Improving contact performance of toe-loaded involute beveloid gears using non-involute profiles

Based on the conjugate meshing theory, this study achieves line contact transmission for intersected beveloid gears. A mathematical model for the spatial gearing of both involute and non-involute beveloid gears is established and the tooth surface equations for the non-involute beveloid gears is derived. Based on tooth surface modification, the tooth flank differences between involute and non-involute beveloid gears are compared. Precise solid models of both gear pairs are developed, and loaded tooth contact analysis (LTCA) is performed under various loading conditions, misalignments, and modification approaches. The results demonstrate that applying non-involute modifications to beveloid gear pairs increases the tooth contact pattern from approximately 50% to nearly 100%, reduces the tooth contact stress by about 50%, reduces root tooth contact stress by approximately 70%, and reduces transmission error by around 70%. These improvements significantly enhance the load-carrying capacity of involute beveloid gear pair. Furthermore, the non-involute beveloid gears demonstrate superior performance in improving the contact characteristics of toe-loaded tooth surfaces, even in the presence of significant misalignments. Stress concentration and edge contact can be effectively alleviated by applying end relief to the non-involute beveloid gears.