In gear design, gear performance metrics such as safety factors for tooth root stress and surface durability, peak-to-peak static transmission error (PPSTE), efficiency, mass, and volume are considered. They are calculated by the geometric parameters of gear macro- and micro-geometry, and manufacturing errors related to gear geometry significantly affect gear performance. However, previous studies have only focused on the micro-geometry errors. In this study, Monte Carlo-type robustness analysis was performed considering the manufacturing errors for tooth thickness, tip diameter, and center distance. Gear performance metrics except PPSTE were calculated based on the international standards and geometric characteristics. PPSTE was evaluated analytically due to lack of standards. When the errors were considered, two gear pairs with the safety factors satisfying the design requirements and similar performance for PPSTE, efficiency, mass, and volume showed different gear performances. There were many samples in gear pair 1 that could not satisfy the design requirements of safety factors, and gear pair 2 had the robustness of PPSTE not only at the specific torque but also with wide torque range when compared to gear pair 1. These results imply that considering the gear macro-geometry errors and robustness of PPSTE is significantly important when designing gears.
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