Accuracy Analysis of Complex Transmission System with Distributed Tooth Profile Errors

Tooth profile errors are the internal excitations that cause gear meshing errors, which are critical error factors affecting gear transmission accuracy. In existing studies, it is usually regarded as a constant or random distribution function. However, the actual machined tooth profile error is not a constant, so this estimation is inconsistent with the actual situation, resulting in an inaccurate evaluation of transmission accuracy. This paper proposes a method for representing tooth profile errors using distribution errors (including systematic and random errors), and a mathematical model of distributed tooth profile errors is presented. The contact stresses of the complex transmission system were compared with those obtained by formulas, proving that tooth profile errors increase contact stress. A method for calculating gear meshing error is proposed to evaluate the actual output accuracy of the complex transmission system. Compared with the test, the output accuracy is reduced by 13.8% under the temperature environment and distributed tooth profile errors. The proposed methods can accurately predict the transmission accuracy of precision transmission systems at the design stage and provide theoretical support for reducing systematic and random errors at the gear machining stage.