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Strain Wave Gearing

Flexspline Cyclic Fatigue: Finite Element Stress Inversion in Strain Wave Gearing

Elastic deformation mechanics of thin-walled alloy steel flexsplines deflected by elliptical wave generators.

By Dr. Chen Wei, Robotic Mechanism Designer October 08, 2026 • 9 min read
Flexspline Cyclic Fatigue: Finite Element Stress Inversion in Strain Wave Gearing

Elliptical Wave Generator Displacement Profiles

The elliptical ball bearing wave generator continuously deflects the flexspline cup, engaging opposite tooth pairs simultaneously.

Cyclic Bending Stress and Multi-Million Cycle Fatigue

Designing below the material fatigue endurance limit requires deep-drawn 40CrMoV vacuum-melted alloy steels with low inclusion counts.

Tooth Pitch Differential (Two Teeth Per Revolution)

Because the circular spline contains two more teeth than the flexspline, one full input revolution produces a 1/50th or 1/100th reverse step.

⚠️ Technical & Safety Verification

The empirical methods outlined in this study reflect verified precision robotic actuation & strain wave gearing dynamics protocols and field measurements. Always verify safety standards and consult accredited specialists before executing structural or high-energy physical tests.

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