Experimental method of tooth contact analysis (TCA) under load using rapid prototyping (RP)

The paper contains description of an experimental method of Tooth Contact Analysis (TCA). In practice there is mainly more than one pair of teeth in contact in gear. In determined orientation of gear wheels instantaneous contact ellipses occur between teeth. Shape and size of the contact ellipses are dependent on gear material, geometry and load. In manufacturing practice only mating areas are determined on control machines without operating load. Mainly analytical methods and a Finite Element Method are used to determine instantaneous contact ellipses. It is essential to observe changes in instantaneous contact ellipses relative to the rotations of wheels in gear drive in the range of a single pitch. In proposed solution of the problem the instantaneous contact ellipses and bearing area are experimentally determined using a rapid prototyping (RP) process. Prototypes of gear are assembled in a special device and loaded by torque. A transparent resin has been used to observe the instantaneous contact pattern. The principle of a mechanical similarity was applied.