Among the best ways to transfer power along with rotational motion, whether it involves an adjustment in speed or direction, through the point of origin to its destination is through gearing. The main functions of gears are for transferring torque as well as angular speed difference between two shafts. In the subject of gear studies, optimal design works well to ascertain the ideal gear characteristics for fulfilling design. There are multiple variables that go into gear design and iterative methods must also be used in the gear construction to maximize the gear's specifications.

This present research presents a gear shaft design that is constructed with the use of SOLIDWORKS and the manufacturing process of the design done by the use of the Edgecam software and also a Finite Element Analysis (FEA) for assessing the engineering as well as vibration evaluation of an automotive gearbox component shaft with gearing. Analysis includes examining the part's displacement behavior with corresponding stress. ANSYS is used to build a 3-dimensional finite element simulation. The meshing of the model is done with the ANSYS Workbench. Boundary requirements including external loads are also utilized.

The manufacturing design will be done in two parts due to the high level of complexity associated with the gear shaft. The first part will include the parametric configurations used for machining one end of the gear shaft and the second part will include the parametric configurations used for machining the other end of the gear shaft. This means that when the machining process has to be done on the CNC machine, there will be two separate CNC codes to be utilized which can run successively. During the manufacturing design phase, important information can be obtained, such as the overall time for machining of one or both ends of the gear shaft as well as the safety conditions that were utilized during the process.

In order to get a better understanding of the finite element analysis operation, a bigger gear will be created and will mate with the teeth of the gear shaft model to transfer rotary motion from one gear to another. The analysis will involve the von-mises stress and total deformation that takes place at the exact point of contact between both gears based on the selected material properties for the gear models. This will result in the awareness of the changes in the mechanical properties of the gear shaft and its resulting mating gear.