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Article · Applied Mechanics · April 16, 2026

Comparative Investigation of Composite Materials for Spur Gears Using a Novel Tooth Contact Analysis Method and Density Functional Theory

Maksat Temirkhan, Ильяс Есенгабылов, Assem Kyrykbayeva, Azamat Kaliyev, Sharaina Zholdassova, Chingis Kharmyssov

Maksat Temirkhan
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Abstract

This study presents a comparative investigation of MgCu intermetallic compounds, CuCoMnSn Heusler alloys, and carbon steel for spur gear applications using a novel tooth contact analysis (TCA) method. The TCA employs a nonlinear two-variable equation, providing a fast and accurate computational tool for evaluating gear contact behavior. By integrating material-specific elastic properties from density functional theory (DFT) studies, the analysis predicts contact paths, stress distributions, and responses to angular misalignments. Material selection strongly influences gear performance: MgCu is promising for lightweight applications, while CuCoMnSn is better suited where mechanical performance is prioritized. The CuCoMnSn alloy also exhibits half-metallic ferromagnetic behavior, offering potential functional advantages beyond mechanical performance. These results highlight the promise of intermetallics and Heusler alloys for high-performance, misalignment-tolerant gears and demonstrate the effectiveness of combining DFT-informed material modeling with the novel TCA method for optimized spur gear design.

Gear and Bearing Dynamics AnalysisMaterial Selection and PropertiesAdhesion, Friction, and Surface Interactionsspur gearstooth contact analysiscarbon steel

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