Abstract
This paper presents the application of the finite element method (FEM) for the analysis of a restored gear tooth in a cylindrical gear system, where the tooth has been rebuilt using electroslag surfacing. The study focuses on the influence of stress-relief holes on the strength of the restored tooth. The main emphasis is placed on the design of holes in stress-prone areas, enabling stress redistribution and reducing stress concentration at the root of the restored tooth. This is achieved by introducing circular holes, which help to reduce bending stresses. Previous research has addressed the stress–strain state and electroslag surfacing processes in gear mechanisms. The novelty of the present study lies in the development of shock-absorbing holes specifically designed to decrease stress concentrations following electroslag surfacing. For the finite element analysis, performed in the ANSYS software, a bimaterial approach was used, since the rebuilt gear tooth consists of the base gear material and a resurfaced layer with higher hardness. The introduction of stress-relief holes at the tooth root significantly reduces tensile stresses. This stress reduction can lead to a substantial increase in the service life of the restored tooth, making this approach particularly valuable for improving gear reliability. Computational results show that the tensile stress in the critical region is 57,648 MPa with the shock-absorbing holes, whereas it reaches 74.693 MPa without them—an increase of 25.75%. These findings can be beneficial for engineers and designers working in the field of mechanical power transmission, as they offer effective solutions for enhancing the strength and durability of gear systems.