A systematic methodology combining optimization, three dimensional analytical rigid body dynamics and a novel method, namely, Pseudo-Interference Stiffness Estimation method (PISE), is proposed to dramatically reduce gear design time and improve the spur gear system dynamic performance. The main aim of this methodology is to search for the profiles of tooth crowning and shaving that eventually lead to the optimum dynamic tooth load in the gear mesh. An example of the detailed design study is numerically investigated. The results show that the dynamic tooth load can be reduced to up to 50 percent of its original value. However, this reduction is only valid at the operating ranges of the design load and design speed. It is also found that the effect of profile modification on the dynamic response of the gear system was mostly observed to be a reduction in the peak dynamic tooth load at the resonance speed. Later, the investigation of gear tooth durability was conducted to validate an improvement of gear life. The rating factors given in AGMA publication, Hertzian contact stress, bending fatigue stress, flash temperature and PV index are employed in gear durability determination. The results show that, with the reduction of 50 percent in dynamic tooth load, the reductions in PV index, bending fatigue, Hertzian contact stress, and flash temperature can be achieved up to 64, 58, 28 and 39 percent, respectively.
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