Computerized tooth profile generation and undercut analysis of noncircular gears manufactured with shaper cutters

Pitch curves of a conjugate noncircular gear pair are derived based on kinematic considerations. A method for considering the inverse mechanism relationship and the equation of meshing, is proposed here to derive a complete mathematical model of noncircular gears manufactured with involute-shaped shaper-cutters. The proposed method is similar to the contact line method and the envelope method but is easier to apply to the determination of tooth profiles. A computer program is developed for generation the tooth profile with backlashes. Undercutting analysis is also investigated by considering the relative velocity and equation of meshing. Finally modified elliptical gears are presented to illustrate the tooth profile generation when the proposed mathematical model is applied and to investigate the phenomenon of tooth undercutting.