Stress and Deformation Analysis of Additively Manufactured Spur Gears Using Directed Energy Deposition (DED)

Gears are the most fundamental way of transmitting power from one shaft to another shaft accurately. Over the years no other methods have proven that much accurate and efficient. To make sure that the gears are in proper working condition, it is very important to understand the basic methodology used for the manufacturing of gears. This study presents a comprehensive stress analysis of spur gears manufactured through additive manufacturing using Ti-6Al-4V, Inconel 625, 316 Stainless Steel concluding whether they are feasible to manufacture providing the desired properties can also be achieved. For manufacturing of spur gears, the Direct deposition Energy Method is employed, which is a type of technique used in additive manufacturing. After manufacturing, the gear stress analysis can be performed using Theoretical, Experimental and Finite Element. This work includes the theoretical and Finite Element methods as experimental methods are costly and time-consuming. Finite element analysis (FEA) is conducted to evaluate root bending stresses, and tooth deformation under identical load conditions for each material to verify the adopted manufacturing approach. The findings reveal that the root bending stress is nearly similar in all three gears as it depends on tooth geometry and tooth deformation is least in case of 316 Stainless steels followed by Inconel 625, Ti-6Al-4V. The additive processes enhanced weight-to-strength ratios and improved overall efficiency. This study is focused on the growing need for lightweight, high-performance gears in Advanced industries like aerospace and automotive. Traditional gear manufacturing methods, while accurate, are limited in material efficiency and design flexibility. By exploring additive manufacturing using the Directed Energy Deposition (DED) method and analyzing materials such as Ti-6Al-4V, Inconel 625, and 316 Stainless Steel, the research evaluates the structural feasibility and performance of spur gears. The use of theoretical and finite element analysis helps validate this approach, offering insights that support the Adoption of AM for critical gear applications.