Hello. I am designing some gears for my boss and I am new to gear design so I have a general question. For basic gear/spline design, when calculating for tangential load, bending stress, surface stress, etc. should I use the max operating torque or is it more typical to use the nominal operating torque with a conservative application factor? This is probably a pretty simple question but I cannot seem to find a straightforward answer in my books. It seems more intuitive to use the max operating torque, however, this may result in expensive gears that are overkill if the load rarely operates at it's max torque. I realize it is probably possible to take both into account with a more thorough design, but these gears do not need to be super precise so I am just looking for a general rule of thumb when using the Lewis equation and other similar equations if anyone knows one.
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