Gearing With Varied Transmission Ratio

GEARING WITH VARIED
TRANSMISSION RATIO
AUGUST 1, 2022
YURI WANG
Preface
Gearing with varied transmission ratio can realize special functional relationship and be
therefore used in instrumentation and industry. Since their tooth profile and manufacturing
process are quite different from those of constant transmission ratio with fixed rotating axes,
and current theory of gearing mainly focuses on gear tooth profile for constant transmission
ratio with fixed rotating axes, which is, therefore, unable to solve problems related to design,
formation and manufacturing of tooth profile for gear set with varied transmission ratio.
Consequently, their development and application are not well promoted due to lack of fully
theoretical understanding of generation and manufacturing process for tooth profile of varied
transmission ratio.
This book emphasizes theory of conjugate tooth profile with varied transmission ratio and is
composed of four parts.
Part I is theoretical foundation of subsequent sections of this book and some parts of theory of
conjugate surfaces created by Chih-Hsin Chen [1, 2, 3, 4] according to relationship with rest of
this book.
Part II is application of part I in non-circular gear with parallel rotating axes and discusses
calculation of tooth profile, curvature and machine-setting parameters manufactured by rack,
shaper and hob respectively.
Part III and part IV describe new types of invented line-contact tooth profiles of gearing with
varied transmission ratio for two intersecting rotating axes and two crossed rotating axes
respectively, including generation and calculation of tooth profile, curvature and manufacturing
process. Since these types of gear sets are not existent in current industrial practice,
mathematical formulas, calculation methods and manufacturing process presented in part III
and part IV are derived from mathematic discovery rather than engineering practice.
Generation of tooth profiles presented in part III and part IV requires special relative motion of
cutter with respect to workpiece, therefore, it is necessary to design and develop special
machine in order to achieve required relative motion of cutter with respect to workpiece. Part
III and part IV give an occasion to develop new types of gearing and corresponding
manufacturing CNC equipment.
All algorithms in this book are verified numerically and graphically with computer program.
Numerical examples are provided in every part.
It is hoped that this book provides some help to better understand theory of conjugate surfaces
I
and its application in gearing with varied transmission ratio and promote development and
application of this type of gear.
Yuri Wang
August, 2022
II
Contents
Part I Theory of Conjugate Surface 1
Chapter 1 Rotation of Vector 2
1.1.1 Rotation of a Vector about Fixed Oriented Axis 2
1 Expression for Rotation of a Vector 2
2 Expanded Formula for Rotation of a Vector 2
3 Some Properties of Rotation of Vector 3
4 Sequence Reciprocation of Successive Rotations about Two Axes with
Shared Origin 4
5 Resolution of Rotation of a Vector 5
1.1.2 Differential of Rotation of a Vector 7
1 Differential Quantity Caused by Differential Change of Rotating Angle 7
2 Differential Quantity Caused by Differential Change of Rotating Axis 8
3 Differential Quantity Caused by Differential Change of Both Rotating
Angle and Axis 9
Chapter 2 Engineering Differential Geometry 10
1.2.1 Boundary Surface 10
1 Expression of Boundary Surface 10
2 Unit Normal at Ant Point on Boundary Surface 11
3 Curvature of Surface 11
1.2.2 Intersection Curve 21
1 Representation of Intersection Curve 21
III
2 Unit Tangent to Intersection Curve at Any Point 21
3 Principal Normal Vector and Curvature at Any Point
on Intersection Curve 22
4 Unit Binormal Vector to Intersecting Curve at Any Point 25
5 Torsional Curvature of Intersecting Curve at Any Point 25
6 Frenet-Serret Frame 27
7 Geometric Angular Velocity of Intersection Curve 27
8 Relative Geometric Angular Velocity of Intersecting Curve
with Respect to Boundary Surface 28
9 Relative Curvature and Relative Torsional Curvature of Intersecting
Curve with Respect to Boundary Surface 29
10 Geodesic Curve 30
11 Differential Equation of Geometric Angular Displacement
For Parallel Transport along a Given Curve on Given Surface 30
12 Parallel Transport of a Vector along a Given Curve on Given Surface 31
13 Displacement of a Vector along a Given Curve on Given Surface 32
14 Relationship between Parallel Transport and Displacement of
a Vector along a Given Curve on Given Surface 34
Chapter 3 Conjugate Motion, Conjugate Surface and Requirements of Conjugate Contact 37
1.3.1 Canonical Form of Conjugate Motion 37
1.3.2 Canonical Form of Simple Conjugate Motion 38
1.3.3 Dual Coordinate System for Simple Conjugate Motion 39
1.3.4 Displacement of Any Point on Rigid Body in Simple Conjugate Motion
IV
with Single Degree of Freedom 40
1 Independent Parameters of Variable 40
2 Displacement of Point on Rigid Body I 40
3 Common Point on Rigid Body II 41
4 Initial Position of Common Point on Rigid Body II 41
1.3.5 Linear Velocity of Point in Simple Conjugate Motion with Single
Degree of Freedom 42
1 Linear Velocity of Common Point on Rigid Body I 42
2 Linear Velocity of Common Point on Rigid Body II 42
3 Relative Linear Velocity of Common Point on Rigid Body I
with Respect to Rigid Body II 42
1.3.6 Angular Velocity of Simple Conjugate Motion with Single Degree
of Freedom 43
1.3.7 Conjugate Contact Point and Conjugate Point 43
1 Definition 43
2 Requirements to be Satisfied by Conjugate Contact Point 43
1.3.8 Instantaneous Contact Line and Contact Line 44
1 Definition 44
2 Calculation of Instantaneous Contact Line 45
1.3.9 Path of Contact and the Second Conjugate Surface 47
Chapter 4 Pitch Surface and Surface of Screw Axis 48
1.4.1 Definition of Pitch Surface 48
V
1.4.2 Existent Condition of Pitch Surfaces 48
1.4.3 Equation of Pitch Surfaces 48
1 Equation of the First Pitch Surface 48
2 Path of Contact for Pitch Surfaces 48
3 Equation of the Second Pitch Surface 49
1.4.4 Unit Normal to Pitch Surface at Instantaneous Contact Position 49
1.4.5 Rate of Rotating Angular Increment with Respect to Arc-Length, Ratio of
Arc-Length on Path of Contact with Respect to Arc-Length on the First
Conjugate Surface and Unit Tangent to Path of Contact 53
1 Rate of Rotating Angular Increment with Respect to Arc-Length 53
2 Ratio of Arc-Length on Path of Contact with Respect to Arc-Length
on the First Conjugate Surface and Unit Tangent to Path of Contact 53
1.4.6 Unit Normal to Path of Contact Corresponding to a Pair of Pitch Surface 53
1.4.7 Relationship of Conjugate Curvatures at Pitch Point 55
1.4.8 Curvatures of Pitch Surfaces 56
1.4.9 Relationship of Curvatures between a Pair of Pitch Surfaces and a Pair of
Corresponding Conjugate Surfaces 63
1 Alternative Expression for Relative Linear Velocity of Common Point
On Rigid Body I with Respect to Rigid Body II at an Instant Rotating
Angle 𝜀1 63
1.4.10 Planer Case 69
1 Dual Coordinate Systems 69
2 Equation of the First Pitch Surface 69
VI
3 Path of Contact of Pitch Surfaces 70
4 Equation of the Second Pitch Surface 71
5 Unit Normal to Pitch Surface at Instantaneous Contact Point 71
6 Rate of Angular Increment with Respect to Arc-Length on Pitch Surface 72
7 Ratio of Arc-Length on Path of Contact with Respect to Conjugate
Arc-Length on the First Pitch Surface and Unit Tangent to Path
Of Contact 73
8 Unit Normal to Path of Contact Corresponding to a Pair of Pitch Surfaces 73
9 Relationship of Conjugate Curvatures at Pitch Point 73
10 Curvatures of Pitch Surfaces 74
11 Relationship of Curvatures between Pitch Surfaces (𝐴0 , ̅̅̅

𝐴0 ) and
Corresponding Conjugate Surfaces (𝐴, 𝐴̅) 75
12 Arc-Length of Pitch Curves 76
1.4.11 Surfaces of Screw Axes 77
1 Definition 77
2 Equations of Surfaces of Screw Axes 77
1.4.12 Summary of Chapter 4 81
Chapter 5 Curvature Parameters within Differential Region of Conjugate Contact
Point between a Pair of Line Conjugate Contact Surfaces 82
1.5.1 Three Basic Differential Quantities and Their Conjugate Relationships 82
1 Three Basic Differential Quantities 82
2 Conjugate Relationship among Three Differential Quantities 84
1.5.2 Rate of Rotating Angular Increment 87
VII
1 Definition 87
𝑑𝜀1𝑝
2 Calculation of ( 𝑑𝑠 ) 87
1 𝜏
3 Some Special Tangent Directions 91
1.5.3 Calculation of Relative Curvature 93
1 In Direction of 𝒆 93
𝒗𝟏𝟐
𝒑
2 In Direction of 93
|𝒗𝟏𝟐
𝒑 |
3 In Direction of 𝒈 94
4 In Any Tangent Direction 𝝉 94
1.5.4 Calculation of Some Conjugate Parameters 95
1 Curvature of the Second Conjugate Surface 95
2 Intersection Angle between a Pair of Conjugate Directions (𝝉, 𝝉′ ) 96
3 Ratio of Conjugate Arc-Length 97
1.5.5 Calculation of Some Parameters on Path of Contact 97
1 Unit Normal to Path of Contact 97
2 Relationship between Engagement Direction and Conjugate Direction 98
3 Ratio of Engagement Arc-Length with Respect to Conjugate Arc-Length 99
4 Some Special Unit Normal Directions 99
1.5.6 Planar Case 100
1 Rate of Rotating Angular Increment 100
2 Three Conjugate Relationships 103
3 Relative Curvature 104
4 Ratio of Conjugate Arc-Length 106
VIII
5 Ratio of Engagement Arc-Length with Respect to Conjugate
Arc-Length 106
6 Unit Tangent to Path of Contact 106
1,5.7 Summary of Chapter 5 106
Chapter 6 Curvature Calculation of the First Conjugate Surface Generated by Intersecting
Curve as the Second Conjugate Surface 108
1.6.1 Curvature of the First Conjugate Surface Generated by Intersecting Curve
as the Second Conjugate Surface 108
1 Given Parameters 108
2 Calculation of Curvature 108
1.6.2 Calculation of Curvature for Conical Helicoid 111
1 Coordinate System 111
2 Conjugate Motion 111
3 Parameters of Cutting Edge 113
4 Curvature of Surface Generated by Cutting Edge 113
Chapter 7 Motion Requirement for Generating Surface (Surface of Cutter) with Respect
To Group of Line Contact Conjugate Surfaces with Interchangeability 116
1.7.1 Interchangeability of Conjugate Surfaces 116
1.7.2 Motion Requirement for Interchangeability of Conjugate Surfaces 116
1.7.3 Motion Requirement for Interchangeability of Conjugate Surfaces
In the Case of Intersecting Rotating Axes 120
1.7.4 3 Motion Requirement for Interchangeability of Conjugate Surfaces
In the Case of Cross Fixed Rotating Axes 121
IX
Part II Non-Circular Gear with Parallel Rotating Axes 124
Chapter 1 Non-Circular Gear Manufactured by Shaper 125
2.1.1 Motion Requirements and Machine Setting Parameters 125
1 Motion Condition of Cutters 125
2 Motion Parameters of Cutters 131
3 Machine Setting Parameters 133
4 Summary of Motion Parameters 138
2.1.2 Calculation of Tooth Profile 139
1 Cutting Edges of Cutters 139
3 Cutting Position 142
4 Tooth Profile of Driving Gear 147
5 Tooth Profile of Driven Gear 148
2.1.3 Curvature of Tooth Profile 149
1 Curvature of Tooth Profile 𝐴 of Driving Gear 149
2 Curvature of Tooth Profile 𝐴̅ of Driven Gear 151
Chapter 2 Non-Circular Gear Manufactured by Rack 164
1 Expression for Cutting Edge of Rack 164
3 Rotary Angle and Position of Rack 165
2.2.2 Tooth Profile of Workpieces 171
X
1 Tooth Profile of Workpiece 1 171
2.2.3 Curvature of Tooth Profile of Workpieces 174
1 Curvature of Tooth Profile of Workpiece 1 174
Chapter 3 Non-Circular Gear Manufactured by Hob 181
2.3.1 Geometry Property of Cylindrical Helicoid with Constant Lead 181
1 Unit Normal to Cylindrical Helicoid 181
2 Curvature of Cylindrical Helicoid 182
2.3.2 Geometry Property of Involute Helicoid with Constant Lead 182
1 Intersection of Involute Helicoid with Plane Tangent to Base Cylinder 182
2 Unit Normal to Involute Helicoid 188
3 Curvature of Involute Helicoid 189
4 Conjugate Surface of Involute Helicoid in Line Contact between
Parallel Rotating Axes 190
2.3.3 Geometry Property of Archimedean Helicoid with Constant Lead 199
1 Unit Normal to Archimedean Helicoid 199
2 Curvature of Archimedean Helicoid 201
3 Conjugate Surface of Archimedean Helicoid in Line Contact between
Parallel Rotary Axes 201
2.3.4 Effective Relative Velocity and Motion Requirements 203
1 Establishing Coordinate System 203
2 Mount Angle of Hobs 205
XI
3 Effective Relative Velocity 206
4 Motion Requirement 210
2.3.5 Calculation of Tooth Profiles and Machine Setting Parameters 212
1 Calculation of Conjugate Cutting Point on Helicoid Hob 212
2.3.7 Limit Tooth Profile Angle of Hob 231
Chapter 4 Non-Circular Helical Gear Manufactured by Involute Hob 239
1 Relative Motion of Workpieces with Respect to Hobs 239
2 Establishing Coordinate System 240
3 Effective Relative Velocity 245
4 Motion Requirements 249
2.4.2 Calculation of Teeth Profiles and Machine Setting Parameters 251
1 Calculation of Conjugate Cutting Point on Helicoid of Hob 251
XII
2.4.4 Limit Tooth Profile Angle of Hob 271
Part III Gear Transmission with Varied Transmission Ratio Between Two
Intersecting Rotating Axes 279
Chapter 1 Pitch Curve of Workpiece 1 & 2 280
3.1.1 Coordinate System and Relative Velocity 280
2 Index Curve 280
3 Relative Velocity 281
3.1.2 Pitch Curves of Workpiece 1 & 2 282
1 First Pitch Curve 282
2 Second Pitch Curve 282
3 Arc-Length of Pitch Curve 282
4 Calculation of Parameter 𝑅0 283
Chapter 2 Cutter Surfaces 284
3.2.1 General Equation of Conical Surface 284
3.2.2 Cutter Surface for Workpiece 1 285
3.2.3 Cutter Surface for Workpiece 2 287
Chapter 3 Machine Setting Parameters 289
3.3.1 Coordinate System 289
1 Machine Coordinate System 289
2 Integration of Machine Coordinate System with Coordinate System of
XIII
Workpiece 1 and 2 289
3.3.2 Ratio of Roll 291
1 Design Reference Point 291
3 Calculation for Machine Setting Parameters 293
Chapter 4 Calculation of Tooth Profile 297
3.4.1 Instantaneous Contact Point 297
1 Instantaneous Contact Point and Instantaneous Contact line
in the Case of Tilt Device 297
2 Instantaneous Contact Point in the Case of No Tilt Device 302
3.4.2 Tooth Profile 305
Chapter 5 Calculation of Curvature 307
3.5.1 Curvature of Cutter Surface in Direction of Tangent to Cutting Edge 307
3.5.2 Curvature of Tooth Profile of Workpiece 1 308
1 Curvature of Cutter Surface in Direction of Relative Velocity of Cutter
Surface with Respect to Workpiece 1 308
2 Calculation of Some Parameters 310
XIV
Part IV Gear Transmission with Varied Transmission Ratio between Two Crossed
Rotating Axes 321
Chapter 1 Parameter Design of Tooth Profile of Workpiece 1 & 2 322
4.1.1 Index Curve 322
4.1.2 Pitch Angle, Spiral Angle and Pressure Angle 325
1 Pitch Angle 325
2 Spiral Angle 327
3 Pressure Angle 329
Chapter 2 Machine Setting Parameters 332
4.2.1 Coordinate System 332
1 Motion of Machining 332
4.2.2 Calculation of Machine Setting Parameters 334
2 Calculation for Machine Setting Parameters with Tilt Device 334
3 Calculation for Machine Setting Parameters without Tilt Device 337
Chapter 3 Calculation of Tooth Profile 339
4.3.1 Instantaneous Contact Point and Instantaneous Contact Line 339
1 Instantaneous Contact Point and Instantaneous Contact Line
In the Case of Tilt Device 339
2 Instantaneous Contact Point and Instantaneous Contact Line
In the Case of No Tilt Device 345
XV
4.3.2 Tooth Profile 348
Chapter 4 Calculation of Curvature 362
1 Curvature of Cutter Surface in Direction of Tangent to Cutting Edge 362
Chapter 5 Helical Gear Set with Varied Transmission Ratio between Crossed
Rotating Axes 378
4.5.1 Index Curve 378
2 Index Curve of Workpiece 1 378
3 Index Curve of Workpiece 2 379
4.5.2 Pitch Angle, Spiral Angle and Pressure Angle 379
1 Unit Normal to Gear Blank Surface of Workpiece 1 379
2 Pitch Angle 379
3 Spiral Angle 380
XVI
4 Pressure Angle 381
4.5.3 Machine Setting Parameters 381
2 Surface of Cutter 382
3 Calculation of Machine Setting Parameters 383
4.5.4 Instantaneous Contact Point and Instantaneous Contact Line 387
1 Instantaneous Contact Point 387
2 Instantaneous Contact Line 391
4.5.5 Tooth Profiles of Workpiece 1 & 2 391
4.5.6 Calculation of Curvature 399
1 Curvature of Workpiece 1 399
1.1 Calculation of Some Parameters 400
1.2 Curvature of Tooth Profile of Workpiece 1 401
2 Curvature of Workpiece 2 402
2.1 Calculation of Some Parameters 402
2.2 Curvature of Tooth Profile of Workpiece 2 403
References 404
XVII
Part I
Theory of Conjugate Surface
Introduction
All kinds of modern mechanical machining process, though variant in appearance, yet in sense
of geometry and kinematics, can be reduced to a common phenomenon, that is, a geometrical
configuration can be transformed by means of conjugate motions into another conjugate
geometrical configuration. Similarly, all kinds of modern mechanical transmission and all kinds
of modern mechanisms employed in mechanization and automation, though variant in
appearance, yet in sense of geometry and kinematics, can be reduced into a common
phenomenon, that is, the motion at an input end can be transformed by means of a pair of (or a
series of pairs of) conjugate geometrical configurations into another conjugate motion at
output end. In a word, all kinds of mechanical machining process, mechanical transmission and
various mechanisms employed in mechanization and automation may be regarded as variant
aspects of a common problem, that is, problem of mutual transformation between conjugate
geometrical configurations and conjugate motions. Theory which deals with this problem is
called “Theory of Conjugate Surfaces”
This part provides brief introduction of “Theory of Conjugate Surfaces” cited from reference [1],
[2], [3] and [4] and is the theoretical foundation for subsequent sections of this book.
~1~
Chapter 1
Rotation of a Vector
1.1.1 Rotation of a Vector about Fixed Oriented Axis

