Computerized design, simulation of meshing and stress analysis of non-generated double circular-arc helical gear drives with different combinations of transverse pressure angle

The computerized design of non-generated double circular-arc helical gear drives with different combinations of transverse pressure angle based on the active design of the meshing line function is presented. The application of different transverse pressure angles for the double circular-arc tooth profiles is discussed and the parametric equations for the driving and driven gear tooth surfaces are derived. The meshing performance and mechanical behavior are studied in terms of the achieved contact patterns and the evolution of the contact and bending stresses for nine cases of design. The results show that one of the cases of design of double circular-arc helical gear drives considering a combination of transverse pressure angles of 25 and 15 degrees for the convex and concave circular-arc profiles of the pinion shows better mechanical performance with respect to the other combinations of different transverse pressure angles. The proposed geometry of non-generated gears is appropriate for manufacturing by injection molding or additive manufacturing for plastic, ceramic, metal as well as nanocomposite gears.