Spur gears are the most frequent power transmission gears. The sensitivity of gear teeth to failure under high loads has led to the development of alternate gear fabrication materials as machines are required to operate under varied loads and speeds. Metal matrix composite (MMC) gears, which transfer power quickly and well, are popular. Low brittleness, strong impact resistance, high strength, and long lifespan are MMC properties. Researchers and manufacturers are currently directing their efforts toward the development, production, and utilization of composite materials for gears, driven by their superior mechanical properties, including reduced weight, heightened hardness, and strength. This investigation focuses on forecasting the strain behavior in gears made of aluminum graphene nanoparticulates (GNPs) with three distinct GNP volume fractions (30%, 40%, and 55%) denoted Al/GNPs/70/30, 60/40, and 45/55, respectively. Additionally, gears with 94%, 96%, and 99.5% cerium oxide weight fractions are studied. ANSYS WORKBENCH performed finite-element method on spur gear designs created in SOLIDWORKS. The volume proportion of GNP reinforcement inversely affects strain values, with Al/GNPs/45/55 performing the best. This composition exhibits a strain value of 2.6777 × 10−5 at 100 N load. At the same load, the 94% cerium oxide composite performs optimally with a strain value of 2.0213 × 10−5. These findings show that composite materials can improve gear reliability and efficiency, leading gear materials engineering.
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