Rotation of a vector is a very useful and important tool in dealing with kinematical and
geometrical problems of tooth profile analysis and calculation. Therefore, here are given two
formulae regarding rotation of a vector, that is, formula for rotation of a vector about single
rotating axis, and formula for rotation of a vector by a differential rotating angle about an axis.
1 Expression for Rotation of a Vector

𝝎
Figure 1.1.1-1. Rotation of Vector
Given an arbitrary point-vector 𝑨 and an arbitrary unit vector 𝝎. Rotating vector 𝑨 by an angle
𝜀 (by the right-hand rule) about 𝝎 as an axis results in a new point-vector 𝒂 sharing the same
origin 𝑂 with the vector 𝑨 as shown in figure.1.1.1-1. Now introducing a new operational sign
" ⊗ ", the new point-vector 𝒂 can be expressed as
𝒂 = (𝜀𝝎) ⊗ 𝑨 (1.1.1-1)
The expression (1.1.1-1) is referred to as the expression for rotation of a vector.
2 Expanded Formula for Rotation of a Vector

As shown in figure 1.1.1-2,
⃗⃗⃗⃗⃗ = 𝑂𝐸
𝒂 = (𝜀𝝎) ⊗ 𝑨 = 𝑂𝐵 ⃗⃗⃗⃗⃗ + ⃗⃗⃗⃗⃗ ⃗⃗⃗⃗⃗⃗
𝐸𝐷 + 𝐷𝐵
Where:
~2~
̅̅̅̅ ̅̅̅̅
⃗⃗⃗⃗⃗ = |𝑂𝐸| 𝑂𝐴
𝑂𝐸 ⃗⃗⃗⃗⃗ = |𝐶𝐷| 𝑨 = cos 𝜀 𝑨,
̅̅̅̅|
|𝑂𝐴 ̅̅̅̅|
|𝐶𝐴
̅̅̅̅
|𝐸𝐷 | ̅̅̅̅ ̅̅̅̅ ̅̅̅̅
⃗⃗⃗⃗⃗
𝐸𝐷 = |𝑂𝐶 ̅̅̅̅ |𝝎 = ⌊𝐷𝐴⌋ (𝑨 ∙ 𝝎)𝝎 = |𝐶𝐴|−|𝐶𝐷| (𝑨 ∙ 𝝎)𝝎 = (1 − cos 𝜀)(𝑨 ∙ 𝝎)𝝎,
|𝑂𝐶
̅̅̅̅ | ̅̅̅̅|
|𝐶𝐴 |𝐶𝐴|
⃗⃗⃗⃗⃗⃗ ̅̅̅̅| 𝝎×𝑨 = |𝐶𝐵
𝐷𝐵 = |𝐷𝐵 ̅̅̅̅ | sin 𝜀 𝝎×𝑨
̅̅̅̅| sin 𝜀
= |𝐶𝐴
𝝎×𝑨
= sin 𝜀 (𝝎 × 𝑨).
|𝝎×𝑨| ̅̅̅̅| sin 𝜃
|𝑂𝐴 ̅̅̅̅|
|𝐶𝐴 }
𝝎 𝐵
𝐶 𝜀 𝐷 𝐴
𝒂 𝑨
𝜃 𝐸
Figure 1.1.1-2 Derivation of formular for rotation of a vector
Therefore, expanded formula for rotation of a vector is as follow:
𝒂 = (𝜀𝝎) ⊗ 𝑨 = cos 𝜀 𝑨 + (1 − cos 𝜀)(𝑨 ∙ 𝝎)𝝎 + sin 𝜀 (𝝎 × 𝑨). (1.1.1-2)
3 Some Properties of Rotation of Vector

1) Property I
(𝜀𝝎) ⊗ 𝝎 = 𝝎 (1.1.1-3)
2) Property II
(𝜀𝝎) ⊗ (𝐶𝑨) = 𝐶[(𝜀𝝎) ⊗ 𝑨] (1.1.1-4)
3) Property III
(𝜀𝝎) ⊗ (𝑨 ± 𝑩) = (𝜀𝝎) ⊗ 𝑨 ± (𝜀𝝎) ⊗ 𝑩 (1.1.1-5)
4) Property IV
(𝜀1 𝝎) ⊗ [(𝜀2 𝝎) ⊗ 𝑨] = (𝜀2 𝝎) ⊗ [(𝜀1 𝝎) ⊗ 𝑨] = [(𝜀1 + 𝜀2 )𝝎] ⊗ 𝑨 (1.1.1-6)
5) Property V
(𝑑𝜀𝝎) ⊗ 𝑨 = 𝑨 + 𝑑𝜀(𝝎 × 𝑨) (1.1.1-7)
~3~
Application of expression (1.1.1-2) gives
(𝑑𝜀𝝎) ⊗ 𝑨 = cos 𝑑𝜀 𝑨 + (1 − cos 𝑑𝜀)(𝑨 ∙ 𝝎)𝝎 + sin 𝑑𝜀 (𝝎 × 𝑨)
Substitution of cos 𝑑𝜀 ≈ 1 and sin 𝜀 ≈ 𝑑𝜀 into expression above generates expression (1.1.1-
7).
6) Property VI
𝝎 × [(𝜀𝝎) ⊗ 𝑨] = (𝜀𝝎) ⊗ (𝝎 × 𝑨) (1.1.1-8)
7) Property VII
[(𝜀𝝎) ⊗ 𝑨] ∙ [(𝜀𝝎) ⊗ 𝑩] = 𝑨 ∙ 𝑩 (1.1.1-9)
8) Property VIII
[(𝜀𝝎) ⊗ 𝑨] × [(𝜀𝝎) ⊗ 𝑩] = (𝜀𝝎) ⊗ (𝑨 × 𝑩) (1.1.1-10)
9) Property IX
{[(𝜀𝝎) ⊗ 𝑨] × [(𝜀𝝎) ⊗ 𝑩]} ∙ [(𝜀𝝎) ⊗ 𝑪] = (𝑨 × 𝑩) ∙ 𝑪 (1.1.1-11)
10) Property X
[(𝜀𝝎) ⊗ 𝑨] × {[(𝜀𝝎) ⊗ 𝑩] × [(𝜀𝝎) ⊗ 𝑪]} = (𝜀𝝎) ⊗ [𝑨 × (𝑩 × 𝑪)] (1.1.1-12)
11) Property XI
{[(𝜀𝝎) ⊗ 𝑨] × [(𝜀𝝎) ⊗ 𝑩]} ∙ {[(𝜀𝝎) ⊗ 𝑪] × [(𝜀𝝎) ⊗ 𝑫]} = (𝑨 × 𝑩) ∙ (𝑪 × 𝑫) (1.1.1-13)
4 Sequence Reciprocation of Successive Rotations about two Axes with Shared

Origin
Assume that a rigid body rotates by an angle 𝜃1 about 𝝎1 as an axis, followed by rotating by an
angle 𝜃2 about 𝝎2 as an axis, and rotating axes 𝝎1 and 𝝎2 share the same origin 𝑂, and then,
any point vector 𝑹 with respect to 𝑂 on rigid body reaches to (𝜃2 𝝎2 ) ⊗ [(𝜃1 𝝎1 ) ⊗ 𝑹], this
point vector can be obtained by rotation of vector with equivalent order change of rotating
axes as follow
(𝜃2 𝝎2 ) ⊗ [(𝜃1 𝝎1 ) ⊗ 𝑹] = {𝜃1 [(𝜃2 𝝎2 ) ⊗ 𝝎1 ]} ⊗ [(𝜃2 𝝎2 ) ⊗ 𝑹] (1.1.1-14)
Expression (1.1.1-14) is called expression of equivalent order exchange of successive rotations
~4~
of vector about two axes with shared origin.
5 Resolution of Rotation of a Vector

Rotation of a vector about 𝝎 by an angle 𝜃 can be resolved into three successive rotations
about two prescribed mutually perpendicular axes, i.e., 𝝎1 and 𝝎0 (𝝎1 ∙ 𝝎0 = 0), with a
common origin on the axis 𝝎 as follow:
(𝜃𝝎) ⊗ 𝑹 = (𝜃1 𝝎1 ) ⊗ {(𝜃0 𝝎0 ) ⊗ [(𝜃2 𝝎1 ) ⊗ 𝑹]} (1.1.1-15)
Where: 𝑹 is any point-vector. 𝜃0 , 𝜃1 and 𝜃2 are determined by following equations

𝜃
𝜃0 = 2 sin−1 {√1 − (𝝎 ∙ 𝝎1 )2 sin 2} ,
(0 ≤ 𝜃0 ≤ 𝜋),
𝑖𝑓 𝝎 ∙ 𝝎0 ≥ 0, 𝑖𝑓 𝝎 ∙ 𝝎0 < 0,
𝜃1 = 𝛿1 + 𝛿2 , } 𝑜𝑟 𝜃1 = 𝜋 + 𝛿1 − 𝛿2 ,}
𝜃2 = 𝛿1 − 𝛿2 . 𝜃2 = 𝛿1 + 𝛿2 − 𝜋.
𝜃 𝜋 𝜋
𝛿1 = tan−1 [(𝝎 ∙ 𝝎1 ) tan 2] , − 2 ≤ 𝛿1 ≤ 2 ,
𝝎∙(𝝎1 ×𝝎0 ) 𝜋 𝜋
𝛿2 = tan−1 [ ] , − 2 ≤ 𝛿2 ≤ 2 . }
𝝎∙𝝎0
Example 1.1.1 Parametric Expression of general helicoid with constant lead
Generatrix of helicoid is given as shown in figure 1.1.1-3.
𝑮0 = 𝑥0 (Γ)𝒊 + 𝑦0 (Γ)𝒋 + 𝑧0 (Γ)𝒌 (1.1.1-16)
𝑮0
Figure 1.1.1-3 Formation of General Helicoid
Helicoid is generated by rotating generatrix 𝑮0 by an angle 𝜃 about 𝒌 as an axis together with

translating a distance 𝜃𝑏 along axis 𝒌 as follow
~5 ~
𝑯 = (𝜃𝒌) ⊗ 𝑮0 + 𝜃𝑏𝒌 = 𝑥ℎ (Γ, 𝜃)𝒊 + 𝑦ℎ (Γ, 𝜃)𝒋 + 𝑧ℎ (Γ, 𝜃)𝒌
(1.1.1-17)
= [𝑥0 (Γ) cos 𝜃 − 𝑦0 (Γ) sin 𝜃]𝒊 + [𝑥0 (Γ) sin 𝜃 + 𝑦0 (Γ) cos 𝜃]𝒋 + [𝑧0 (𝛼) + 𝑏𝜃]𝒌
Where: 𝑏 > 0 for right-hand of helicoid and 𝑏 < 0 for left-hand of helicoid. Γ and 𝜃 are two
surface parameters,
𝑥ℎ (Γ, 𝜃) = 𝑥0 (Γ) cos 𝜃 − 𝑦0 (Γ) sin 𝜃 ,

𝑦ℎ (Γ, 𝜃) = 𝑥0 (Γ) sin 𝜃 + 𝑦0 (Γ) cos 𝜃 ,}
𝑧ℎ (Γ, 𝜃) = 𝑧0 (Γ) + 𝑏𝜃.
Example 1.1.2 Parametric Equation of Involute helicoid
Generatrix of involute helicoid is an involute curve as shown in figure 1.1.1-4, that is,
𝑮0 = 𝑥0 (Γ)𝒊 + 𝑦0 (Γ)𝒋 + 𝑧0 (Γ)𝒌 = (−Γ𝒌) ⊗ (−𝑟𝑏 cos 𝜎0 𝒊 − 𝑟𝑏 sin 𝜎0 𝒋 + 𝑟𝑏 Γ𝒔0 )

(1.1.1-18)
= −𝑟𝑏 [Γ sin(Γ − 𝜎0 ) + cos(Γ − 𝜎0 )]𝒊 − 𝑟𝑏 [Γ cos(Γ − 𝜎0 ) − sin(Γ − 𝜎0 )]𝒋
Where: 𝑟𝑏 is radius of bass circle of involute curve. 𝒔0 = sin 𝜎0 𝒊 − cos 𝜎0 𝒋. 𝜎0 is involute

function and
𝑥0 (Γ) = −𝑟𝑏 [Γ sin(Γ − 𝜎0 ) + cos(Γ − 𝜎0 )],

𝑦0 (Γ) = −𝑟𝑏 [Γ cos(Γ − 𝜎0 ) − sin(Γ − 𝜎0 )],}
𝑧0 (Γ) = 0.
𝑮0
𝜎0
𝑟𝑏 Γ𝒔0 Γ 𝑟𝑏
𝑂 𝒋
Figure 1.1.1-4 Involute Curve
Correspondingly, involute helicoid is resulted from substituting expression (1.1.1-18) into

expression (1.1.1-17) as follow
~6~
𝑯 = (𝜃𝒌) ⊗ 𝑮0 + 𝜃𝑏𝒌 = 𝑥ℎ (Γ, 𝜃)𝒊 + 𝑦ℎ (Γ, 𝜃)𝒋 + 𝑧ℎ (Γ, 𝜃)𝒌 (1.1.1-19)
Where: Γ and 𝜃 are surface parameters and
𝑥ℎ (Γ, 𝜃) = −𝑟𝑏 [Γ sin(Γ − 𝜎0 − 𝜃) + cos(Γ − 𝜎0 − 𝜃)],

𝑦ℎ (Γ, 𝜃) = −𝑟𝑏 [Γ cos(Γ − 𝜎0 − 𝜃) − sin(Γ − 𝜎0 − 𝜃)] cos 𝜃 ,}
𝑧ℎ (Γ, 𝜃) = 𝑏𝜃.
Example 1.1.3. Parametric Equation of Archimedean Helicoid
Generatrix of Archimedean helicoid is a straight line in axial intersection as shown in figure

1.1.1-5, that is,
𝑮0 = 𝑥0 (𝑠)𝒊 + 𝑦0 (𝑠)𝒋 + 𝑧0 (𝑠)𝒌

(1.1.1-20)
= 𝑠(− cos ∅0 𝒊 + sin ∅0 𝒌) − 𝑟0 𝒊 = −(𝑟0 + 𝑠 cos ∅0 )𝒊 + 𝑠 sin ∅0 𝒌
Substitution of expressions (1.1.1-20) into (1.1.1-17) yields expression of Archimedean helicoid

as follow:
𝑯 = (𝜃𝒌) ⊗ 𝑮0 + 𝜃𝑏𝒌 = 𝑥ℎ (𝜃, 𝑠)𝒊 + 𝑦ℎ (𝜃, 𝑠)𝒋 + 𝑧ℎ (𝜃, 𝑠)𝒌 (1.1.1-21)
Where:
𝑥ℎ (𝜃, 𝑠) = −(𝑟0 + 𝑠 cos ∅0 ) cos 𝜃 ,

𝑦ℎ (𝜃, 𝑠) = −(𝑟0 + 𝑠 cos ∅0 ) sin 𝜃 , }
𝑧ℎ (𝜃, 𝜇) = 𝑠 sin ∅0 + 𝜃𝑏.
𝑠 𝑟0
∅0
𝑂 𝒊
Figure 1.1.1-5 Generatrix of Archimedean Helicoid
1.1.2 Differential of Rotation of a Vector

1 Differential Quantity Caused by Differential Change of Rotating Angle
~7~
With differential increment ∆𝜀 of rotating angle of point-vector 𝑨 about 𝝎 as an axis from
rotating angle 𝜀 to 𝜀 + ∆𝜀, difference ∆𝒂 between two end points is defined as differential quantity
caused by differential increment ∆𝜀 (∆𝜀 is an infinitesimal) of rotating angle 𝜀 , that is,
∆𝒂 = [(𝜀 + ∆𝜀)𝝎] ⊗ 𝑨 − (𝜀𝝎) ⊗ 𝑨 (1.1.2-1)
Expanding formula above gives
∆𝒂 = [(𝜀 + ∆𝜀)𝝎] ⊗ 𝑨 − (𝜀𝝎) ⊗ 𝑨 = (∆𝜀𝝎) ⊗ [(𝜀𝝎) ⊗ 𝑨] − (𝜀𝝎) ⊗ 𝑨

