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Gear design is one of the most critical components in the Mechanical Power Transmission industry. Among all the gear design parameters pressure angle is the most critical parameter, which mainly affects the load carrying capacity of the gear. Generally gears are designed with a symmetric pressure angle for drive and coast side. It means that both flank side of gear are able to have same load carrying capacity. In some applications, such as in wind turbines, the gears experience only uni-directional loading. In such cases, the geometry of the drive side need not be symmetric to the coast side. This allows for the design of gears with asymmetric teeth. Therefore new gear designs are needed because of the increasing performance requirements, such as high load capacity, high endurance, long life, and high speed. These gears provide flexibility to designers due to their non-standard design.

In today's automotive industry Benchmarking plays a vital role to improve performance, quality of critical functions and key areas of an organization by understanding and evaluating the products & processes in relation to Best Practices. Gear Reverse Engineering (here in after called as GRE) a part of Benchmarking is an activity which follows an analytical approach to calculate basic key parameters for an unknown gear pair. This paper propose a diagnostic tool/method, which determines basic gear parameters for an unknown gear pair, by simply measuring few dimensions as input followed by step wise analytical approach. This tool/method simplifies the gear designer job at initial stage by eliminating frequent trial & errors, iterations and complex measurements, which saves time & cost.