Abstract
Gear analysis is typically performed using calculation based on gear standards. Standards provide a good basis in gear geometry calculation for involute gears, but these are unsatisfactory for handling geometry deviations such as tooth flank modifications. The efficient utilization of finite-element calculation also requires the geometry generation to be parameterized. A parameterized numerical approach was developed to create discrete helical gear geometry and contact line by simulating the gear manufacturing, i.e. the hobbing process. This method is based on coordinate transformations and a wide set of numerical calculation points and their synchronization, which permits deviations from common involute geometry. As an example, the model is applied to protuberance tool profile and grinding with tip relief. A fairly low number of calculation points are needed to create tooth flank profiles where error is <1 μm.
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