Gear Generator is a tool for creating involute spur gears and download them in DXF or SVG format. In addition it let you compose full gear layouts with connetcted gears to design multiple gears system with control of the input/output ratio and rotation speed.

The theory and practice of gear design is rich with examples of successful and sometimes outstanding combinations of various mathematical, manufacturing, and methodological approaches to the choice of the best parameters, defining the gear itself, its generating tools, and processes of generation and meshing of tooth flanks [1, 2, 3, and others]. Knowledge of involute spur and helical gears can be considered to be almost complete compared with other types of gears, and they also apply different approaches to the optimal (or rational) choice of their geometrical parameters. This paper proposes a new approach—Advanced Gear Design (AGD)—on the basis of two reputed approaches, one of which is known as Direct Gear Design? (DGD) [4, 5, 6] and the other can be named as the Method of Dynamic Blocking Contours (DBC) [7, 8, 9]. The proposed approach uses the advantages of the first two in order to obtain the best decision when designing involute spur and helical gears.

1: What We Imply By Optimal Design We are going to consider two tasks that are typical for the optimal design of any product, including a gear: • Optimizing the design, implying the choice of the best design decision according to the given criterion or a group of criteria; • Optimizing the process of design, implying the increase of its productivity and quality. The proposed concept of the first task solution means the rejection of the traditional approach to the design of involute spur and helical gears, where the first step is the assignment of parameters (as a rule, standard ones) of the initial generating tool (generating rack). Such an approach is justified in many practical cases from the manufacturing point of view, but it has restrictions, imposed both on the number of gear parameters and on the choice of the optimal decision. In the proposed approach the tool parameters are secondary and are determined after the gear parameters are chosen according to the given quality criteria with account of possible restrictions of design (geometrical) and manufacturing character. Here, any alterations of the tooth shape—including asymmetry—are possible, which provide necessary gear performance [4]. The basis of the approach to the second task solution is such a design version, when part of the parameters—let’s call them key ones—which greatly influence the gear performance, are chosen at the early stage of the process, affiliating the assignment of initial data, on the basis of the results of previous calculations and investigations, accumulated in the form of tables, graphs, formulas, or anything else.

The experience of practical implementation of such an approach shows that the dual effect of optimization can be achieved here: • Increase of the design process productivity due to the fact that a number of gear performance characteristics can be forecast (predicted) at the early stage of this process, omitting complex and lengthy calculations; • Achieving the best gear quality according to those characteristics, which are possible to forecast with the help of the mentioned key parameters. Direct Gear Design Approach The idea of Direct Gear Design is not new. Ancient engineers successfully used it centuries ago, using the desired gear performance and known operating conditions to define gear geometry. Then they made gear drives according to this geometry using available materials, technology, and tools. It is important to note that the gear geometry was defined first. In other words, gear parameters were primary, and the manufacturing process and tool parameters were secondary. This is an essence of Direct Gear Design.

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This design approach is developed for involute gears and based on the Theory of Generalized Parameters created by Prof. Vulgakov [4], and it can be defined as an application-driven gear drive development process with primary emphasis on performance maximization and cost efficiency without concern for any predefined tooling parameters. Gear Tooth And Mesh Synthesis There is no need for a basic (or generating) gear rack to describe the gear tooth profile.

Two involutes of the base circle, the arc distance between them, and tooth tip circle describe the gear tooth (). The equally spaced teeth form the gear. The fillet between teeth is not in contact with the mating gear teeth. However, this portion of the tooth profile is critical because this is the area of the maximum bending stress concentration. Two (or more) gears with the equal base circle pitch can be put in mesh ().