The general calculating method of load sharing to every tooth pair in meshing, load distribution, and contact pattern on tooth flank of helical gears with manufacturing and alignment error is shown, for which some parts of tooth flanks on the geometrical line of contact can separate from each other due to the errors. For such gears, stiffness of meshing tooth pair, exciting force of gear vibration, and total composite error (single flank) under loaded condition is derived. Using this calculating method, tooth stiffness, vibration excitation, tooth fillet stress, and contact pattern are calculated for some helical and spur gears, and they are compared with measured results.

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