Abstract
A hypoid gear drive transforms torque between crossed axes and is widely used in front and rear axles. Current requirements for greater engine power and higher fuel efficiency mean hypoid gear axles must have a higher power density. Therefore, engineers need a tool, which efficiently and accurately optimizes hypoid gear stress, to check design feasibility before prototyping and testing is done. This paper proposes a new, practical methodology that more accurately and efficiently calculates the stress of hypoid gears under loading.