Gear contact-set consistency check

A gear contact-set consistency check verifies that a proposed solution satisfies force balance and the unilateral contact conditions used to define a gear mesh active-contact set. Solving an equation for selected contacts is insufficient if an omitted tooth should be loaded or an included tooth would require tension.

For the model $F_j=k_j\max (\delta -e_j,0)$, choose a trial active set $\mathcal{A}$ and solveThe check then requires positive $k_j(\delta -e_j)$ for included pairs and $\delta \le e_j$ for excluded pairs. Recomputing every contact with the unilateral law gives the force residualA consistent exact solution has $r_F=0$ together with the inclusion inequalities.

An original example has stiffnesses $100,50,150N/\mu \mathrm{m}$ and gaps $0,2,5\mu \mathrm{m}$. At $F_{\mathrm{applied}}=900\mathrm{N}$, a trial set containing only the first two pairs gives $\delta =20/3\mu \mathrm{m}$. It balances those selected forces but exceeds the third gap by $5/3\mu \mathrm{m}$. The omitted contact would carry $250\mathrm{N}$, giving $r_F=250\mathrm{N}$. Including all three gives the consistent approach $35/6\mu \mathrm{m}$.

Conversely, including all three at applied load $500\mathrm{N}$ gives the un-clipped solution $\delta =4.5\mu \mathrm{m}$ and a third force $-75\mathrm{N}$. Rejecting that tensile contact and solving with the first two gives $\delta =4\mu \mathrm{m}$ and forces $400,100,0\mathrm{N}$.

Numerical tolerances should keep their units and roles clear. A displacement tolerance near a gear tooth engagement threshold is not the same quantity as a force-residual tolerance. At an exact zero-force touch, either a geometric-touch flag or the positive-force active convention may be useful, but the reported convention must be stated. The one-sided gear mesh tangent stiffness can differ across that boundary.

Primary dynamic gear analysis couples tooth stiffness and calculated loads as contact position changes.^[ref] The scalar check above validates internal consistency of its quasistatic model; it does not establish that the model includes every deformation or dynamic effect in a real mesh.