= ∆𝜀𝝎 × [(𝜀𝝎) ⊗ 𝑨] + [(𝜀𝝎) ⊗ 𝑨] − [(𝜀𝝎) ⊗ 𝑨] = 𝝎 × 𝒂∆𝜀
That is
∆𝒂 = 𝝎 × 𝒂∆𝜀 (1.1.2-2)
Where: 𝒂 = (𝜀𝝎) ⊗ 𝑨.
2 Differential Quantity Caused by Differential Change of Rotating Axis

The difference 𝛿𝒂 between two end points of point-vector 𝑨 rotating about 𝝎 and(𝝎 + 𝛿𝝎) as
axes respectively is defined as differential quantity caused by differential change 𝛿𝝎 of rotating
axis 𝝎 , that is,
𝛿𝒂 = [𝜀(𝝎 + 𝛿𝝎)] ⊗ 𝑨 − (𝜀𝝎) ⊗ 𝑨 (1.1.2-3)
Due to 𝝎 and (𝝎 + 𝛿𝝎) being unit vectors, then,
𝝎 ∙ 𝝎 = 1 = (𝝎 + 𝛿𝝎) ∙ (𝝎 + 𝛿𝝎) = 𝝎 ∙ 𝝎 + 2𝝎 ∙ 𝛿𝝎 + 𝛿𝝎 ∙ 𝛿𝝎
Omitting second-order infinitesimal in expression above leads
𝝎 ∙ 𝛿𝝎 = 0 (1.1.2-4)
Also,
𝑨 = (−𝜀𝝎) ⊗ [(𝜀𝝎) ⊗ 𝑨 ] = (−𝜀𝝎) ⊗ 𝒂

(1.1.2-5)
= cos 𝜀 𝒂 + (1 − cos 𝜀)(𝝎 ∙ 𝒂)𝝎 − sin 𝜀 𝝎 × 𝒂
Neglecting second-order infinitesimal, application of expressions (1.1.2-4) and (1.1.2-5) yields
~8~
[𝜀(𝝎 + 𝛿𝝎)] ⊗ 𝑨 = [𝜀(𝝎 + 𝛿𝝎)] ⊗ [cos 𝜀 𝒂 + (1 − cos 𝜀)(𝝎 ∙ 𝒂)𝝎 − sin 𝜀 𝝎 × 𝒂]
cos 𝜀 [cos 𝜀 𝒂 + (1 − cos 𝜀)(𝝎 ∙ 𝒂)𝝎 − sin 𝜀 𝝎 × 𝒂]
={ +(1 − cos 𝜀)[cos 𝜀 𝒂 ∙ (𝝎 + 𝛿𝝎) + (1 − cos 𝜀)(𝝎 ∙ 𝒂) − sin 𝜀 (𝝎 × 𝒂) ∙ 𝛿𝝎](𝝎 + 𝛿𝝎) }
+ sin 𝜀 [cos 𝜀 (𝝎 + 𝛿𝝎) × 𝒂 + (1 − cos 𝜀)(𝝎 ∙ 𝒂)(𝛿𝝎 × 𝝎) − sin 𝜀 [[𝒂 ∙ (𝝎 + 𝛿𝝎)]𝝎 − 𝒂]]
𝒂 + (1 − cos 𝜀){cos 𝜀 (𝒂 ∙ 𝛿𝝎)𝝎 + (𝝎 ∙ 𝒂)𝛿𝝎 − sin 𝜀 [(𝛿𝝎 × 𝝎) ∙ 𝒂]𝝎}
={ }
+ sin 𝜀 [cos 𝜀 (𝛿𝝎 × 𝒂) + (1 − cos 𝜀)(𝝎 ∙ 𝒂)(𝛿𝝎 × 𝝎) − sin 𝜀 (𝛿𝝎 ∙ 𝒂)𝝎]
𝒂 + (1 − cos 𝜀)[(𝝎 ∙ 𝒂)𝛿𝝎 − (𝛿𝝎 ∙ 𝒂)𝝎] + sin 𝜀 cos 𝜀 (𝛿𝝎 × 𝒂)
={ }
+(1 − cos 𝜀) sin 𝜀 {(𝝎 ∙ 𝒂)(𝛿𝝎 × 𝝎) − [(𝛿𝝎 × 𝝎) ∙ 𝒂]𝝎}
= 𝒂 + (1 − cos 𝜀)[𝒂 × (𝛿𝝎 × 𝝎)] + sin 𝜀 cos 𝜀 (𝛿𝝎 × 𝒂) + (1 − cos 𝜀) sin 𝜀 {𝒂 × [(𝛿𝝎 × 𝝎) × 𝝎]}
= 𝒂 + [(1 − cos 𝜀)(𝝎 × 𝛿𝝎) + sin 𝜀 𝛿𝝎] × 𝒂
Substitution of expression above into expression (1.1.2-3) gives
𝛿𝒂 = [(1 − cos 𝜀)(𝝎 × 𝛿𝝎) + sin 𝜀 𝛿𝝎] × 𝒂 (1.1.2-6)
3 Differential Quantity Caused by Differential Change of both Rotating Angle

and Axis
The difference 𝑑𝒂 between two end points of point vector 𝑨 rotating both by an angle 𝜀 about
𝝎 as an axis and by an angle (𝜀 + 𝑑𝜀) about (𝝎 × 𝑑𝝎) as an axis respectively is defined as
differential quantity caused by differential change of both rotating angle and axis, that is.
𝑑𝒂 = [(𝜀 + 𝑑𝜀)(𝝎 + 𝑑𝝎)] ⊗ 𝑨 − [(𝜀𝝎) ⊗ 𝑨 ] (1.1.2-7)
With the aid of expressions (1.1.2-1), (1.1.2-2), (1.1.2-3) and (1.1.2-6), expression (1.1.2-7) is
updated as follow
𝑑𝒂 = [(𝜀 + 𝑑𝜀)(𝝎 + 𝑑𝝎)] ⊗ 𝑨 − [(𝜀𝝎) ⊗ 𝑨 ]

= [(𝜀 + 𝑑𝜀)(𝝎 + 𝑑𝝎)] ⊗ 𝑨 − [𝜀(𝝎 + 𝑑𝝎)] ⊗ 𝑨 + [𝜀(𝝎 + 𝑑𝝎)] ⊗ 𝑨 − [(𝜀𝝎) ⊗ 𝑨 ]
= (𝝎 + 𝛿𝝎) × [[𝜀(𝝎 + 𝛿𝝎)] ⊗ 𝑨]𝑑𝜀 + [(1 − cos 𝜀)(𝝎 × 𝑑𝝎) + sin 𝜀 𝑑𝝎] × 𝒂
Neglecting second order infinitesimal, it gives
𝑑𝒂 = [𝑑𝜀𝝎 + (1 − cos 𝜀)(𝝎 × 𝑑𝝎) + sin 𝜀 𝑑𝝎] × 𝒂 (1.1.2-8)
Where: Where: 𝒂 = (𝜀𝝎) ⊗ 𝑨.
~9~
Chapter 2
Engineering Differential Geometry
1.2.1 Boundary Surface

Boundary surface is a part of entity one side of which is entity and the other side is void as
shown in figure 1.2.1-1.
(𝑑𝑵)𝝉 𝑵 + (𝑑𝑵)𝝉
𝑵
𝜕𝑹
𝑵×𝝉 𝜕𝑣
𝒌 𝑑𝑠 𝝉
𝑃 𝑃′
𝜕𝑹
𝑹
𝜕𝑢
𝑂 𝒋
Figure 1.2.1-1 Boundary Surface

1 Expression of Boundary Surface
1) Implicit Form
Let coordinates of an arbitrary point on boundary surface be (𝑥, 𝑦, 𝑧).
A boundary surface is defined by an implicit equation of the form as follow:
~ 10 ~
𝐹(𝑥, 𝑦, 𝑧) = 0 (1.2.1-1)
2) Parametrized Form
Assume 𝑹 is a point-vector of an arbitrary point on boundary surface, each of the coordinates of point-
vector 𝑹 is represented separately as an explicit function of two independent parameters (𝑢, 𝑣)
𝑹(𝑢, 𝑣) = 𝑥(𝑢, 𝑣)𝒊 + 𝑦(𝑢, 𝑣)𝒋 + 𝑣(𝑢, 𝑣)𝒌 (1.2.1-2)
Parametric form is more natural and easier for design and analyses of tooth profile and
presenting 3D-shape in computer. Therefore, only parametrized form is concerned here.
2 Unit Normal at any Point on the Boundary Surface

The partial derivative of 𝑹(𝑢, 𝑣) is
𝜕𝑹 𝜕𝑥 𝜕𝑦 𝜕𝑧
= 𝜕𝑢 𝒊 + 𝜕𝑢 𝒋 + 𝜕𝑢 𝒌,
𝜕𝑢
𝜕𝑹 𝜕𝑥 𝜕𝑦 𝜕𝑧
} (1.2.1-3)
= 𝜕𝑣 𝒊 + 𝜕𝑣 𝒋 + 𝜕𝑣 𝒌.
𝜕𝑣
The unit normal 𝑵 to the boundary surface at a point is given by

𝜕𝑹 𝜕𝑹
×
𝜕𝑢 𝜕𝑣
𝑵= 𝜕𝑹 𝜕𝑹 = 𝐴𝒊 + 𝐵𝒋 + 𝐶𝒌 (1.2.1-4)
| × |
𝜕𝑢 𝜕𝑣
Substitution of expressions (1.2.1-2) and (1.2.1-3) into (1.2.1-4) yields

1 𝜕𝑦 𝜕𝑧 𝜕𝑧 𝜕𝑦
𝐴 = 𝑄 (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣 ) ,
1 𝜕𝑧 𝜕𝑥 𝜕𝑥 𝜕𝑧
𝐵 = 𝑄 (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) ,
1 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥 (1.2.1-5)
𝐶 = 𝑄 (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) ,
𝜕𝑦 𝜕𝑧 𝜕𝑧 𝜕𝑦 2 𝜕𝑧 𝜕𝑥 𝜕𝑥 𝜕𝑧 2 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥 2
𝑄 = ±√(𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣 ) + (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) + (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) .}
Where: sign " ± " is decided by 𝑵 pointing from entity to void.
3 Curvature of Surface
1) Definition
Let 𝑵 be a unit normal to surface at any point 𝑃 and 𝝉 be an arbitrary unit tangent vector.
~ 11 ~
Point 𝑃′ is adjacent to point 𝑃 in tangent direction 𝝉 with arc-length 𝑑𝑠 from point 𝑃, and 𝑵 +
𝑑𝑵
(𝑑𝑵)𝝉 is unit normal at point 𝑃′ . Let 𝑑𝑠 approach to zero, and then the limit vector ( ) is
𝑑𝑠 𝝉
defined as curvature of surface at point 𝑃 in the tangent direction 𝝉.
2) Expanded Form for Curvature of Surface
Due to 𝑵 being a unit normal, that is,
𝑵∙𝑵=1
Then
𝑑 𝑑𝑵
[𝑑𝑠 (𝑵 ∙ 𝑵)] = 2𝑵 ∙ ( 𝑑𝑠 ) = 0
𝝉 𝝉
𝑑𝑵
Therefore, ( 𝑑𝑠 ) lies on tangent plane and can be resolved in two perpendicular directions 𝝉
𝝉
and 𝑵 × 𝝉 respectively.
𝑑𝑵
( 𝑑𝑠 ) = 𝐾𝜏 𝝉 + 𝐺𝜏 (𝑵 × 𝝉) (1.2.1-6)
𝝉
3) Normal Curvature
a) Definition
In expression (1.2.1-6), the component 𝐾𝜏 in direction 𝝉 is defined as normal curvature of

surface at point 𝑃 in the tangent direction 𝝉.
b) Geometric Implication of Normal Curvature 𝐾𝜏
Constructing a plane at point 𝑃 including 𝝉 and 𝑵 as shown in figure 1.2.1-2. The intersection
curve between this plane and surface is 𝒘(𝑠). The point vector on intersection curve
corresponding to arc-length 𝑠 + ∆𝑠 is
𝑑𝒘 1 𝑑2 𝒘
𝒘(𝑠 + ∆𝑠 ) = 𝒘(𝑠) + ∆𝑠 + 2 𝑑𝑠2 (∆𝑠)2 + 𝑜[(∆𝑠)2 ]
𝑑𝑠
Where: 𝑜[(∆𝑠)2 ] is a higher-second order infinitesimal.
The distance from point 𝒘(𝑠 + ∆𝑠 ) to tangent plane along direction of unit normal 𝑵 is ℎ
𝑑𝒘 1 𝑑2 𝒘
ℎ = −[𝒘(𝑠 + ∆𝑠 ) − 𝒘(𝑠)] ∙ 𝑵 = − [ 𝑑𝑠 ∆𝑠 + 2 𝑑𝑠2 (∆𝑠)2 + 𝑜[(∆𝑠)2 ]] ∙ 𝑵 (1.2.1-7)
~ 12 ~
𝑑𝒘
Due to being a unit tangent 𝝉 to intersection curve at point 𝑃, then
𝑑𝑠
𝑑𝒘
∙𝑵=0
𝑑𝑠
𝑑𝒘
Taking derivative of expression ∙ 𝑵 = 0 with respect to arc-length 𝑠 results in
𝑑𝑠
𝑑2 𝒘 𝑑𝒘 𝑑𝑵 𝑑2 𝒘 𝑑𝑵
∙𝑵+ ∙ ( 𝑑𝑠 ) = ∙ 𝑵 + 𝝉 ∙ ( 𝑑𝑠 ) = 0
𝑑𝑠2 𝑑𝑠 𝝉 𝑑𝑠2 𝝉
Tangent plane 𝑃 𝝉
∆𝑠
1
𝐾𝜏
𝒘(𝑠)
Figure 1.2.1-2 Geometric Implication of Normal Curvature
With aid of expression (1.2.1-6), the equation above leads
𝑑2 𝒘
∙ 𝑵 = −𝐾𝜏
𝑑𝑠2
With neglect of second or higher order infinitesimal, expression (1.2.1-7) becomes

1
ℎ = 2 𝐾𝜏 (∆𝑠)2 (1.2.1-8)
Let ℎ0 be distance when ∆𝑠 = 1, then
𝐾𝜏 = 2ℎ0 (1.2.1-9)
~13 ~
4) Torsional Curvature
Definition
In expression (1.2.1-6), the component 𝐺𝜏 in direction 𝑵 × 𝝉 is defined as torsional curvature of

surface at point 𝑃 in the tangent direction 𝝉.
5) Geometric Angular Velocity

𝑑𝑵 𝑑𝑵
Due to ( 𝑑𝑠 ) ∙ 𝑵 = 0, ( 𝑑𝑠 ) can be visualized as virtual linear velocity of end point of 𝑵
𝝉 𝝉
generated by rotation of 𝑵 with geometric angular velocity 𝛀𝜏 (geometric parameter of arc-
length 𝑠 being visualized as virtual time parameter), that is,
𝑑𝑵
( 𝑑𝑠 ) = 𝛀𝜏 × 𝑵 (1.2.1-10)
𝜏
It can be assumed that 𝛀𝜏 lies on tangent plane, then,

𝑑𝑵
𝛀𝜏 = 𝑵 × (𝛀𝜏 × 𝑵 ) = 𝑵 × ( 𝑑𝑠 ) = 𝑵 × [𝐾𝜏 𝝉 + 𝐺𝜏 (𝑵 × 𝝉) ]
𝜏
Thus
𝛀𝜏 = 𝐾𝜏 (𝑵 × 𝝉) − 𝐺𝜏 𝝉 (1.2.1-11)
6) Relationship of Torsional Curvatures between Two Mutually Perpendicular Tangent

Directions
A pair of mutually perpendicular unit vectors 𝒑 , 𝒒 are selected arbitrarily at normal point 𝑃 in
tangent plane, that is,
𝒑 ∙ 𝑵 = 0,
𝒒 ∙ 𝑵 = 0,} (1.2.1-12)
𝒑 ∙ 𝒒 = 0.
Without loss of generality, assume
𝑵=𝒑×𝒒 (1.2.1-13)
Torsional curvature 𝐺𝑝 in tangent direction 𝒑 is equal to negative of torsional curvature 𝐺𝑞 in

tangent direction 𝒒, that is,
𝐺𝑝 = −𝐺𝑞 (1.2.1-14)
~ 14 ~
Proof:
Constructing a transformation function of parameters in expression (1.2.1-2) as
𝑢 = 𝑢(𝑝, 𝑞),
} (1.2.1-15)
𝑣 = 𝑣(𝑝, 𝑞).
That the transformation function (1.2-15) makes surface expression (1.2.1-2) satisfy following
condition
𝜕𝑹 𝜕𝑹 𝜕𝑢 𝜕𝑹 𝜕𝑣
𝒑 = 𝜕𝑝 = 𝜕𝑢 𝜕𝑝 + 𝜕𝑣 𝜕𝑝 ,
𝜕𝑹 𝜕𝑹 𝜕𝑢 𝜕𝑹 𝜕𝑣
} (1.2.1-16)
𝒒= = + .
𝜕𝑞 𝜕𝑢 𝜕𝑞 𝜕𝑣 𝜕𝑞
Dot products of the first and second formulae in expression (1.2.1-16) with 𝒑 and 𝒒 respectively
result in
𝜕𝑹 𝜕𝑢 𝜕𝑹 𝜕𝑣
1 = (𝜕𝑢 ∙ 𝒑) 𝜕𝑝 + ( 𝜕𝑣 ∙ 𝒑) 𝜕𝑝 ,
𝜕𝑹 𝜕𝑢 𝜕𝑹 𝜕𝑣
0 = (𝜕𝑢 ∙ 𝒒) 𝜕𝑝 + ( 𝜕𝑣 ∙ 𝒒) 𝜕𝑝 ,
𝜕𝑹 𝜕𝑢 𝜕𝑹 𝜕𝑣
(1.2.1-17)
1 = (𝜕𝑢 ∙ 𝒒) 𝜕𝑞 + ( 𝜕𝑣 ∙ 𝒒) 𝜕𝑞 ,
𝜕𝑹 𝜕𝑢 𝜕𝑹 𝜕𝑣
0 = (𝜕𝑢 ∙ 𝒑) 𝜕𝑞 + ( 𝜕𝑣 ∙ 𝒑) 𝜕𝑞 .}
The transformation function (1.2.1-15) can be derived by solving simultaneous partial

differential equation (1.2.1-17).
Application of expressions (1.2.1-13) and (1.2.1-16) yields

