Abstract
A novel method called Real Tooth Contact Analysis (RTCA) is proposed to elucidate the tooth-face contact law of the cylindrical gear with variable hyperbolic circular-arc-tooth-trace (VH-CATT cylindrical gears) and predict the direction and size of the contact pattern. This study establishes a coating surface model for the tooth surface coated with red lead powder of a specific thickness, and a contact analysis model considering installation errors. Utilizing a three-dimensional complete tooth surface mathematical model and TCA technology, an algorithm based on the surface intersection principle is devised to solve the model. Studied the effects of gear geometric parameters and installation errors on tooth surface contact trajectory and instantaneous contact pattern. A quantitative relationship is established through fitting, revealing that the ratio between the nominal cutter radius and the contact patch length is nonlinearly proportional only to the gear modulus. Based on these quantitative correlations, the concept of a critical radius-to-width ratio for VH-CATT cylindrical gears is introduced. This provides methods for predicting the contact pattern length and determining the permissible range of other geometrical parameters for such gears under specific operating conditions, thereby offering a crucial theoretical foundation for their forward design.
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