Loaded tooth contact analysis of intersected beveloid and cylindrical involute gear pair with small shaft angle

A working pitch cone based geometry design approach for the intersected beveloid and cylindrical involute gear pair with small shaft angle was proposed. The cutter and geometry design parameters can be determined by the proposed method. Also, a quasi-static loaded mesh model was developed to calculate the contact characteristics. Then the influences of torque load, helix angle and misalignments on the mesh behaviors were investigated. Results show that the contact type is point contact both for light and heavy load situations. The increase of load tends to increase the root stress, transmission error and mesh stiffness obviously. However, the variations of the peak-peak value of transmission error and mean value of the mesh stiffness are greater under light load level compared with heavier load level. The increase of the helix angle obviously tends to increase the contact area, which is desirable. It also decreases the peak-peak value of transmission error and increases the mean mesh stiffness due to more area coming into contact. The shaft angle error tends to shift the position of the contact pattern and the peak value of the root stress along the tooth width direction slightly. Overall, the contact characteristics are not sensitive to the shaft angle error and gear axial position error.