𝜕𝑹 𝜕𝑹
𝑵=𝒑×𝒒= × 𝜕𝑞 (1.2.1-18)
𝜕𝑝
Then,
𝑑𝑵 𝜕2𝑹 𝜕𝑹 𝜕𝑹 𝜕2𝑹 𝜕2𝑹 𝜕2 𝑹

( 𝑑𝑠 ) = × 𝜕𝑞 + 𝜕𝑝 × 𝜕𝑞𝜕𝑝 = × 𝒒 + 𝒑 × 𝜕𝑞𝜕𝑝
𝒑 𝜕𝑝2 𝜕𝑝2
and
𝑑𝑵 𝜕2𝑹 𝜕𝑹 𝜕𝑹 𝜕2𝑹 𝜕2𝑹 𝜕2𝑹

( 𝑑𝑠 ) = 𝜕𝑝𝜕𝑞 × 𝜕𝑞 + 𝜕𝑝 × 𝜕𝑞2 = 𝜕𝑝𝜕𝑞 × 𝒒 + 𝒑 × 𝜕𝑞2
𝒒
Employment of expression (1.2.1-6) gives
~ 15 ~
𝑑𝑵 𝜕2𝑹 𝜕2𝑹
𝐺𝑝 = ( 𝑑𝑠 ) ∙ (𝑵 × 𝒑) = (𝒑 × 𝜕𝑞𝜕𝑝) ∙ (𝑵 × 𝒑) = − 𝜕𝑞𝜕𝑝 ∙ 𝑵,
𝒑
𝑑𝑵 𝜕2𝑹 𝜕2𝑹
}
𝐺𝑞 = ( 𝑑𝑠 ) ∙ (𝑵 × 𝒒) = (𝜕𝑝𝜕𝑞 × 𝒒) ∙ (𝑵 × 𝒒) = 𝜕𝑝𝜕𝑞 ∙ 𝑵.
𝒒
Finally, it leads to
𝐺𝑝 = −𝐺𝑞
End of Proof.
7) Relationship of Normal and Torsional Curvatures between Different Tangent Directions
Given two pairs of mutually perpendicular unit tangent vectors at point 𝑃 in tangent plane as
such 𝒖, 𝒗 = 𝑵 × 𝒖 and 𝒕, 𝒒 = 𝑵 × 𝒕, 𝒕 is reached by rotating 𝒖 an angle 𝜃𝑢𝑡 about 𝑵, that is,
𝒖 = (−𝜃𝑢𝑡 𝑵 ) ⊗ 𝒕 = cos 𝜃𝑢𝑡 𝒕 − sin 𝜃𝑢𝑡 𝒒,

𝜋 } (1.2.1-19)
𝒗 = [(2 − 𝜃𝑢𝑡 ) 𝑵 ] ⊗ 𝒕 = sin 𝜃𝑢𝑡 𝒕 + cos 𝜃𝑢𝑡 𝒒.
Let 𝐾𝑢 , 𝐾𝑣 , 𝐾𝑡 be normal curvatures and 𝐺𝑢 , 𝐺𝑣 , 𝐺𝑡 be torsional curvatures in tangent

directions 𝒖, 𝒗 and 𝒕 respectively. Due to 𝒖 and 𝒗 being perpendicular to each other, with
expression (1.2.1-14), thus, 𝐺𝑢 = −𝐺𝑣 .
Assume that point 𝑃′ is reached by translation of point 𝑃 with distance 𝑑𝑠 along direction 𝒕 as
The difference (∆𝑵)𝑃→𝑃′ of unit vectors between points 𝑃′ and 𝑃 is calculated by application of
expression (1.2.1-6)
𝑑𝑵
(∆𝑵)𝑃→𝑃′ = ( ) 𝑑𝑠 = (𝐾𝑡 𝒕 + 𝐺𝑡 𝒒)𝑑𝑠 (1.2.1-20)
𝑑𝑠 𝒕
(∆𝑵)𝑃→𝑃′ can also be in consequence of superimposing difference (∆𝑵)𝑃1→𝑃′ generated by

translation of point 𝑃1 with distance 𝑑𝑠 sin 𝜃𝑢𝑡 along direction 𝒗 upon difference (∆𝑵)𝑃→𝑃1
generated by translation of point 𝑃 with distance 𝑑𝑠 cos 𝜃𝑢𝑡 along direction 𝒖 as follow
(∆𝑵)𝑃→𝑃′ = (∆𝑵)𝑃→𝑃1 + (∆𝑵)𝑃1→𝑃′ (1.2.1-21)
Application of expression (2.1-6) results in

𝑑𝑵
(∆𝑵)𝑃→𝑃1 = ( ) 𝑑𝑠 cos 𝜃𝑢𝑡 = (𝐾𝑢 𝒖 + 𝐺𝑢 𝒗)𝑑𝑠 cos 𝜃𝑢𝑡 ,
𝑑𝑠 𝒖
𝑑𝑵
} (1.2.1-22)
(∆𝑵)𝑃1→𝑃′ = ( ) 𝑑𝑠 sin 𝜃𝑢𝑡 = (𝐾𝑣 𝒗 − 𝐺𝑣 𝒖)𝑑𝑠 sin 𝜃𝑢𝑡 = (𝐾𝑣 𝒗 + 𝐺𝑢 𝒖)𝑑𝑠 sin 𝜃𝑢𝑡
𝑑𝑠 𝒗
~ 16 ~
𝒗=𝑵×𝒖
𝒒=𝑵×𝒕
𝑃′
𝑑𝑠
𝜃𝑢𝑡 𝑑𝑠 sin 𝜃𝑢𝑡
𝑃 𝑃1 𝒖
Figure 1.2.1-3. Two pairs of Mutually Perpendicular Unit Tangent Vectors
With help of expression (1.2.1-19), substitution of expressions (1.2.1-20) and (1.2.1-22) into
(1.2.1-21) yields
𝐾𝑡 𝒕 + 𝐺𝑡 𝒒 = (𝐾𝑢 𝒖 + 𝐺𝑢 𝒗) cos 𝜃𝑢𝑡 + (𝐾𝑣 𝒗 + 𝐺𝑢 𝒖) sin 𝜃𝑢𝑡

[𝐾 (cos 𝜃𝑢𝑡 𝒕 − sin 𝜃𝑢𝑡 𝒒) + 𝐺𝑢 (sin 𝜃𝑢𝑡 𝒕 + cos 𝜃𝑢𝑡 𝒒)] cos 𝜃𝑢𝑡
={ 𝑢 }
+[𝐾𝑣 (sin 𝜃𝑢𝑡 𝒕 + cos 𝜃𝑢𝑡 𝒒) + 𝐺𝑢 (cos 𝜃𝑢𝑡 𝒕 − sin 𝜃𝑢𝑡 𝒒)] sin 𝜃𝑢𝑡
Therefore, relationship of normal and torsional curvatures between different tangent directions
is derived as follow
𝐾𝑡 = 𝐾𝑢 cos2 𝜃𝑢𝑡 + 𝐾𝑣 sin2 𝜃𝑢𝑡 + 2𝐺𝑢 sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 ,

} (1.2.1-23)
𝐺𝑡 = −(𝐾𝑢 − 𝐾𝑣 ) sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 + 𝐺𝑢 (cos2 𝜃𝑢𝑡 − sin2 𝜃𝑢𝑡 ).
Also, expression (1.2.1-21) can be rewritten as follow:

𝑑𝑵 𝑑𝑵 𝑑𝑵
( 𝑑𝑠 ) 𝑑𝑠 = ( 𝑑𝑠 ) 𝑑𝑠 cos 𝜃𝑢𝑡 + ( 𝑑𝑠 ) 𝑑𝑠 sin 𝜃𝑢𝑡
𝒕 𝒖 𝒗
Due to cos 𝜃𝑢𝑡 = 𝒖 ∙ 𝒕 and sin 𝜃𝑢𝑡 = 𝑵 ∙ (𝒖 × 𝒕 ), then, expression above is updated as follow:
𝑑𝑵 𝑑𝑵 𝑑𝑵
( 𝑑𝑠 ) = ( 𝑑𝑠 ) (𝒖 ∙ 𝒕) + ( 𝑑𝑠 ) (𝒗 ∙ 𝒕) (1.2.1-24)
𝒕 𝒖 𝒗
𝑑𝑵
Substitution of expression (1.2.1-10), i.e., ( 𝑑𝑠 ) = 𝛀𝜏 × 𝑵, into expression (1.2.1-24) gives
𝜏
𝛀𝒕 = 𝛀𝒖 (𝒖 ∙ 𝒕) + 𝛀𝒗 (𝒗 ∙ 𝒕) (1.2.1-25)
~ 17 ~
Where: 𝒗 = 𝑵 × 𝒖
8) Coordinative Equation of Surface Curvatures
Equation (1.2.1-23) can be updated as follow
𝐾𝑡 − 𝐾𝑢 = [−(𝐾𝑢 − 𝐾𝑣 ) sin 𝜃𝑢𝑡 + 2𝐺𝑢 cos 𝜃𝑢𝑡 ] sin 𝜃𝑢𝑡 ,

} (1.2.1-26)
𝐺𝑡 + 𝐺𝑢 = [−(𝐾𝑢 − 𝐾𝑣 ) sin 𝜃𝑢𝑡 + 2𝐺𝑢 cos 𝜃𝑢𝑡 ] cos 𝜃𝑢𝑡 .
When −(𝐾𝑢 − 𝐾𝑣 ) sin 𝜃𝑢𝑡 + 2𝐺𝑢 cos 𝜃𝑢𝑡 ≠ 0, then

𝐾𝑡 −𝐾𝑢
tan 𝜃𝑢𝑡 = (1.2.1-27)
𝐺𝑡 +𝐺𝑢
Expression (1.2.1-25) shows that among normal curvatures 𝐾𝑡 , 𝐾𝑢 and torsional curvatures 𝐺𝑡 ,
𝐺𝑢 in any two tangent directions 𝒕, 𝒖 and their intersection angle 𝜃𝑢𝑡 , only four parameters are
independent, because these five parameters must satisfy equation (1.2.1-27). Therefore,
expression (1.2.1-27) is defined as coordinative equation of surface curvatures.
9) Alternative Expression for Coordinative Equation of Surface Curvatures
Expression (1.2.1-27) can be written as

𝐾𝑡 −𝐾𝑢 𝑵∙(𝒖×𝒕)
= tan 𝜃𝑢𝑡 =
𝐺𝑡 +𝐺𝑢 𝒖∙𝒕
Then
[𝐾𝑡 𝒕 + 𝐺𝑡 (𝑵 × 𝒕)] ∙ 𝒖 = [𝐾𝑢 𝒖 + 𝐺𝑢 (𝑵 × 𝒖)] ∙ 𝒕
With help of expression (1.2.1-6), expression above can be updated as follow:

𝑑𝑵 𝑑𝑵
( 𝑑𝑠 ) ∙ 𝒖 = ( 𝑑𝑠 ) ∙ 𝒕 (1.2.1-28)
𝑡 𝑢
And
𝛀𝒕 ∙ (𝑵 × 𝒖) = 𝛀𝒖 ∙ (𝑵 × 𝒕) (1.2.1-29)
10) Relative Curvature, Relative Normal Curvature and Relative Torsional Curvature
a) Definition
Let two surfaces 𝑆1, 𝑆2 contact each other at point 𝑃 and 𝑵1 , 𝑵2 be unit normal to surfaces 𝑆1,
𝑆2 at point 𝑃 respectively, thus,
~ 18 ~
𝑵1 = −𝑵2
𝑑𝑵1 𝑑𝑵2
( ) is curvature of surface 𝑆1 at point 𝑃 in any tangent direction 𝝉 and ( ) is curvature
𝑑𝑠 𝜏 𝑑𝑠 𝜏
̅
𝑑𝑵
of surface 𝑆2 at point 𝑃 in any tangent direction 𝝉. Thus, relative curvature ( 𝑑𝑠 ) at point 𝑃 of
𝜏
surfaces 𝑆1with respect to 𝑆2 in tangent direction 𝝉 is defined as
̅
𝑑𝑵 𝑑𝑵1 𝑑𝑵2
( 𝑑𝑠 ) = ( ) +( ) (1.2.1-30)
𝜏 𝑑𝑠 𝜏 𝑑𝑠 𝜏
Due to
𝑑𝑵1
( ) = 𝐾1𝜏 𝝉 + 𝐺1𝜏 (𝑵1 × 𝝉),
𝑑𝑠 𝜏
𝑑𝑵2
}
( ) = 𝐾2𝜏 𝝉 + 𝐺2𝜏 (𝑵2 × 𝝉) = 𝐾2𝜏 𝝉 − 𝐺2𝜏 (𝑵1 × 𝝉).
𝑑𝑠 𝜏

̅
𝑑𝑵
( 𝑑𝑠 ) = (𝐾1𝜏 + 𝐾2𝜏 )𝝉 + (𝐺1𝜏 − 𝐺2𝜏 )(𝑵1 × 𝝉)
𝜏
Relative normal curvature 𝐾̅𝜏 and relative torsional curvature 𝐺𝜏̅ at point 𝑃 in any tangent
direction 𝝉 are defined as
̅𝜏 = 𝐾1𝜏 + 𝐾2𝜏 ,
𝐾
} (1.2.1-31)
𝐺𝜏̅ = 𝐺1𝜏 − 𝐺2𝜏 .
Then, substitution of expression (1.2.1-30) into expression above generates

̅
𝑑𝑵
̅𝜏 𝝉 + 𝐺𝜏̅ (𝑵1 × 𝝉)
( 𝑑𝑠 ) = 𝐾 (1.2.1-32)
𝜏
b) Relative Geometric Angular Velocity
With aid of expression (1.2.1-10), definition of relative curvature, i.e., expression (1.2.1-30), is
rewritten as
̅
𝑑𝑵
( 𝑑𝑠 ) = 𝛀1𝝉 × 𝑵1 + 𝛀2𝝉 × 𝑵2 (1.2.1-33)
𝜏
Due to expression (1.2.1-11), that is,
𝛀1𝜏 = 𝐾1𝜏 (𝑵1 × 𝝉) − 𝐺1𝜏 𝝉,

}
𝛀2𝜏 = 𝐾2𝜏 (𝑵2 × 𝝉) − 𝐺2𝜏 𝝉 = −𝐾2𝜏 (𝑵1 × 𝝉) − 𝐺2𝜏 𝝉.
~ 19 ~
̅
𝑑𝑵
( 𝑑𝑠 ) = (𝛀1𝝉 − 𝛀2𝜏 ) × 𝑵1 = [(𝐾1𝜏 + 𝐾2𝜏 )(𝑵1 × 𝝉) − (𝐺1𝜏 − 𝐺2𝜏 )𝝉] × 𝑵1
𝜏
̅1𝜏 (𝑵1 × 𝝉) − 𝐺1𝜏
= [𝐾 ̅ 𝝉] × 𝑵1
̅ 𝜏 at point 𝑃 of surfaces 𝑆1with respect to 𝑆2 in tangent

Relative geometric angular velocity 𝛀
direction 𝝉 is defined as
̅ 𝜏 = 𝛀1𝝉 − 𝛀2𝜏 = (𝐾1𝜏 + 𝐾2𝜏 )(𝑵1 × 𝝉) − (𝐺1𝜏 − 𝐺2𝜏 )𝝉 = 𝐾

