Optimization method for off-center loads of intersecting-axis beveloid gears based on cone angle adjustment

A method involving cone angle adjustment is proposed to address off-center loading on intersecting-axis beveloid gear teeth caused by installation constraints. Based on the backlash-free involute gear meshing principle, analytical relationships are established among the cone angle, transverse pressure angle, helix angle, and imaginary rack parameters. Using scale factor λ and translation factor η , a meshing geometry model for cone angle adjustment is developed, where the minimum mesh gap distribution is controlled by λ and the contact position by η . Loaded tooth contact analysis is performed on a typical intersecting-axis beveloid gear pair under heavy loads with multiple adjustment factor sets. Results show that, after optimization, the contact pattern expands along the tooth width, peak contact pressure decreases, and transmission error fluctuation reduces. Even with small cone angle errors, performance exceeds that of the original toe-loaded gear pair considered in this study. Parameter analysis indicates that, with proper η , the adjusted cone angle can accommodate small shaft angle errors. This method requires no additional tooth modification and effectively suppresses off-center loading, providing theoretical support for high-performance beveloid gear applications.