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Spur gears are widely used in industry where the power transmission is required at heavy loads with smoother and noiseless operation. The study in this paper shows that the complex design problem of spur gear requires superior software skills for modeling and analysis. The problem been has solved using Pro/E and ANSYS software which provides equivalent results to that of AGMA. In this paper, spur gear was modeled using Pro/Engineer wildfire 4.0 and stress analysis was carried out using ANSYS 11.0. The results obtained from both AGMA and FEM were compared and found to be approximately similar.