In this paper, the mechanical properties and surface morphology of Aluminium alloy 6061 composite with differing weight percentages of 40 µm grain size Titanium carbide used to fabricate spur gears are studied. A comparison is made between the conventional spur gear model and the developed composite with better strength, the complete analysis is done using ANSYS. The Aluminium alloy 6061 composite samples reinforced with 5%, 10% and 15% by weight Titanium carbide particles are fabricated by stir casting process. Tensile, hardness and impact tests are conducted for all the composites to determine their mechanical properties. The modelling and Finite Element Analysis of the spur gear is done using CATIA and ANSYS respectively. It is noted that increased weight percentage of Titanium carbide gives higher tensile strength, impact strength and hardness values. ANSYS analysis of spur gear of aluminium alloy 6061 with 15% Titanium carbide composite shows that it has better fatigue life than the gear made out of conventional cast iron.