Using the finite element method, influences of chordal tooth thickness at the critical section of tooth, radius of curvature of fillet, rim thickness, and supporting condition of a thin-rimmed spur gear on the tooth fillet and root stresses are investigated. Summing up a lot of FEM calculated results, a set of approximate formulae is derived for the calculation of tooth fillet and root stresses of a thin-rimmed spur gear. A comparison between the FEM calculated stress values and the values from these approximation formulae has shown good agreement.

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