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This paper introduces the concept of nondimensional gear teeth to be used in gear stress minimization problems. The proposed method of modeling reduces the computational time significantly when compared to other existing methods by essentially reducing the total number of design variables. Instead of modeling the loaded gear tooth and running BEA to calculate the maximum root stress at every iterative step of the optimization procedure, the stress is calculated by interpolation of tabulated values, which were calculated previously by applying the BEM on nondimensional models corresponding to different combinations of the design parameters. The complex algorithm is used for the optimization and the root stresses of the optimum gears are compared with the stresses of the standard gears for the same transmitted torque. Reduction in stress up to 36.5% can be achieved in this way. This reduction in stress has been confirmed experimentally with two-dimensional photoelasticity.

In this paper, a comprehensive methodology for calculating load sharing in multiple tooth contact is presented based on the experimental stress‐optical method of caustics. The technique is applied to a set of poly‐methyl‐methacrylate gears at various meshing positions covering a complete meshing cycle, including single and multiple gear tooth contact. The load sharing factor (LSF) is calculated using well‐established mathematical formulae from the photographs of the transmitted caustics and the obtained results are compared with the pertinent International Organisation for Standardisation and American Gear Manufacturers Association standards with which good agreement is verified. The proposed method is a reliable alternative for measuring load distribution in gear teeth compared with photoelasticity and other experimental techniques.

Problem statement: In this study a comprehensive methodology for calculating load sharing in Roller-bearing contact was presented based on the experimental stress-optical method of caustics and Photoelasticity. Approach: The theoretical equations describing the geometry of transmitted caustic in relation to the length of the contact zone were derived and a simple mathematical set of equations correlating the maximum diameter of transmitted caustic with the magnitude of load was given.For this contact problem, the basic theory of photoelasticity was given. Results: The techniques of caustics and photoelasticity were applied on a set of PMMA (Plexiglas) Roller-bearings and on a set of PCBA (Lexan) Roller-bearings, respectively. Conclusion: The proposed method of the caustics is a reliable alternative for measuring load distribution in Roller-bearings compared to photoelasticity technique