Abstract
Quasi-static modelling of non-conjugate contact of tooth-modified spur and helical gears has been studied at length, but existing models are hindered by convergence problems and require a brute-force numerical approach. Here, a novel, computationally efficient, and stable and unconditionally convergent model is developed for non-conjugate tooth contact in three dimensions and applied to crowned spur and helical gears to assess parametrically the sensitivity of various in- and out-of-plane misalignments on the path of contact, transmission error, and contact pressure. Performance metrics are defined, and comparisons are made between three different crowning modification functions.