cae case studies: gear contact analysis

The client, one of the top farm equipment manufacturers in India, was experiencing field failures in gears in one of their indigenously designed tractors. The failures were in the following two forms:

The bull gear at the final reduction was undergoing pitting failure
The crown wheel pinion tooth was failing at the base fillet region (failure predominantly due to bending stresses)

With the gear parameters as inputs, Alcyon conducted a turnkey project that involved:

Modeling the gears (crown gear, bevel pinion, bull gear pair) in 3D precisely, including features such as fillets that are important for FEA.
Validating the incidence of field failure under various conditions including factors such as gear shaft bends due to assembly and loading errors.
Suggesting likely design modifications to the client that would avoid the failure.
Analyzing the modified gears