𝛀 ̅𝜏 (𝑵1 × 𝝉) − 𝐺𝜏̅ 𝝉 (1.2.1-34)
̅
𝑑𝑵
Then, relative curvature ( 𝑑𝑠 ) of expression (1.2.1-32) is expressed alternatively as
𝜏
̅
𝑑𝑵
( ̅ 𝜏 × 𝑵1
) =𝛀 (1.2.1-35)
𝑑𝑠 𝜏
c) Relationship of Relative Curvature between Different Tangent Directions
Assume that any unit tangent vector 𝒕 is obtained by rotating unit tangent vector 𝒖 by an angle
𝜃𝑢𝑡 about 𝑵1 , due to 𝑵1 = −𝑵2 , unit tangent vector 𝒕 is also obtained by rotating unit tangent
vector 𝒖 by an angle (−𝜃𝑢𝑡 ) about 𝑵2 . Let normal and torsional curvatures of surface 𝑆1 in
tangent directions 𝒖 and 𝒗 = 𝑵1 × 𝒖 be 𝐾1𝑢 , 𝐾1𝑣 and 𝐺1𝑢 = −𝐺1𝑣 respectively. Likewise, let
normal and torsional curvatures of surface 𝑆2 in tangent directions 𝒖 and 𝒗 = 𝑵1 × 𝒖 be 𝐾2𝑢 ,
𝐾2𝑣 and 𝐺2𝑢 = −𝐺2𝑣 respectively. Therefore, relative normal and torsional curvatures in 𝒖 and
𝒗 are as follow:
̅𝑢 = 𝐾1𝑢 + 𝐾2𝑢 , 𝐾
𝐾 ̅𝑣 = 𝐾1𝑣 + 𝐾2𝑣 ,
} (1.2.1-36)
𝐺𝑢̅ = 𝐺1𝑢 − 𝐺2𝑢 = −(𝐺1𝑣 − 𝐺2𝑣 ) = −𝐺𝑣̅ .
Application of expressions (1.2.1-23) results in
𝐾1𝑡 = 𝐾1𝑢 cos2 𝜃𝑢𝑡 + 𝐾1𝑣 sin2 𝜃𝑢𝑡 + 2𝐺1𝑢 sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 ,
𝐺1𝑡 = −(𝐾1𝑢 − 𝐾1𝑣 ) sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 + 𝐺1𝑢 (cos 2 𝜃𝑢𝑡 − sin2 𝜃𝑢𝑡 ),
𝐾2𝑡 = 𝐾2𝑢 cos2 (−𝜃𝑢𝑡 ) + 𝐾2𝑣 sin2 (−𝜃𝑢𝑡 ) + 2𝐺2𝑢 sin(−𝜃𝑢𝑡 ) cos(−𝜃𝑢𝑡 )
(1.2.1-37)
= 𝐾2𝑢 cos2 𝜃𝑢𝑡 + 𝐾2𝑣 sin2 𝜃𝑢𝑡 − 2𝐺2𝑢 sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 ,
𝐺2𝑡 = −(𝐾2𝑢 − 𝐾2𝑣 ) sin(−𝜃𝑢𝑡 ) cos(−𝜃𝑢𝑡 ) + 𝐺2𝑢 [cos 2 (−𝜃𝑢𝑡 ) − sin2(−𝜃𝑢𝑡 )]
= (𝐾2𝑢 − 𝐾2𝑣 ) sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 + 𝐺2𝑢 (cos 2 𝜃𝑢𝑡 − sin2 𝜃𝑢𝑡 ). }
Application of expressions (1.2.1-31) and (1.2.1-37) gives
̅𝑡 = 𝐾1𝑡 + 𝐾2𝑡 = 𝐾
𝐾 ̅𝑢 cos 2 𝜃𝑢𝑡 + 𝐾̅𝑣 sin2 𝜃𝑢𝑡 + 2𝐺𝑢̅ sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡
} (1.2.1-38)
𝐺̅𝑡 = 𝐺1𝑡 − 𝐺2𝑡 = −(𝐾
̅𝑢 − 𝐾̅𝑣 ) sin 𝜃𝑢𝑡 cos 𝜃𝑢𝑡 + 𝐺𝑢̅ (cos 2 𝜃𝑢𝑡 − sin2 𝜃𝑢𝑡 ).
~ 20 ~
Expression (1.2.1-38) can be also written in other form as
̅
𝑑𝑵 ̅
𝑑𝑵 ̅
𝑑𝑵
( 𝑑𝑠 ) = ( 𝑑𝑠 ) (𝒖 ∙ 𝒕) + ( 𝑑𝑠 ) (𝒗 ∙ 𝒕) (1.2.1-39)
𝑡 𝑢 𝑣
With help of expression (1.2.1-35). expression (1.2.1-39) is expressed alternatively as follow:
̅𝑡 = 𝛀
𝛀 ̅ 𝑢 (𝒖 ∙ 𝒕) + 𝛀
̅ 𝑣 (𝒗 ∙ 𝒕) (1.2.1-40)
1.2.2 Intersection Curve

Intersection between two boundary surfaces is called as intersection curve.
1 Representation of Intersection Curve

Intersection curve is represented in two forms.
1) Implicit Form
Simultaneous equation of implicit forms of both boundary surface 𝐼 𝐹𝐼 (𝑥, 𝑦, 𝑧) = 0 and

boundary surface 𝐼𝐼 𝐹𝐼𝐼 (𝑥, 𝑦, 𝑧) = 0 , that is,
𝐹𝐼 (𝑥, 𝑦, 𝑧) = 0,
} (1.2.2-1)
𝐹𝐼𝐼 (𝑥, 𝑦, 𝑧) = 0.
2) Parametrized Form
Simultaneous equation of parametrized forms of both boundary surface 𝐼 𝑹 = 𝑹𝐼 (𝑢, 𝑣) and

boundary surface 𝐼𝐼 𝑹 = 𝑹𝐼𝐼 (𝑞, 𝑡), that is,
𝑹 = 𝑹𝐼 (𝑢, 𝑣),
} (1.2.2-2)
𝑹 = 𝑹𝐼𝐼 (𝑞, 𝑡).
Where: 𝑢, 𝑣, 𝑞 and 𝑡 are four surface parameters, due to simultaneous equation (1.2.2-2), only
one parameter is independent among parameters 𝑢, 𝑣, 𝑞 and 𝑡.
2 Unit Tangent to Intersection Curve at Any Point

Due to intersection curve lying on both boundary surfaces, unit tangent 𝜻 at any point 𝑃 of
intersection curve is perpendicular to both unit normal 𝑵𝐼 of boundary surface 𝑹𝐼 and unit
normal 𝑵𝐼𝐼 of boundary surface 𝑹𝐼𝐼 , and thus, unit tangent vector 𝜻 to intersection curve can
be defined as
~ 21 ~
𝑵 ×𝑵
𝜻 = |𝑵𝐼 ×𝑵𝐼𝐼 | (1.2.2-3)
𝐼 𝐼𝐼
3 Principal Normal Vector and Curvature at Any Point on Intersection Curve

1) Definition
𝑑𝜻
Since unit tangent vector 𝜻(𝑠) to intersection curve has constant length, 𝑑𝑠 will be orthogonal
𝑑𝜻
to 𝜻(𝑠). Assuming 𝑑𝑠 ≠ 0, the principal normal vector 𝝃(𝑠) is defined as follow
𝑑𝜻
𝑑𝑠
𝝃(𝑠) = 𝑑𝜻 (1.2.2-4)
| |
𝑑𝑠
𝑑𝜻 𝑑𝜻
Module |𝑑𝑠| of 𝑑𝑠 is defined as curvature 𝜅𝑐 (𝑠) of intersection curve at point 𝑃, that is,
𝑑𝜻
𝜅𝑐 (𝑠) = |𝑑𝑠| (1.2.2-5)
𝑑𝜻
2) Expanded Form of (𝑑𝑠)
Employment of expression (1.2.2-3) results in

𝑑𝑵𝐼 𝑑𝑵𝐼𝐼
( ) ×𝑵𝐼𝐼 𝑵𝐼 ×( )
𝑑𝜻 𝑑 𝑵 ×𝑵 𝑑𝑠 𝜻 𝑑𝑠 𝜻 𝜻 𝑑 (1.2.2-6)
= ( 𝐼 𝐼𝐼 ) = + − |𝑵 (|𝑵𝐼 × 𝑵𝐼𝐼 |)
𝑑𝑠 𝑑𝑠 |𝑵𝐼 ×𝑵𝐼𝐼 | |𝑵𝐼 ×𝑵𝐼𝐼 | |𝑵𝐼 ×𝑵𝐼𝐼 | 𝐼 ×𝑵𝐼𝐼 | 𝑑𝑠
With aid of expression (1.2.1-6), it results in

𝑑𝑵
( 𝑑𝑠𝐼) = 𝐾𝐼𝜻 𝜻 + 𝐺𝑰𝜻 (𝑵𝐼 × 𝜻),
𝜻
𝑑𝑵𝐼𝐼
} (1.2.2-7)
( ) = 𝐾𝐼𝐼𝜻 𝜻 + 𝐺𝑰𝑰𝜻 (𝑵𝐼𝐼 × 𝜻).
𝑑𝑠 𝜻
Where: 𝐾𝐼𝜻 and 𝐺𝑰𝜻 are normal and torsional curvatures of boundary surface 𝐼 in direction 𝜻
respectively. 𝐾𝐼𝐼𝜻 and 𝐺𝑰𝑰𝜻 are normal and torsional curvatures of boundary surface 𝐼𝐼 in
direction 𝜻 respectively.
Application of expressions (1.2.2-3) and (1.2.2-7) generates
~ 22 ~
𝑑 𝑑 1 𝑑
(|𝑵𝐼 × 𝑵𝐼𝐼 |) = [√(𝑵𝐼 × 𝑵𝐼𝐼 ) ∙ (𝑵𝐼 × 𝑵𝐼𝐼 )] = 2|𝑵 ×𝑵 [(𝑵𝐼 × 𝑵𝐼𝐼 ) ∙ (𝑵𝐼 × 𝑵𝐼𝐼 )]
𝑑𝑠 𝑑𝑠 𝐼 𝐼𝐼 | 𝑑𝑠
𝑑𝑵𝐼 𝑑𝑵
[( ) ×𝑵𝐼𝐼 +𝑵𝐼 ×( 𝐼𝐼 ) ]∙(𝑵𝐼 ×𝑵𝐼𝐼 )
𝑑𝑠 𝜻 𝑑𝑠 𝜻 𝑑𝑵 𝑑𝑵𝐼𝐼 (1.2.2-8)
= |𝑵𝐼 ×𝑵𝐼𝐼 |
= [𝜻 × ( 𝑑𝑠𝐼) ] ∙ 𝑵𝐼𝐼 + [( ) × 𝜻] ∙ 𝑵𝐼
𝜻 𝑑𝑠 𝜻
= (𝐺𝑰𝜻 − 𝐺𝑰𝑰𝜻 )𝑵𝐼 ∙ 𝑵𝐼𝐼
Substitution of expressions (1.2.2-7) and (1.2.2-8) into (1.2.2-6) generates

𝑑𝜻 𝐾𝐼𝜻 𝜻×𝑵𝐼𝐼 +𝐾𝐼𝐼𝜻 𝑵𝐼 ×𝜻
= |𝑵𝐼 ×𝑵𝐼𝐼 |
(1.2.2-9)
𝑑𝑠
Let ∅𝐼,𝐼𝐼 be intersecting angle between 𝑵𝐼 and 𝑵𝐼𝐼 as follow
𝑵𝐼𝐼 = (∅𝐼,𝐼𝐼 𝜻) ⊗ 𝑵𝐼 = cos ∅𝐼,𝐼𝐼 𝑵𝐼 + sin ∅𝐼,𝐼𝐼 𝜻 × 𝑵𝐼
then
|𝑵𝐼 × 𝑵𝐼𝐼 | = sin ∅𝐼,𝐼𝐼 (1.2.2-10)
Substitution of expressions (1.2.2-10) into (1.2.2-9) results in

𝑑𝜻 𝐾𝐼𝜻 𝜻×𝑵𝐼𝐼 +𝐾𝐼𝐼𝜻 𝑵𝐼 ×𝜻
= (1.2.2-11)
𝑑𝑠 sin ∅𝐼,𝐼𝐼
Substitution of expressions (1.2.2-11) into (1.2.2-4) generates curvature of intersection curve as

follow
𝑑𝜻 √𝐾2 𝐼𝜻 −2𝐾𝐼𝜻 𝐾𝐼𝐼𝜻 cos ∅𝐼,𝐼𝐼 +𝐾2 𝐼𝐼𝜻

𝜅𝑐 (𝑠) = |𝑑𝑠| = (1.2.2-12)
sin ∅𝐼,𝐼𝐼
3) Rotating Angle ∅𝐼,𝜉 of 𝑵𝐼 about 𝜻 to 𝝃(𝑠) .
Substitution of expressions (1.2.2-10) and (1.2.2-11) into (1.2.2-4) results in

𝐾𝐼𝜻 𝜻×𝑵𝐼𝐼 +𝐾𝐼𝐼𝜻 𝑵𝐼 ×𝜻
𝝃(𝑠) = (1.2.2-13)
√𝐾2 𝐼𝜻 −2𝐾𝐼𝜻 𝐾𝐼𝐼𝜻 cos ∅𝐼,𝐼𝐼 +𝐾2 𝐼𝐼𝜻
Due to
𝝃 = (∅𝐼,𝜉 𝜻) ⊗ 𝑵𝐼 = cos ∅𝐼,𝜉 𝑵𝐼 + sin ∅𝐼,𝜉 𝜻 × 𝑵𝐼 (1.2.2-14)
Thus,
~ 23 ~
𝐾𝐼𝜻 cos ∅𝐼,𝐼𝐼 −𝐾𝐼𝐼𝜻
sin ∅𝐼,𝜉 = (𝜻 × 𝑵𝐼 ) ∙ 𝝃 = ,
−𝐾𝐼𝜻 sin ∅𝐼,𝐼𝐼 𝐾𝐼𝜻
(1.2.2-15)
cos ∅𝐼,𝜉 = 𝝃 ∙ 𝑵𝐼 = =− 𝜅𝑐
}
4) Rotating Angle ∅𝐼𝐼,𝜉 of 𝑵𝐼𝐼 about 𝜻 to 𝝃 .
Due to
𝝃 = (∅𝐼𝐼,𝜉 𝜻) ⊗ 𝑵𝐼𝐼 = cos ∅𝐼𝐼,𝜉 𝑵𝐼𝐼 + sin ∅𝐼𝐼,𝜉 𝜻 × 𝑵𝐼𝐼 (1.2.2-16)
Thus,
𝐾𝐼𝜻 −𝐾𝐼𝐼𝜻 cos ∅𝐼,𝐼𝐼
sin ∅𝐼𝐼,𝜉 = (𝜻 × 𝑵𝐼𝐼 ) ∙ 𝝃 = ,
−𝐾𝐼𝐼𝜻 sin ∅𝐼,𝐼𝐼 𝐾𝐼𝐼𝜻
(1.2.2-17)
cos ∅𝐼𝐼,𝜉 = 𝝃 ∙ 𝑵𝐼𝐼 = =− .
𝜅𝑐
}
5) Curvature Condition for Curve Lying on Surface
Inspection of expressions (1.2.2-15) and (1.2.2-17) leads to
𝐾𝐼𝜻 𝐾𝐼𝐼𝜻 𝐾𝐼𝐼𝜻

𝜅𝑐 = − cos ∅ = − cos ∅ = − cos(∅ (1.2.2-18)
𝐼,𝜉 𝐼𝐼,𝜉 𝐼,𝜉 −∅𝐼,𝐼𝐼 )
Geometry meaning of expression (1.2.2-18) is as shown in figure 1.2.2-1.
Expression (1.2.2-18) shows that in order for a curve within a differential

region at a point lying on a surface with accuracy up to second order
infinitesimal, normal curvature 𝐾𝜁 of surface along tangent direction 𝜻 to
curve must be equal to negative value of multiplication of curvature 𝜅𝑐 of
curve with cosine of intersecting angle ∅𝑁,𝜉 between normal vector to surface
and principal normal vector 𝝃 to curve, that is,
𝐾𝜁 = −𝜅𝑐 cos ∅𝑁,𝜉 (1.2.2-19)
Expression (1.2.2-18) is referred to condition of curvature for a curve lying on surface. In an

addition to condition (1.2.2-18), tangent vector 𝝃 to curve must be perpendicular to unit
normal 𝑵 to surface.
~24 ~
𝑵𝐼 ∅𝐼,𝐼𝐼 𝑵𝐼𝐼
∅𝐼,𝜉 ∅𝐼𝐼,𝜉
𝐾𝐼𝐼𝜻 𝐾𝐼𝜻
𝜅𝑐
Figure 1.2.2-1 Relationship between Normal Curvature 𝐾𝜁 of Surface in Tangent

Direct to Curve and Curvature 𝜅𝑐 of Curve
4 Unit Binormal Vector to Intersecting Curve at Any Point

Unit binormal vector 𝜷 to intersecting curve at any point 𝑃 is defined as follow
𝜷=𝜻×𝝃 (1.2.2-20)
Substitution of expressions (1.2.2-13) into (1.2.2-20) gives

−𝐾𝐼𝜁 𝑵𝐼𝐼 +𝐾𝐼𝐼𝜁 𝑵𝐼
𝜷= (1.2.2-21)
√𝐾2 𝐼𝜁 −2𝐾𝐼𝜁 𝐾𝐼𝐼𝜁 cos ∅𝐼,𝐼𝐼 +𝐾2 𝐼𝐼𝜁
5 Torsional Curvature of Intersecting Curve at Any Point

