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Thanks for the info, Terry. I did a line contact stress analysis on my teeth, and found that the stress levels were about 3X too high for the material I was using. Yeah, that is different than fretting, but still a failure mode. The material in question (G10) was being considered because it...

Thanks CoryPad and dinjin. I have never analyzed a gear tooth (or spline tooth), so the Lewis Equation was a new one on me. The two analysis' I suggested seemed obvious though. I have the "Gear Handbook" by Dudley, and remarkably enough the index does not even have a listing for stress, but I...

I am designing an involute spline with a fillet root. I want to do a simple analyis to see if the stresses are even in the ball park before I hand off to finite element person. Seems like line contact stress at pitch diameter to check the bearing stress is good. And potentially a shear stress...