Mathematical Model and Characteristic Analysis of Elliptical Gears Manufactured by Circular-Arc Shaper Cutters

A circular-arc elliptical gear drive with convex (or concave) tooth profiles, which is used in an oil pump with a larger pumping volume, was simulated by using circular-arc shaper cutters with concave (or convex) tool profiles. Mathematical models of circular-arc elliptical gears, based on the theory of gearing and the gear generation mechanism, were also developed. The generated elliptical gear drive has a convex–concave tooth profile contact. Because of its complex geometry, the profile of circular-arc elliptical gears may exhibit tooth undercutting, and pointed teeth. Pointed teeth usually appear on the major axis of the elliptical pitch curve. A geometric relation was developed and applied to prevent the pointed teeth on the elliptical gears. A larger pressure angle at major axis and circular-arc radius can eliminate tooth undercutting and increase its tooth thickness at the addendum circle for small teeth. Moreover, a computer simulation program was developed to generate the tooth profile of circular-arc elliptical gears without tooth undercutting and pointed teeth.