Abstract: This study presents a comprehensive static structural analysis of a gear and rack mechanism using ANSYS, focusing on evaluating stress and torque responses under applied loading conditions. The primary objective is to assess the total deformation, stress distribution, and critical load concentrations within the gear and rack assembly using Finite Element Analysis (FEA). The gear is subjected to a specified torque while the rack is fixed, simulating realistic operational constraints. Results indicate that maximum deformation occurs at the gear tooth tip, while the rack remains largely stable, validating the boundary conditions and meshing quality. The observed stress and deformation patterns align with theoretical expectations, confirming the reliability of the simulation approach. This analysis not only aids in understanding the mechanical behavior of gear-rack systems under load but also highlights the significance of FEA tools like ANSYS in optimizing mechanical design for safety and performance in engineering applications.

Keywords: Gear-rack mechanism, static structural analysis, ANSYS, finite element analysis, stress distribution

| DOI: 10.17148/IARJSET.2025.125243