Computerized design, generation and simulation of meshing and contact of hyperboloidal-type normal circular-arc gears

•The point-contact design method of HNCGs was achieved.•The relationship between the variations and the errors of HNCGs was established.•The computer program TCA of HNCGs was developed.•The influences of misalignment errors in HNCGs on the shift of bearing contact were discovered.

The authors proposed an approach for computerized simulation of meshing and contact of misaligned hyperboloidal-type normal circular-arc gears (HNCGs). According to local conjugate theory, the point-contact design method for HNCGs was presented, and the equations of pinion-gear tooth surfaces were deduced. Using the moving frame method, the errors and the variations were quantified, and the error-variation equations were established. Based on Hertz contact hypothesis, the contact region of pinion-gear teeth was determined, and the computerized simulation program for tooth contact was developed. By the visualization of 3D- and 2D-contact regions, the influence of misalignment errors on the shift of the bearing contact has been explored. Numerical examples that illustrate the developed theory were provided.