1) Definition
𝑑𝝃 𝑑𝝃
Due to unit principal normal 𝝃 being unit vector, that is, 𝝃 ∙ 𝝃 = 1, thus, ∙ 𝝃 = 0, therefore,
𝑑𝑠 𝑑𝑠
can be resolved as follow
𝑑𝝃 𝑑𝝃 𝑑𝝃
= (𝑑𝑠 ∙ 𝜻) 𝜻 + (𝑑𝑠 ∙ 𝜷) 𝜷
𝑑𝑠
𝑑𝝃 𝑑𝜻
Because of 𝝃 ∙ 𝜻 = 0 , 𝑑𝑠 𝜻 = −𝝃 ∙ 𝑑𝑠 = −𝜅𝑐 , therefore, expression above becomes
~ 25 ~
𝑑𝝃 𝑑𝝃
= −𝜅𝑐 𝜻 + (𝑑𝑠 ∙ 𝜷) 𝜷 (1.2.2-22)
𝑑𝑠
𝑑𝝃 𝑑𝝃
Component (𝑑𝑠 ∙ 𝜷) of 𝑑𝑠 in direction 𝜷 of unit binormal vector is defined as torsional curvature
of intersection curve
𝑑𝝃
𝜒𝑐 = (𝑑𝑠 ∙ 𝜷) (1.2.2-23)
2) Calculation Formula
Taking derivative of expression (1.2.2-14) with respect to arc-length of intersecting curve yields
𝑑𝝃 𝑑∅𝐼,𝜉 𝑑𝑵 𝑑
= −(sin ∅𝐼,𝜉 𝑵𝐼 + cos ∅𝐼,𝜉 𝑵𝐼 × 𝜻) + cos ∅𝐼,𝜉 ( 𝑑𝑠𝐼 ) − sin ∅𝐼,𝜉 [𝑑𝑠 (𝑵𝐼 × 𝜻)] (1.2.2-24)
𝑑𝑠 𝑑𝑠 𝜁 𝜁
Substitution of expressions (1.2.2-14) into (1.2.2-20) results in
𝜷 = −(sin ∅𝐼,𝜉 𝑵𝐼 + cos ∅𝐼,𝜉 𝑵𝐼 × 𝜻) (1.2.2-25)
Substitution of expressions (1.2.2-24) and (1.2.2-25) into (1.2.2-23) generates

𝑑∅𝐼,𝜉 𝑑𝑵 𝑑
𝜒𝑐 = − cos 2 ∅𝐼,𝜉 (𝑵𝐼 × 𝜻) ∙ ( 𝑑𝑠𝐼) + sin2 ∅𝐼,𝜉 𝑵𝐼 ∙ [𝑑𝑠 (𝑵𝐼 × 𝜻)]
𝑑𝑠 𝜁 𝜁
𝑑∅𝐼,𝜉 𝑑𝑵𝐼 𝑑∅𝐼,𝜉
(1.2.2-26)
= − (𝑵𝐼 × 𝜻) ∙ ( 𝑑𝑠 ) = − 𝐺𝐼,𝜁
𝑑𝑠 𝜁 𝑑𝑠
𝑑∅𝐼,𝜉
3) Calculation of ( )
𝑑𝑠
Due to
|𝑵𝐼 × 𝑵𝐼𝐼 | = sin ∅𝐼,𝐼𝐼 ,

}
𝑵𝐼 ∙ 𝑵𝐼𝐼 = cos ∅𝐼,𝐼𝐼 .
Substitution of expressions above into (1.2.2-8) leads to

𝑑 𝑑 𝑑∅𝐼,𝐼𝐼
(|𝑵𝐼 × 𝑵𝐼𝐼 |) = (sin ∅𝐼,𝐼𝐼 ) = cos ∅𝐼,𝐼𝐼 = (𝐺𝐼𝜁 − 𝐺𝐼𝐼𝜁 )𝑵𝐼 ∙ 𝑵𝐼𝐼
𝑑𝑠 𝑑𝑠 𝑑𝑠
Thus,
𝑑∅𝐼,𝐼𝐼
= 𝐺𝐼𝜁 − 𝐺𝐼𝐼𝜁 (1.2.2-27)
𝑑𝑠
Expression (1.2.2-18) can be rewritten as follow
~26 ~
𝐾𝐼𝜁 cos(∅𝐼,𝜉 − ∅𝐼,𝐼𝐼 ) = 𝐾𝐼𝐼𝜁 cos ∅𝐼,𝜉
Taking derivative of expression above with respective arc-length 𝑠 of intersecting curve yields
𝑑𝐾𝐼𝜻 𝑑𝐾𝐼𝐼𝜻
𝐾𝐼𝜻 (𝐺𝐼𝜁 −𝐺𝐼𝐼𝜁 ) sin(∅𝐼,𝜉 −∅𝐼,𝐼𝐼 )+( ) cos(∅𝐼,𝜉 −∅𝐼,𝐼𝐼 )−( ) cos ∅𝐼,𝜉
𝑑∅𝐼,𝜉 𝑑𝑠 𝜻 𝑑𝑠 𝜻
= (1.2.2-28)
𝑑𝑠 𝐾𝐼𝜻 sin(∅𝐼,𝜉 −∅𝐼,𝐼𝐼 )−𝐾𝐼𝐼𝜻 sin ∅𝐼,𝜉
6 Frenet-Serret Frame
Inspection of expressions (1.2.2-13) and (1.2.2-20) shows that {𝜻, 𝝃, 𝜷} form a right-handed
orthonormal basis for 3-D dimension space ℛ 3 . Therefore, any vector is a linear combination of
𝑑𝝃 𝑑𝝃 𝑑𝝃 𝑑𝝃
𝜻, 𝝃 and 𝜷. Now, = (𝑑𝑠 ∙ 𝜻) 𝜻 + (𝑑𝑠 ∙ 𝝃) 𝝃 + (𝑑𝑠 ∙ 𝜷) 𝜷. But expressions (1.2.2-13), (1.2.2-20),
𝑑𝑠
𝑑𝝃 𝑑𝝃 𝑑𝝃
(1.2.2-22) and (1.2.2-23) shows that ∙ 𝜻 = −𝜅𝑐 , ∙ 𝝃 = 0 and ∙ 𝜷 = 𝜒𝑐 . It gives
𝑑𝑠 𝑑𝑠 𝑑𝑠
𝑑𝝃
= −𝜅𝑐 𝜻 + 𝜒𝑐 𝜷 (1.2.2-29)
𝑑𝑠
Taking derivative of expression (1.2.2-20) with respect to arc-length of curve 𝑠 results in

𝑑𝜷 𝑑 𝑑𝜻 𝑑𝝃
= 𝑑𝑠 (𝜻 × 𝝃) = 𝑑𝑠 × 𝝃 + 𝜻 × 𝑑𝑠 = 𝜻 × (−𝜅𝑐 𝜻 + 𝜒𝑐 𝜷) = −𝜒𝑐 𝝃 (1.2.2-30)
𝑑𝑠
Combination of expressions (1.2.2-4), (1.2.2-29), and (1.2.2-30) generates

𝑑𝜻
= 𝜅𝑐 𝝃,
𝑑𝑠
𝑑𝝃
= −𝜅𝑐 𝜻 + 𝜒𝑐 𝜷, (1.2.2-31)
𝑑𝑠
𝑑𝜷
= −𝜒𝑐 𝝃. }
𝑑𝑠
Expression (1.2.2-31) is called Frenet-Serret formula.
7 Geometric Angular Velocity of Intersection Curve

Let arc-length 𝑠 (geometry parameter) of intersection curve be visualized as a virtual time
𝑑𝜻 𝑑𝝃 𝑑𝜷
parameter, rate of change of three vectors , and 𝑑𝑠 can be considered as virtual linear
𝑑𝑠 𝑑𝑠
velocities of end points of three coordinate axes 𝜻, 𝝃 and 𝜷 generated by rotation with virtual
angular velocity 𝝎𝑐 , that is,
~ 27 ~
𝑑𝜻
= 𝝎𝑐 × 𝜻,
𝑑𝑠
𝑑𝝃
= 𝝎𝑐 × 𝝃, (1.2.2-32)
𝑑𝑠
𝑑𝜷
= 𝝎𝑐 × 𝜷.}
𝑑𝑠
𝝎𝑐 = 𝜒𝑐 𝜻 + 𝜅𝑐 𝜷 (1.2.2-33)
8 Relative Geometric Angular Velocity of Intersection Curve with Respect to

Boundary Surface
1) Definition
Difference vector ∆𝝎𝑐 by subtracting geometric angular velocity of boundary surface in tangent
direction 𝜻 of intersection curve from geometric angular velocity of intersection curve is
defined as relative geometric angular velocity of intersection curve with respect to boundary
surface, that is,
∆𝝎𝑐 = 𝝎𝑐 − 𝛀𝜁 (1.2.2-34)
2) Calculation Formula
𝝎𝑐 = 𝜒𝑐 𝜻 − 𝜅𝑐 (sin ∅𝐼,𝜉 𝑵𝐼 + cos ∅𝐼,𝜉 𝑵𝐼 × 𝜻) (1.2.2-35)
Likewise
𝝎𝑐 = 𝜒𝑐 𝜻 − 𝜅𝑐 (sin ∅𝐼𝐼,𝜉 𝑵𝐼𝐼 + cos ∅𝐼𝐼,𝜉 𝑵𝐼𝐼 × 𝜻) (1.2.2-36)
With aid of definition of geometric angular velocity of boundary surface, i.e., expression (1.2.1-11), the
relative geometric angular velocity of intersection curve with respect to boundary surface 𝐼 is
derived as follow
∆𝐼 𝝎𝑐 = 𝝎𝑐 − 𝛀𝐼𝜁 = 𝜒𝑐 𝜻 − 𝜅𝑐 sin ∅𝐼,𝜉 𝑵𝐼 − (𝜅𝑐 cos ∅𝐼,𝜉 + 𝐾𝐼𝜁 )(𝑵𝐼 × 𝜻) + 𝐺𝐼𝜁 𝜻
Due to expression (1.2.2-17), that is, 𝜅𝑐 cos ∅𝐼,𝜉 + 𝐾𝐼𝜁 = 0, therefore,
∆𝐼 𝝎𝑐 = 𝝎𝑐 − 𝛀𝐼𝜁 = (𝜒𝑐 + 𝐺𝐼𝜁 )𝜻 − 𝜅𝑐 sin ∅𝐼,𝜉 𝑵𝐼 (1.2.2-37)
Likewise, the relative geometric angular velocity of intersection curve with respect to boundary
~ 28 ~
surface 𝐼𝐼 is as follow
∆𝐼𝐼 𝝎𝑐 = (𝜒𝑐 + 𝐺𝐼𝐼𝜁 )𝜻 − 𝜅𝑐 sin ∅𝐼𝐼,𝜉 𝑵𝐼𝐼 (1.2.2-38)
9 Relative Curvature and Relative Torsional Curvature of Intersection Curve

with Respect to Boundary Surface
1) Definition
The component of relative geometric angular velocity ∆𝝎𝑐 in direction of unit normal 𝑵 to
boundary surface is defined as relative curvature ∆𝜅𝑐 of intersection curve with respect to
boundary surface, that is,
∆𝜅𝑐 = ∆𝝎𝑐 ∙ 𝑵 = −𝜅𝑐 sin ∅𝑁,𝜉 (1.2.2-39)
The component of relative geometric angular velocity ∆𝝎𝑐 in direction of unit tangent 𝜻 to
intersection curve is defined as relative torsional curvature of intersection curve with respect to
boundary surface, that is,
∆𝜒𝑐 = ∆𝝎𝑐 ∙ 𝜻 (1.2.2-40)
2) Calculation

𝑑∅𝐼,𝜉
𝜒𝑐 + 𝐺𝐼,𝜁 = 𝑑𝑠
Likewise
𝑑∅𝐼𝐼,𝜉
𝜒𝑐 + 𝐺𝐼𝐼,𝜁 = 𝑑𝑠
If 𝑵 stands for either 𝑵𝐼 or 𝑵𝐼𝐼 , two expressions above can be combined as one as follow
𝑑∅𝑁,𝜉
𝜒𝑐 + 𝐺𝑁,𝜁 = (1.2.2-41)
𝑑𝑠
Substitution of expressions (1.2.2-37) and (1.2.2-38) into (1.2.2-39) and (1.2.2-40) yields
∆𝜅𝑐 = −𝜅𝑐 sin ∅𝑁,𝜉 (1.2.2-42)
And
~ 29 ~
𝑑∅𝑁,𝜉
∆𝜒𝑐 = (1.2.2-43)
𝑑𝑠
10 Geodesic Curve
Definition:
A curve on surface is called geodesic curve, if at any point on this curve, relative geometric
angular velocity ∆𝝎𝑐 of curve with respect to surface is equal to zero, that is,
∆𝜅𝑐 = −𝜅𝑐 sin ∅𝑁,𝜉 = 0,

𝑑∅𝑁,𝜉 } (1.2.2-44)
∆𝜒𝑐 = = 0.
𝑑𝑠
11 Differential Equation of Geometric Angular Displacement for Parallel

Transport along a Given Curve on Given Surface
Given a curve on a surface, prescribe an initial point 𝑃0 on the curve, arc-length 𝑠 corresponding
to point 𝑃0 is 𝑠 = 𝑠0, unit tangent vector to the curve at point 𝑃0 is 𝜻(𝑠0 ) = 𝜻0 , and geometric
angular velocity of surface at point 𝑃0 in direction 𝜻0 is 𝛀𝜁 (𝑠0 ) = 𝛀𝜻0 . Assume that rotating
angle of initial geometric angular displacement at point 𝑃0 is 𝜀(𝑠0 ) = 0, and the corresponding
𝛀𝜻
rotating axis is 𝝎(𝑠0 ) = |𝛀 0 | .When a moving point 𝑃 moves along a given curve from point 𝑃0 ,
𝜻0
its corresponding arc-length becomes 𝑠 from 𝑠0 . As 𝑠 changes, unit tangent vector to curve at
point 𝑃 becomes 𝜻(𝑠) = 𝜻, and geometric angular velocity of surface in direction 𝜻(𝑠) is
𝛀𝜁 (𝑠) = 𝛀𝜻 . Let rotating angle of geometric angular displacement corresponding to point 𝑃 be
𝜀(𝑠) = 𝜀 and rotating axis be 𝝎(𝑠) = 𝝎, application of expression (1.1.2-8) for differential
formula of rotation of vector generates relationship between parallel geometric angular
displacement 𝜀, 𝝎 and geometric angular velocity 𝛀𝜁 as follow
𝑑𝜀 𝑑𝝎 𝑑𝝎
𝑑𝑠
𝝎+ (1 − cos 𝜀) (𝝎 ×
𝑑𝑠
) + sin 𝜀 𝑑𝑠 = 𝛀𝜁 (𝑠) (1.2.2-45)
Formula (1.2.2-45) is called differential equation of geometric angular displacement for parallel
transport along a curve on surface.
Given a curve and surface, 𝛀𝜁 (𝑠) is a known function of 𝑠, plus initial conditions at initial point
𝑃0 as
𝜀(𝑠0 ) = 0,
𝛀𝜻 } (1.2.2-46)
𝝎(𝑠0 ) = |𝛀 0 | .
𝜻0
~30 ~
With help of initial condition (1.2.2-46), solution to equation (1.2.2-45) gives geometric angular
displacement as follow
𝜀 = 𝜀(𝑠),
} (1.2.2-47)
𝝎 = 𝝎(𝑠).
12 Parallel Transport of a Vector along a Given Curve on Given Surface

1) Definition
Given a surface, a curve on this surface and an initial point 𝑃0 on this curve (arc-length of curve
corresponding to point 𝑃0 is 𝑠0 ). Let 𝐑 0 be an any vector with its origin at point 𝑃0 . As origin of
vector 𝐑 0 moves to point 𝑃 along given curve on the given surface from initial point 𝑃0 (arc-
length of curve corresponding to point 𝑃 is 𝑠 ), the vector 𝐑 0 becomes
𝐑 𝑒 = (𝜀𝝎) ⊗ 𝑹0 (1.2.2-48)
Where: 𝜀 and 𝝎 are determined by (1.2.2-47).
Vector 𝐑 𝑒 is defined as resultant vector of 𝑹0 through parallel translatort of vector along a

given curve on given surface.
2) Parallel Transport of Unit Normal to Surface
Let unit normal 𝑵0 to surface at point 𝑃0 be 𝑹0 , as point 𝑃0 moves to point 𝑃 along a given
curve on the surface, the corresponding resultant vector from parallel transport is 𝑵𝑒 as follow
𝑵𝑒 = (𝜀𝝎) ⊗ 𝑵0 (1.2.2-49)
(𝑑𝑵)𝜁 = (𝛀𝜁 𝑑𝑠 ) × 𝑵 = [𝑑𝜀𝝎 + (1 − cos 𝜀)(𝝎 × 𝑑𝝎) + sin 𝜀 𝑑𝝎] × 𝑵
By comparison with expression (1.1.2-8), it gives
𝑵 = (𝜀𝝎) ⊗ 𝑵0 = 𝑵𝑒 (1.2.2-50)
Therefore, after parallel transport from point 𝑃0 to point 𝑃 along a given curve on given
surface, the unit normal 𝑵0 to surface at point 𝑃0 becomes the unit normal 𝑁 to surface at
point 𝑃.
3) Parallel Transport of Tangent Vector to Surface

~31 ~
Let 𝝉0 be any unit tangent vector to surface at point 𝑃0 , after being parallel transported to point
𝑃 along a given curve on the surface, 𝝉0 becomes
𝝉𝑒 = (𝜀𝝎) ⊗ 𝝉0 (1.2.2-51)
Due to 𝝉0 being perpendicular to unit normal 𝑵0 to surface at point 𝑃0 , that is, 𝑵0 ∙ 𝝉0 = 0,

application of expressions (1.2.2-49), (1.2.2-51) and (1.1.1-9) leads
𝝉𝑒 ∙ 𝑵 = [(𝜀𝝎) ⊗ 𝝉0 ] ∙ [(𝜀𝝎) ⊗ 𝑵0 ] = 𝑵0 ∙ 𝝉0 = 0
It shows that tangent vector to surface is preserved as tangent vector to surface through
parallel transport.
13 Displacement of a Vector along a Given Curve on Given Surface

