The design of spur gears plays a important role in efficient power transmission systems, where interference between mating teeth can lead to noise, vibration, wear, and eventual failure. This review paper focuses on various methods used to minimize interference in spur gear design and improve overall performance. Interference mainly occurs when the gear teeth are improperly designed or when the number of teeth is too low, leading to undercutting and weak tooth profiles. To address this issue, several design modifications are discussed, including increasing the pressure angle, using stub teeth, applying profile shifting, and optimizing the number of teeth. Increasing the pressure angle helps in reducing interference by allowing fewer teeth without undercutting and improving tooth strength. Stub teeth reduce the addendum, thereby minimizing the chances of interference at the tooth tip. Profile modification techniques such as tip relief are also effective in reducing contact stresses and improving meshing conditions. Additionally, advancements in computational tools like finite element analysis have enabled better evaluation of stress distribution and tooth behavior under load. The paper reviews existing research and highlights the importance of selecting appropriate design parameters for achieving interference-free operation. Overall, minimizing interference not only enhances gear life but also ensures smooth, quiet, and efficient performance in mechanical systems.

Keywords: Spur Gear, Gear Interference, Contact Ratio, Undercutting, Profile Shifting, Pressure Angle, Addendum Modification, Gear Geometry, Involute Profile, Transmission Efficiency, Noise Reduction, Gear Tooth Strength.