When comparing, say, a 22-tooth pinion to a “larger” 24-tooth pinion with the same motor (therefore same torque) and spur gear, the 22-tooth pinion will put more stress on the spur gear. This is because a smaller pinion has a smaller radius, and for the same amount of motor torque, a smaller radius creates higher contact force between the pinion and spur gear teeth (simply put, less teeth to share the same load). Higher contact force increases both bending stress and surface stress on the spur gear teeth. Additionally, the 22-tooth pinion results in a higher gear ratio, which means the spur gear must handle more torque from the load, further increasing stress.
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