1) Differential Equation for Geometric Angular Displacement Corresponding to
Displacement of a Vector along a Given Curve on Given Surface
In expression (1.2.2-45), replacing geometric angular velocity 𝛀𝜁 of surface by geometric

angular velocity 𝝎𝑐 of curve, and using 𝜑 and 𝝈 as geometric angular displacement to replace 𝜀
and 𝝎, then, differential equation for geometric angular displacement corresponding to
displacement along a given curve on given surface is derived as
𝑑𝜑 𝑑𝝈 𝑑𝝈
𝑑𝑠
𝝈+ (1 − cos 𝜑) (𝝈 ×
𝑑𝑠
) + sin 𝜑
𝑑𝑠
= 𝝎𝑐 (𝑠) (1.2.2-52)
Initial condition for differential equation is
𝜑(𝑠0 ) = 0,
𝝎 (𝑠 ) 𝝎 } (1.2.2-53)
𝝈(𝑠0 ) = |𝝎𝑐(𝑠0)| = |𝝎𝑐0| .
𝑐 0 𝑐0
Geometric angular displacement is derived from solution to differential equation (1.2.2-52)

with initial condition (1.2.2-53) as follow
𝜑 = 𝜑(𝑠),
} (1.2.2-54)
𝝈 = 𝝈(𝑠).
2) Definition of Displacement of Vector along a given curve on given surface
Given a surface, a curve on this surface and an initial point 𝑃0 on this curve (arc-length of curve
corresponding to point 𝑃0 is 𝑠0 ). Let 𝐑 0 be an any vector with its origin at point 𝑃0 . As origin of
vector 𝐑 0 moves to point 𝑃 along given curve on the given surface from initial point 𝑃0 (arc-
~ 32 ~
length of curve corresponding to point 𝑃 is 𝑠 ), the vector 𝐑 0 becomes
𝐑 𝑡 = (𝜑𝝈) ⊗ 𝐑 0 (1.2.2-55)
Where: 𝜑 and 𝝈 are determined by solution to differential equation (1.2.2-52), i.e., expression
(1.2.2-54).
Vector 𝐑 𝑡 is defined as resultant vector of 𝑹0 through displacement of vector along a given

curve on given surface.
3) Tangent Vector, Principal Normal Vector and Binormal Vector to Curve are Preserved as
Tangent Vector, Principal Normal Vector and Binormal Vector to Curve through
Displacement of Vector along Curve.
Let unit tangent vector, unit principal normal vector and unit binormal vector to Curve at point
𝑃0 be 𝜻(𝑠0 ) = 𝜻0 , 𝝃(𝑠0 ) = 𝝃0 and 𝜷(𝑠0 ) = 𝜷0 respectively, through displacement along a
given curve on given surface, they become
𝜻𝑡 = (𝜑𝝈) ⊗ 𝜻0 ,
𝝃𝑡 = (𝜑𝝈) ⊗ 𝝃0 , } (1.2.2-56)
𝜷𝑡 = (𝜑𝝈) ⊗ 𝜷0 .

𝑑𝜻 𝑑𝜑 𝑑𝝈 𝑑𝝈
= 𝝎𝑐 × 𝜻 = [ 𝑑𝑠 𝝈 + (1 − cos 𝜑) (𝝈 × 𝑑𝑠 ) + sin 𝜑 𝑑𝑠 ] × 𝜻,
𝑑𝑠
𝑑𝝃 𝑑𝜑 𝑑𝝈 𝑑𝝈
= 𝝎𝑐 × 𝝃 = [ 𝑑𝑠 𝝈 + (1 − cos 𝜑) (𝝈 × 𝑑𝑠 ) + sin 𝜑 𝑑𝑠 ] × 𝝃,
𝑑𝑠
𝑑𝜷 𝑑𝜑 𝑑𝝈 𝑑𝝈
= 𝝎𝑐 × 𝜷 = [ 𝑑𝑠 𝝈 + (1 − cos 𝜑) (𝝈 × 𝑑𝑠 ) + sin 𝜑 𝑑𝑠 ] × 𝝃.
𝑑𝑠
Comparison between expression (1.1.2-8) and expression above gives
𝜻 = (𝜑𝝈) ⊗ 𝜻0 = 𝜻𝑡 ,
𝝃 = (𝜑𝝈) ⊗ 𝝃0 = 𝝃𝑡 , } (1.2.2-57)
𝜷 = (𝜑𝝈) ⊗ 𝜷0 = 𝜷𝑡 .
Therefore, displacement of a vector along a given curve on surface preserves unit tangent,
principal normal and binormal vectors to a curve on surface.
4) Components of a vector in unit tangent vector, unit principal normal vector and unit
binormal vector are preserved through displacement of a vector along a given curve on
given surface.
~ 33 ~
With help of expression (1.1.1-9), application of expressions (1.2.2-55) and (1.2.2-57) yields
𝐑 𝑡 ∙ 𝜻 = [(𝜑𝝈) ⊗ 𝐑 0 ] ∙ [(𝜑𝝈) ⊗ 𝜻0 ] = 𝐑 0 ∙ 𝜻0 ,
𝐑 𝑡 ∙ 𝝃 = [(𝜑𝝈) ⊗ 𝐑 0 ] ∙ [(𝜑𝝈) ⊗ 𝝃0 ] = 𝐑 0 ∙ 𝝃0 , } (1.2.2-58)
𝐑 𝑡 ∙ 𝜷 = [(𝜑𝝈) ⊗ 𝐑 0 ] ∙ [(𝜑𝝈) ⊗ 𝜷0 ] = 𝐑 0 ∙ 𝜷0 .
14 Relationship between Parallel Transport and Displacement of a Vector along

a Given Curve on Given Surface
1) Relationship between 𝜻𝑒 and 𝜻𝑡
Let 𝜻0 be unit tangent vector to a curve at point 𝑃0 on surface and 𝑵0 be unit normal vector to
the surface at point 𝑃0 , through parallel transport from point 𝑃0 to point 𝑃 along a given curve
on the surface, 𝜻0 and 𝑵0 become 𝜻𝑒 and 𝑵 as follow
𝜻𝑒 = (𝜀𝝎) ⊗ 𝜻0 ,
} (1.2.2-59)
𝑵 = (𝜀𝝎) ⊗ 𝑵0 .
Where: 𝜀 and 𝝎 are calculated by solution to differential equation (1.2.2-45).
Due to
𝜻𝑒 ∙ 𝑵 = [(𝜀𝝎) ⊗ 𝜻0 ] ∙ [(𝜀𝝎) ⊗ 𝑵0 ] = 𝜻0 ∙ 𝑵0 = 0
𝜻𝑒 is perpendicular to unit normal 𝑵 to surface.
Through displacement of a vector from point 𝑃0 to point 𝑃 along a given curve on the surface,
𝜻0 becomes
𝜻𝑡 = (𝜑𝝈) ⊗ 𝜻0
Where: 𝜑 and 𝝈 are determined by solution to differential equation (1.2.2-52).
Due to expression (1.2.2-57), 𝜻𝑡 ∙ 𝑵 = 𝜻 ∙ 𝑵 = 0, 𝜻𝑡 can be reached through rotation of 𝜻𝑒 by

an angle 𝜃 about 𝑵 as an axis in the consequence of both 𝜻𝑡 and 𝜻𝑒 being perpendicular to 𝑵,
that is,
𝜻𝑡 = (𝜃𝑵) ⊗ 𝜻𝑒 = (𝜃𝑵) ⊗ [(𝜀𝝎) ⊗ 𝜻0 ] (1.2.2-60)
With aid of expression (1.1.1-14), I.e., expression of equivalent order exchange of rotation of
vector, substitution of expressions (1.2.2-49) and (1.2.2-57) into expression above results in
~ 34 ~
𝜻 = 𝜻𝑡 = (𝜃𝑵) ⊗ 𝜻𝑒 = (𝜃𝑵) ⊗ [(𝜀𝝎) ⊗ 𝜻0 ]
= {𝜃[(𝜀𝝎) ⊗ 𝑵0 ]} ⊗ [(𝜀𝝎) ⊗ 𝜻0 ] = (𝜀𝝎) ⊗ [(𝜃𝑵0 ) ⊗ 𝜻0 ]
That is,
𝜻 = (𝜀𝝎) ⊗ [(𝜃𝑵0 ) ⊗ 𝜻0 ] (1.2.2-61)
2) Relationship of Geometric Angular Velocities between 𝛀𝜁 and 𝝎𝑐
Employment of expressions (1.2.2-34), (1.2.2-39) and (1.2.2-40) gives
𝝎𝑐 = 𝛀𝜁 + ∆𝝎𝑐 = 𝛀𝜁 + ∆𝜅𝑐 𝑵 + ∆𝜒𝑐 𝜻
Substitution of expressions (1.2.2-45), (1.2.2-50) and (1.2.2-61) into expression above gives
𝑑𝜀 𝑑𝝎 𝑑𝝎
𝝎 + (1 − cos 𝜀) (𝝎 × ) + sin 𝜀 𝑑𝑠 + (𝜀𝝎) ⊗ (∆𝜅𝑐 𝑵0 )
𝝎𝑐 = 𝛀𝜁 + ∆𝝎𝑐 = { 𝑑𝑠 𝑑𝑠 } (1.2.2-62)
+(𝜀𝝎) ⊗ [(𝜃𝑵0 ) ⊗ (∆𝜒𝑐 𝜻0 )]
3) Relationship among Parameters of Geometric Angular Displacements 𝜀, 𝝎, 𝜑 and 𝝈.
Application of expressions (1.2.2-32), (1.2.2-58) and (1.2.2-62) gives
𝑑𝐑 𝑡 = 𝑑[(𝐑 𝑡 ∙ 𝜻)𝜻 + (𝐑 𝑡 ∙ 𝝃)𝝃 + (𝐑 𝑡 ∙ 𝜷)𝜷]

= 𝑑[(𝐑 0 ∙ 𝜻0 )𝜻 + (𝐑 0 ∙ 𝝃0 )𝝃 + (𝐑 0 ∙ 𝜷0 )𝜷]
= (𝐑 0 ∙ 𝜻0 )𝑑𝜻 + (𝐑 0 ∙ 𝝃0 )𝑑𝝃 + (𝐑 0 ∙ 𝜷0 )𝑑𝜷
= (𝐑 𝑡 ∙ 𝜻)𝝎𝑐 × 𝜻𝑑𝑠 + (𝐑 𝑡 ∙ 𝝃)𝝎𝑐 × 𝝃𝑑𝑠 + (𝐑 𝑡 ∙ 𝜷)𝝎𝑐 × 𝜷𝑑𝑠 (1.2.2-63)
= 𝑑𝑠𝝎𝑐 × [(𝐑 𝑡 ∙ 𝜻)𝜻 + (𝐑 𝑡 ∙ 𝝃)𝝃 + (𝐑 𝑡 ∙ 𝜷)𝜷]
𝑑𝜀𝝎 + (1 − cos 𝜀)(𝝎 × 𝑑𝝎) + sin 𝜀 𝑑𝝎 + (𝜀𝝎) ⊗ (∆𝜅𝑐 𝑑𝑠𝑵0 )
={ } × 𝐑𝑡
+(𝜀𝝎) ⊗ [(𝜃𝑵0 ) ⊗ (∆𝜒𝑐 𝑑𝑠𝜻0 )]
On the hand, let 𝐑 𝑡 = (𝜀𝝎) ⊗ {(𝜃𝑵0 ) ⊗ [(∅𝜻0 ) ⊗ 𝐑 0 ]}, by omitting second or higher order
infinitesimal quantities, application of expression (1.1.2-8) gives
𝑑𝐑 𝑡 = [(𝜀 + 𝑑𝜀)(𝝎 + 𝑑𝝎)] ⊗ {[(𝜃 + 𝑑𝜃)(𝑵0 + 𝑑𝑵0 )] ⊗ {[(∅ + 𝑑∅)(𝜻0 + 𝑑𝜻0 )] ⊗ 𝐑 0 }} − 𝐑 𝑡

[(𝜀 + 𝑑𝜀)(𝝎 + 𝑑𝝎)] ⊗
={ [(𝜃 + 𝑑𝜃)(𝑵0 + 𝑑𝑵0 )] ⊗ } − 𝐑𝑡
{ }
{[𝑑∅𝜻0 + (1 − cos ∅)(𝜻0 × 𝑑𝜻0 ) + sin ∅ 𝑑𝜻0 ] × [(∅𝜻0 ) ⊗ 𝐑 0 ] + (∅𝜻0 ) ⊗ 𝐑 0 }
[(𝜀 + 𝑑𝜀)(𝝎 + 𝑑𝝎)] ⊗
[𝑑𝜃𝑵0 + (1 − cos 𝜃)(𝑵0 × 𝑑𝑵0 ) + sin 𝜃 𝑑𝑵0 ] × {(𝜃𝑵0 ) ⊗ [(∅𝜻0 ) ⊗ 𝐑 0 ]}
= − 𝐑𝑡
{ +(𝜃𝑵0 ) ⊗ {[𝑑∅𝜻0 + (1 − cos ∅)(𝜻0 × 𝑑𝜻0 ) + sin ∅ 𝑑𝜻0 ] × [(∅𝜻0 ) ⊗ 𝐑 0 ]} }
{ +(𝜃𝑵0 ) ⊗ [(∅𝜻0 ) ⊗ 𝐑 0 ] }
~ 35 ~
[𝑑𝜀𝝎 + (1 − cos 𝜀)(𝝎 × 𝑑𝝎) + sin 𝜀 𝑑𝝎]
={ +(𝜀𝝎) ⊗ [𝑑𝜃𝑵0 + (1 − cos 𝜃)(𝑵0 × 𝑑𝑵0 ) + sin 𝜃 𝑑𝑵0 ] } × 𝐑𝑡
+(𝜀𝝎) ⊗ {(𝜃𝑵0 ) ⊗ [𝑑∅𝜻0 + (1 − cos ∅)(𝜻0 × 𝑑𝜻0 ) + sin ∅ 𝑑𝜻0 ]}
Let 𝑑𝑵0 = 0 and 𝑑𝜻0 = 0, then, the expression above becomes
[𝑑𝜀𝝎 + (1 − cos 𝜀)(𝝎 × 𝑑𝝎) + sin 𝜀 𝑑𝝎] + (𝜀𝝎) ⊗ (𝑑𝜃𝑵0 )

𝑑𝐑 𝑡 = { } × 𝐑𝑡
+(𝜀𝝎) ⊗ [(𝜃𝑵0 ) ⊗ (𝑑∅𝜻0 )]
A comparison between expression (1.2.2-63) and expression above leads to
𝐑 𝑡 = (𝜀𝝎) ⊗ {(𝜃𝑵0 ) ⊗ [(∅𝜻0 ) ⊗ 𝐑 0 ]},

𝑠 𝑠 } (1.2.2-64)
𝑑𝜃 = ∆𝜅𝑐 𝑑𝑠, 𝑑∅ = ∆𝜒𝑐 𝑑𝑠, 𝜃 = ∫𝑠0 ∆𝜅𝑐 𝑑𝑠 , ∅ = ∫𝑠0 ∆𝜒𝑐 𝑑𝑠 .
Substitution of expressions (1.2.2-55) into (1.2.2-64) generates relationship of parameters of

geometric angular displacements between 𝜑, 𝝈 and 𝜀 , 𝝎 as follow
(𝜑𝝈) ⊗ 𝐑 0 = (𝜀𝝎) ⊗ {(𝜃𝑵0 ) ⊗ [(∅𝜻0 ) ⊗ 𝐑 0 ]} (1.2.2-65)
For geodesic curve, 𝜃 = 0 and ∅ = 0, thus,
(𝜑𝝈) ⊗ 𝐑 0 = (𝜀𝝎) ⊗ 𝐑 0
Therefore, unit tangent vector to geodesic curve on surface is preserved as unit tangent vector
to geodesic curve through parallel translation along geodesic curve on surface.
~ 36 ~
Chapter 3
Conjugate Motion, Conjugate Surfaces and Requirements of

Conjugate Contact
Let 𝜑1 stand for motion of rigid body I and 𝜑2 stand for motion of rigid body II. if rigid body I
and rigid body II keep in contact with each other in motion process, then, a pair of relative
motion (𝜑1 , 𝜑2 ) between rigid body I and rigid body II is constrained by geometric
configurations of both rigid body I and rigid body II, then such a pair of relative motion
(𝜑1 , 𝜑2 ) is called conjugate motion and, their corresponding geometric configurations are
called a pair of conjugate geometric configurations. A pair of conjugate geometric
configurations can be either point, line or surface, but at least one of them is surface.
Therefore, a pair of conjugate geometric configurations are usually called a pair of conjugate
surfaces (𝐴, ̅𝐴).
1.3.1 Canonical Form of Conjugate Motion

Given three spaces 𝑂, 𝑂I , 𝑂II , space 𝑂 stands for reference space, space 𝑂I is used for motion of
rigid body I and space 𝑂II is used for motion of rigid body II. Let rigid body I be statically fixed in
space 𝑂I , then, within a pair of conjugate motion (𝜑1 , 𝜑2 ), motion 𝜑1 of rigid body I with
respect to space 𝑂I is degenerated to static state, and Meanwhile, motion 𝜑2 of rigid body II
with respect to space 𝑂I becomes relative motion 𝜑21 of rigid body II with respect to rigid body
I. The most general form of motion of rigid body is composed of rotation and translation. Let
𝑹2I be an arbitrary point on rigid body II at initial instant with respect to space 𝑂I , then, at
instant 𝑡, 𝑹2I becomes 𝑹2𝑡 , that is,
𝑹2𝑡 = (𝜃𝝎) ⊗ 𝑹2I + 𝒔 (1.3.1-1)
Let 𝝎0 and 𝝎1 be a pair of arbitrarily prescribed mutually perpendicular unit vectors

