A low cost cement reinforced polymeric composite material is designed and developed for fabrication of non-metallic automotive components such as gear. 10 wt% cement fillers are mixed up with pure polypropylene and injection-molding process is followed to fabricate the composite gear. Several experiments have been conducted to study the composite gear failure mechanism and resulting stress distribution along the tooth contact surface. For this, experimental data are used and Hertzian contact theorem is used and a theoretical model has been developed that describes the stress distribution along the tooth contact region. The obtained results indicate that maximum stress variation occurs at the mating surface spot while stress concentration varies with the distance away from the contact point.Keywords: Hertz’s contact theorem, principal stress, composite spur gear, stress distribution.
