3D contact analysis of conjugate spur gears by a complete mating process

Instead of applying fixed boundary conditions to constrain and simplify material behavior in 2D models, the point and line contact of tooth surfaces are substituted by a face-contact model of teeth in this study. The inaccurate prediction of load, deformation, and stress in 3D contacts are solved. Most research uses one pair to three pairs of meshing teeth to simulate the mating process. However, describing the entire process of three contact zones during each mating pair is insufficient. By implementing a combined 3D face contact and finite element method, the contact stress analyses between two spur gear teeth are conducted in 11 different contact positions during a full mating process. The proposed approach provides a complete and effective solution to the contact problem in a quasi-dynamic manner. This model not only determines the load-sharing prediction but also verifies the applied boundary conditions.