In the first part of the thesis, face-milled hypoid gear drives are investigated. Application of theory of gearing provides the description of geometry of pinion and gear surfaces. Derivation of the pinion tooth surface as an envelope to a family of surfaces formed by tooth blades is described conceptually and mathematically. Derivation of the imaginary crown gear for generation is described as well. Simulation of meshing is performed by application of the algorithm of tooth contact analysis, and provides determination of function of transmission errors and the path of contact. A new general approach for determination of the initial conditions of meshing is proposed. Approaches for local and global synthesis are proposed and applied for determination of pinion tool settings for obtaining of favorable conditions of meshing that provide: (i) control and reduction of transmission errors that are the main source of vibrations and noise, (ii) localization of the bearing contact and avoidance of edge contact and areas of concentrated contact stresses.; In the second part, a novel method for simulation of contact of loaded gear drives is proposed. The approach is based on: application of the boundary element method and a pre-processor computer program for generation of contacting models, use of Green operator and the Signorini boundary conditions. The advantages of the new approach in comparison with the previous one, based on general purpose finite element method programs, are: (i) application of a single contacting model (instead of several ones) for analysis of all configurations, and (ii) reduction of required number of nodes and elements. The time required for solution is significantly reduced.; Computer programs have been developed based on the described theory, and numerical examples are provided for illustration.
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