Stress-strain analysis of cycloidal gear tooth segment using FEM

Abstract

In robotics and industrial automation, cycloidal reducers are widely used due to their high transmission ratios, compact design, and low backlash. However, their specific kinematics and multiple simultaneous contacts result in complex stress and deformation states, particularly in the cycloidal gear-tooth region. Most previous studies analyzed the stress–strain state only at isolated angular positions of the cycloidal gear, while the behavior of a single tooth during the complete meshing cycle has remained insufficiently investigated. For this reason, this paper presents a combined analytical–numerical approach based on the finite element method (FEA) for the analysis of a single cycloidal gear tooth throughout the entire meshing cycle with the rollers of the ring gear. The results showed that higher Von Mises stress values occur in contacts between convex and concave surfaces than in contacts between two convex surfaces. In addition, the analysis enabled the identification of the most critical angular positions during operation and provided a more detailed insight into the evolution of stress distribution during meshing.