Computerized generation and tooth contact analysis of spherical gear couplings for high misalignment applications

•A generation method of an external spline (or hub) by a hob is implemented.•Active and fillet profiles of the hub are considered in the generation method.•Unlike existing hub models, the proposed one considers the hob thread surface.•The method allows existence of undercut profiles in the hub model.•Geometric differences between the compared models are highlighted.