In order to automatically calculate the stress distribution of a spur gear tooth on the personal computer, a stress analysis system was developed. This system has four main functions : (1) gear cutting tool design, (2) gear tooth generation, (3) determination of the coordinates of tooth profile and the mesh pattern, and (4) use of a finite-element method for stress analysis and determination of calculated values. It is easy to design a rack cutter by the use of a simple CAD devised by the authors. The tooth profile generated using this cutter can be confirmed on the personal computer. The determination of the coordinates of tooth profile, the mesh pattern, and the boundary condition needed for the finite-element method is carried out automatically. Through an example, it is confirmed that this system is a useful tool for the design of the tooth profile which decreases maximum stress imposed on the fillet of spur gear.