Geometric generation and meshing characteristics analysis of a new S-shaped gear drive

A new type of S-shaped gear drive with a tooth profile combining involute and circular-arc curves is proposed in this paper. Tooth profile design includes convex involute, convex circular-arc, concave involute, and concave circular-arc curves is carried out. Geometric generation and mathematical model of tooth surfaces of the S-shaped gear are established based on imaginary rack method. Utilizing Hertz contact theory, the calculation formula of contact stress of tooth surfaces is provided. Furthermore, simulation analysis of contact stress based on finite element method under various working conditions is studied using ANSYS/Workbench software. And the comparisons of stress results with general involute gear are also provided. Dynamic characteristics analysis of the generated tooth surfaces is put forward using the established virtual prototype. Normal contact force, circumferential force, axial force and radial force of tooth surfaces both S-shaped gear and involute gear are analyzed. Research results show that the developed S-shaped gear has better transmission performance than involute gear. Further study on dynamic analysis and manufacturing method will be carried out.