This paper demonstrates the prediction of loss factor for non-standard gear drives with equal stresses in the root region of the pinion and wheel. This implementation of equal stresses in the root region is achieved in the described model of a spur gear drive with higher transmission ratio using non-standard rack cutter. The aim is to discover the optimal modification point in the tooth profile by varying values of tooth thickness with at most balanced stresses in the gear pair considered for the study. A loss factor is predicted along the path of contact for a complete meshing cycle using finite element method. This paper studies and compares the distinct models and thereby identifies the suitable and appropriate models. The predicted loss factor includes the distribution of load sharing effect during the meshing which is excluded in the compared models. The gear pair is analyzed, and the loss factor is predicted for influence over the major drive parameters. It was observed that the approach employed facilitate substantial enhancement in the efficiency which is confined by the detailed parametric study and numerical simulation of the balanced stresses in the drive.
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