compared to the circular fillet profile. Therefore, the first aim of this study is to develop a general mathematical model for defining the tooth fillet profile analytically for gears manufactured by non-generation cutting processes. For such design flexibility, the circular fillet may not necessarily be the best fillet profile from a bending stress point of view. For gears that are cast, forged, or 3D printed, the tooth fillet can be any curve as long as it is capable of providing a smooth mesh without interference. Tooth fillets are commonly made of circular profiles because they are easy to define analytically and have been shown to be superior from a bending perspective to the trochoid fillet. ![]()
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