Generation and Stress Analysis of Helical Gear Tooth Combining Involute with Epicycloidal and Hypocycloidal Profiles

This paper examines the helical gear that combines the involute with epicycloidal-hypocycloidal profiles. The tooth profile was produced through the shaper-cutting process, which was conducted using an appropriate rack cutter with a Cartesian coordinate system. A computer program was developed using Microsoft Visual Basic and subsequently integrated into SolidWorks using the application programming interface. This numerical investigation aims to analyze the impact of tool parameters on the produced gear tooth profile, with the goal of enhancing the dynamic performance and deformation resistance of the proposed helical gear model. Additionally, this study assesses the effect of teeth thickness on the helical gear model. The results indicate a highly accurate approximation of the involute, cycloidal, and modified gear tooth profiles, which were programmed according to the module, teeth number, and rolling angle. The use of a combination of curves (epicycloidal, involute, and hypocycloidal) in a single tooth resulted in a larger contact area, thereby improving the ability of the gears to withstand greater pressures and extending their lifespan. The modified non-parallel helical gear drive outperformed other non-parallel helical gear drives. The best enhancements in maximum contact stress and teeth bending stress achieved approximately 33.169% and 26.08% compared to the standard involute profile and about 17.69% and 0.67% when compared to the cycloidal profile.