Research on Error Sensitivity Mechanism, Load-Bearing Contact Analysis and Load-Bearing Contact Characteristics of Curved Face Gears Based on Point Cloud Modeling

To address the limitations of traditional analytical modeling in capturing complex surface topographies, this paper presents comprehensive research on the error sensitivity mechanism, loaded tooth contact analysis (LTCA), and load-bearing contact characteristics of curved face gears based on high-precision point cloud modeling. The primary objectives are threefold: (1) to establish a high-fidelity topological reconstruction framework using Non-Uniform Rational B-Splines (NURBS) to bridge the gap between discrete data and finite element analysis (FEA); (2) to reveal the inherent mechanical response and sensitivity mechanism to spatial installation misalignments; and (3) to evaluate the contact performance and transmission error fluctuations under operational loads. Specifically, an analytical discretization method is proposed for point cloud generation, followed by a dual-path validation system integrating “rigid tooth contact analysis (TCA)” and “loaded FEA”. The results demonstrate that the proposed reconstruction achieves a superior accuracy with a Root Mean Square Error (RMSE) of 2.2 × 10−3 mm. Furthermore, shaft angle error is identified as the dominant sensitivity factor affecting transmission smoothness and edge contact, exerting a more significant influence than offset and axial errors. Compared with existing research on arc-tooth and helical face gears, this work provides a more robust closed-loop verification for curved profiles, revealing that material elastic deformation increases transmission error amplitude by 10.1% to 17.2%. These insights offer a theoretical reference for the high-precision assembly and tolerance allocation of helicopter transmission systems.