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Through the help of software developed by the authors, several aspects of design of gear teeth are considered in an
integrated way, namely the kinematics, static stress analysis and design for residual life. In particular, computer codes
have been set up by the authors for generating BEM or FEM meshes of gears manufactured by means of user defined
shape of the tools and cut parameters.
The use of FEM permits a greater versatility in finding the correct constraint or loading conditions, or when important
residual stresses are present, whereas BEM is easier to use for a complete and automatic subcritical propagation
analysis of cracks.
As application it is studied the effect on the fatigue life and on the crack paths of the rack shift factors and of the rim
thickness in gear manufactured on thin hollow shaft for aeronautical applications.