Convergence and accuracy problems of the conventional TCA model - Critical analysis and novel solution for crowned spur gears

In this work the quasi-static model of the three-dimensional geometrical non-conjugate contact problem for two C-1 surfaces is studied. The set of contact equations is formulated by using a new parameterisation that enables to reduce the conventional system of five nonlinear equations with five unknown position and contact parameters to just two nonlinear equations with two changeable parameters. The novel model is computationally efficient and demonstrates increased accuracy and stability of the numerical solution, compared to the conventional model described by Litvin, which suffers from convergence problems and requires a high computational effort. The new model is implemented to spur gear with crowned tooth surfaces to parametrically estimate the susceptibility to diverse misalignments of the contact pressure, transmission error and path of contact.