Abstract: By importing imaginary whole conjugated tooth surface as the reference tooth surface, namely the reference tooth surface of gear is consisted of theoretical tooth surface with machining tool setting parameters, and the reference tooth surfaces of pinion use the tooth surfaces conjugating with the reference tooth surfaces of gear. The imaginary tooth surface is instantaneous line contact without transmission error. Through the topological mesh of reference tooth surface contact lines, the digital synthetic error concept is introduced, and the digital real tooth surfaces of spiral bevel gear with tooth profile error and installation error can be built. A tooth contact analysis (TCA) method based on high precision digital real tooth surface of spiral bevel gears puts forward. The feasibility and effectiveness of this method can be verified through the comparison of TCA software analysis results by Gleason corporation and tooth wear test results.

Key words: spiral bevel gears;real tooth flank;composite error;tooth contact analysis