(𝝎0 ∙ 𝝎1 = 0) which are statically attached to reference space, i.e., space 𝑂. With aid of
resolution of rotation of a vector, i.e., expression (1.1.1-15), expression (1.3.1-1) is updated as
follow:
𝑹2𝑡 = (−𝜀1 𝝎1 ) ⊗ {(−𝛼𝝎0 ) ⊗ [(−𝜀2 𝝎1 ) ⊗ 𝑹2I ]} + 𝒔 (1.3.1-2)
Let space 𝑂I rotate about 𝝎1 together with helical translation along 𝝎1 , then, any point 𝑹1 on
rigid body I at initial instant reaches following position 𝑹1𝑡 at instant 𝑡, that is,
𝑹1𝑡 = (𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 (1.3.1-3)
~ 37 ~
Where: 𝜀1 is rotating angle about 𝝎1 and 𝜎1 is translation along 𝝎1 .
With application of expression (1.1.1-6), combination of expressions (1.3.1-2) and (1.3.1-3)

results in conjugate motion (𝜑1 , 𝜑2 ) with respect to reference space (space 𝑂) as follow:
𝜑1 : 𝑹1𝑡 = (𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 ,
} (1.3.1-4)
𝜑2 : 𝑹2𝑡 = {(−𝛼𝝎0 ) ⊗ [(−𝜀2 𝝎1 ) ⊗ 𝑹2I ]} + 𝜌𝒒.
Where: 𝜌𝒒 = (𝜀1 𝝎1 ) ⊗ 𝒔 + 𝜎1 𝝎1
Expression (1.3.1-4) is called canonical form of conjugate motion.
1.3.2 Canonical Form of Simple Conjugate Motion

For simple conjugate motion, parameter 𝛼 in canonical form of conjugate motion, i.e.,
expression (1.3.1-4) is a constant. With application of sequence-reciprocation of successive
rotations of a vector, i.e., expression (1.1.1-14), the second formula in expression (1.3.1-4) is
updated as follow:
𝑹2𝑡 = {(−𝜀2 )[(−𝛼𝝎0 ) ⊗ 𝝎1 ]} ⊗ [(−𝛼𝝎0 ) ⊗ 𝑹2I ] + 𝜌𝒒 (1.3.2-1)
Due to 𝝎1 and 𝝎0 being fixed unit vectors and 𝛼 being constant, thus, (−𝛼𝝎0 ) ⊗ 𝝎1 is a
constant unit vector, let 𝝎2 be as follow:
𝝎2 = −(−𝛼𝝎0 ) ⊗ 𝝎1 = − cos 𝛼 𝝎1 + sin 𝛼 (𝝎0 × 𝝎1 ) (1.3.2-2)
In the case of cos 𝛼 ≠ 0, due to 𝝎2 , 𝝎0 and(𝝎0 × 𝝎1 ) being not mutually coplanar, 𝜌𝒒 can be
resolved in 𝝎2 , 𝝎0 and (𝝎0 × 𝝎1 ) respectively, that is,
𝜌𝒒 = 𝜎2 𝝎2 + 𝑓𝝎0 + ℎ𝝎0 × 𝝎1 (1.3.2-3)
In the case of cos 𝛼 = 0, due to 𝝎2 , 𝝎0 and𝝎1 being not mutually coplanar, 𝜌𝒒 can be resolved
in 𝝎2 , 𝝎0 and 𝝎1 respectively, that is,
𝜌𝒒 = 𝜎2 𝝎2 + 𝑓𝝎0 + 𝜎1′ 𝝎1 (1.3.2-4)
Set
𝑙𝒑 = 𝑓𝝎0 + ℎ𝝎0 × 𝝎1 𝑤ℎ𝑒𝑛 cos 𝛼 ≠ 0,

} (1.3.2-5)
𝑙𝒑 = 𝑓𝝎0 + 𝜎1′ 𝝎1 𝑤ℎ𝑒𝑛 cos 𝛼 = 0.
Unifying expressions (1.3.2-3) and (1.3.2-4) results in
~ 38 ~
𝜌𝒒 = 𝜎2 𝝎2 + 𝑙𝒑 (1.3.2-6)
Set
𝑹2 = (−𝛼𝝎0 ) ⊗ 𝑹2I (1.3.2-7)
Substitution of expressions (1.3.2-2), (1.3.2-6) and (1.3.2-7) into (1.3.2-1) leads
𝑹2𝑡 = (𝜀2 𝝎2 ) ⊗ 𝑹2 + 𝜎2 𝝎2 + 𝑙𝒑 (1.3.2-8)
In the canonical form of conjugate motion, i.e., expression (1.3.1-4), vectors 𝑹1𝑡 and 𝑹2𝑡 share
the same origin. In order to facilitate analyses and calculation of geometry and kinematics for
simple conjugate motion, the origin of point vector on rigid body I keeps unchanged, but the
origin of point vector on rigid body II is adjusted to the end point of vector 𝑙𝒑. For the sake of
differentiation, point vectors 𝑹1𝑝 and 𝑹2𝑝 on rigid body I and rigid body II with dual origins are
adopted respectively as follow:
𝑹1𝑝 = 𝑹1𝑡 ,
} (1.3.2-9)
𝑹2𝑝 = 𝑹2𝑡 − 𝑙𝒑 .
Substitution of expressions (1.3.1-3) and (1.3.2-8) into (1.3.2-9) generates the canonical form of
simple conjugate motion as follow:
𝜑1 : 𝑹1𝑝 = 𝑹1𝑡 = (𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 ,

} (1.3.2-10)
𝜑2 : 𝑹2𝑝 = 𝑹2𝑡 − 𝑙𝒑 = (𝜀2 𝝎2 ) ⊗ 𝑹2 + 𝜎2 𝝎2 .
Where: 𝑙𝒑 is decided by expression (1.3.2-5).
1.3.3 Dual Coordinate System for Simple Conjugate Motion

Corresponding to canonical form of simple conjugate motion, a dual coordinate system is
constructed as shown in figure 1.3.3-1, that is,
𝒊′ = 𝒊,
′
𝒋 = cos 𝛼 𝒋 − sin 𝛼 𝒌,
𝒌′ = −𝝎2 = sin 𝛼 𝒋 + cos 𝛼 𝒌,
𝒊 = 𝒊′ , (1.3.3-1)
𝒋 = cos 𝛼 𝒋′ + sin 𝛼 𝒌′ ,
𝒌 = 𝝎1 = − sin 𝛼 𝒋′ + cos 𝛼 𝒌′ ,
𝑙𝒑 = ̅̅̅̅̅
𝑂𝑂′ = 𝑓𝒊 + ℎ𝒋, }
Where: (𝑂 − 𝒊, 𝒋, 𝒌) for body I and (𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ ) for body II:
~ 39 ~
𝒌 = 𝝎1 𝒌′ = −𝝎2
𝑂 𝒋
𝑙𝒑 𝑓
ℎ 𝑂′
𝒋′
𝒊(𝝎0 ) 𝒊′ (= 𝒊) 𝝎2
Figure 1.3.3-1 Dual Coordinate System for Simple Conjugate Motion
1.3.4 Displacement of a point on Rigid Body in Simple Conjugate

Motion with Single Degree of Freedom
1 Independent Parameter of Variable
Let 𝜀1 be a rotating angle of rigid body I about 𝝎1 as an axis, 𝜎1 be translation distance of rigid
body I along 𝝎1 , 𝜀2 be a rotating angle of rigid body II about 𝝎2 as an axis, 𝜎2 be translation
distance of rigid body II along 𝝎2 . Assume that coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 is fixed and
coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ translates in direction 𝒑 with respect to coordinate system 𝑂 −
𝒊, 𝒋, 𝒌 and origin 𝑂′ of coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ is defined by 𝑓 and ℎ in coordinate
system 𝑂 − 𝒊, 𝒋, 𝒌.
Due to motion with single degree of freedom, only one variable is independent among 𝜀1 , 𝜎1 ,
𝜀2 , 𝜎2 , 𝑓 and ℎ. Here, 𝜀1 is adopted as independent variable, although any one can be selected
as independent variable in principle, that is,
𝜀2 = 𝜀2 (𝜀1 ), 𝜎1 = 𝜎1 (𝜀1 ), 𝜎2 = 𝜎2 (𝜀1 ),

} (1.3.4-1)
𝑓 = 𝑓(𝜀1 ), ℎ = ℎ(𝜀1 ).
2 Displacement of Point on Rigid Body I

~ 40 ~
Let in initial position, i.e., 𝜀1 = 0 , point-vector 𝑹1 of an arbitrary point 𝑃 on rigid body I with
respect to coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 be 𝑹1 = 𝑥𝒊 + 𝑦𝒋 + 𝑧𝒌 . Then, at instant rotating angle
𝜀1 , point 𝑃 on rigid body I will become 𝑃𝑑 and corresponding point-vector 𝑹1 will be 𝑹1𝑝 as
follow
𝑹1𝑝 = (𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 = 𝑥𝑝 𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌,
𝑥𝑝 = 𝑥 cos 𝜀1 − 𝑦 sin 𝜀1 ,
(1.3.4-2)
𝑦𝑝 = 𝑥 sin 𝜀1 + 𝑦 cos 𝜀1 ,
𝑧𝑝 = 𝑧 + 𝜎1 . }
3 Common Point on Rigid Body II

Assume that point 𝑃𝑑 on rigid body I is also on rigid body II at the same instant rotating angle 𝜀1 ,
then, point 𝑃𝑑 is a common point of both rigid body I and rigid body II. Point-vector 𝑹2𝑝 of
common point 𝑃𝑑 on rigid body II with respect to coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ is as follow:
𝑹2𝑝 = 𝑹1𝑝 − 𝑙𝒑 = 𝑥𝑝′ 𝒊′ + 𝑦𝑝′ 𝒋′ + 𝑧𝑝′ 𝒌′ ,

𝑥𝑝′ = 𝑥𝑝 − 𝑓,
(1.3.4-3)
𝑦𝑝′ = (𝑦𝑝 − ℎ) cos 𝛼 − 𝑧𝑝 sin 𝛼 ,
𝑧𝑝′ = (𝑦𝑝 − ℎ) sin 𝛼 + 𝑧𝑝 cos 𝛼 . }
4 Initial Position of Common Point on Rigid Body II

At initial rotating angle, i.e., 𝜀1 = 0, point 𝑃̅ on rigid body II corresponding to common point 𝑃𝑑
at instant rotating angle 𝜀1 , also corresponding to point 𝑃 on rigid body I at initial rotating
angle, i.e., 𝜀1 = 0, is called initial corresponding point on rigid body II, point -vector 𝑹2 of point
𝑃̅ with respect to coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ is follow:
𝑹2 = (−𝜀2 𝝎2 ) ⊗ 𝑹2𝑝 − 𝜎2 𝝎2 (1.3.4-4)
Substitution of expressions (1.3.4-2) and (1.3.4-3) into expression (1.3.4-4) gives
𝑹2 = 𝑥 ′ 𝒊′ + 𝑦 ′ 𝒋′ + 𝑧 ′ 𝒌′ = (−𝜀2 𝝎2 ) ⊗ [(𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 − 𝑙𝒑] − 𝜎2 𝝎2 (1.3.4-5)
𝑥(cos 𝜀1 cos 𝜀2 − cos 𝛼 sin 𝜀1 sin 𝜀2 ) − 𝑦(sin 𝜀1 cos 𝜀2 + cos 𝛼 cos 𝜀1 sin 𝜀2 )
𝑥′ = { },
+(𝑧 + 𝜎1 ) sin 𝛼 sin 𝜀2 − 𝑓 cos 𝜀2 + ℎ cos 𝛼 sin 𝜀2
𝑥(cos 𝜀1 sin 𝜀2 + cos 𝛼 sin 𝜀1 cos 𝜀2 ) + 𝑦(cos 𝛼 cos 𝜀1 cos 𝜀2 − sin 𝜀1 sin 𝜀2 )
𝑦′ = { },
−(𝑧 + 𝜎1 ) sin 𝛼 cos 𝜀2 − 𝑓 sin 𝜀2 − ℎ cos 𝛼 cos 𝜀2
𝑧 ′ = 𝑥 sin 𝛼 sin 𝜀1 + 𝑦 sin 𝛼 cos 𝜀1 + (𝑧 + 𝜎1 ) cos 𝛼 − ℎ sin 𝛼 + 𝜎2 . }
Where: 𝜀2 , 𝜎1 , 𝜎2 𝑓 and ℎ are all function of 𝜀1 and decided by expression (1.3.4-1).
~ 41 ~
1.3.5 Linear Velocity of Point in Simple Conjugate Motion with Single
Degree of Freedom
1 Linear Velocity of Common Point on Rigid Body I
Let instantaneous rotating angle 𝜀1 be visualized as virtual time parameter, and then, linear
velocity 𝒗𝑝 of common point 𝑃𝑑 (𝑹1𝑝 ) on rigid body I with respect to coordinate system 𝑂 −
𝒊, 𝒋, 𝒌 at instant 𝜀1 is derived by taking derivative of expression (1.3.4-2) with 𝜀1 as follow:
𝑑𝑹1𝑝 𝑑𝜎 𝑑𝜎
𝒗𝑝 = = 𝝎1 × 𝑹1𝑝 + 𝑑𝜀 1 𝝎1 = −𝑦𝑝 𝒊 + 𝑥𝑝 𝒋 + 𝑑𝜀 1 𝒌 (1.3.5-1)
𝑑𝜀1 1 1
2 Linear Velocity of Common Point on Rigid Body II
Likewise, linear velocity 𝒗′𝒑 of common point 𝑃𝑑 (𝑹1𝑝 ) on rigid body II with respect to
coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 at instant 𝜀1 is equal to summation of linear velocity of common
point 𝑃𝑑 (𝑹1𝑝 ) with respect to 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ and velocity of coordinate system𝑂′ − 𝒊′ , 𝒋′ , 𝒌′
with respect to 𝑂 − 𝒊, 𝒋, 𝒌 as follow:
𝑑𝜎 𝑑(𝑙𝒑)
𝒗′𝒑 = 𝑀𝝎2 × 𝑹2𝑝 + 𝑑𝜀 2 𝝎2 + (1.3.5-2)
1 𝑑𝜀1
𝑑𝜀
Where: 𝑀 = 𝑑𝜀2 is transmission ratio.
1
3 Relative Linear Velocity of Common Point on Rigid Body I with Respect to

Rigid Body II
The relative velocity 𝒗12

𝒑 of common point 𝑃𝑑 (𝑹1𝑝 ) on rigid body I with respect to rigid body II
at instant 𝜀1 is derived by application of expressions (1.3.4-3), (1.3.5-1) and (1.3.5-2)
𝑑𝜎 𝑑𝜎 𝑑(𝑙𝒑)
𝒗12 ′ 1 2
𝑝 = 𝒗𝑝 − 𝒗𝑝 = (𝝎1 − 𝑀𝝎2 ) × 𝑹1𝑝 + 𝑑𝜀 𝝎1 + 𝑀𝝎2 × (𝑙𝒑) − 𝑑𝜀 𝝎2 −
1 1 𝑑𝜀1 (1.3.5-3)
12 12 12
= 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑧 𝒌
Where:
12 𝑑𝑓
𝑣𝑝𝑥 = −(1 + 𝑀 cos 𝛼)𝑦𝑝 + 𝑀𝑧𝑝 sin 𝛼 + 𝑀ℎ cos 𝛼 − 𝑑𝜀 ,
1
12 𝑑𝜎2 𝑑ℎ
𝑣𝑝𝑦 = (1 + 𝑀 cos 𝛼)𝑥𝑝 − 𝑀𝑓 cos 𝛼 + 𝑑𝜀 sin 𝛼 − 𝑑𝜀 ,
1 1
12 𝑑𝜎1 𝑑𝜎2
𝑣𝑝𝑧 = −𝑀𝑥𝑝 sin 𝛼 + 𝑀𝑓 sin 𝛼 + 𝑑𝜀 + 𝑑𝜀 cos 𝛼 . }
1 1
~ 42 ~
1.3.6 Angular Velocity of Simple Conjugate Motion with Single
Degree of Freedom
𝑑𝜀
Let 𝜀1 be visualized as virtual time parameter, angular velocity of rigid body I is 𝑑𝜀1 𝝎1 = 𝒌.
1
Let 𝜀1 be visualized as virtual time parameter, angular velocity of rigid body II is

𝑑𝜀2
𝝎2 = 𝑀𝝎2 = −𝑀𝒌′ = −𝑀(sin 𝛼 𝒋 + cos 𝛼 𝒌)
𝑑𝜀1
Let 𝜀1 be visualized as virtual time parameter, relative angular velocity of rigid body I with
respect to rigid body II is 𝛀𝑝 , that is,
𝛀𝑝 = 𝝎1 − 𝑀𝝎2 = 𝑀 sin 𝛼 𝒋 + (1 + 𝑀 cos 𝛼)𝒌 (1.3.6-1)
1.3.7 Conjugate Contact Point and Conjugate Point

1 Definition
At any instant 𝜀1 (𝜀1 is visualized as virtual time parameter), contact point 𝑃𝑑 between a pair of
conjugate surfaces (𝐴, ̅𝐴) are defined as a pair of conjugate contact points (𝑹1𝑝 , 𝑹2𝑝 ) at the
given instant 𝜀1 . At other instant, due to conjugate motion between rigid body I and rigid body
II, a pair of original conjugate contact points (𝑹1𝑝 , 𝑹2𝑝 ) are separated from each other and
become a pair of corresponding points which are defined as a pair of conjugate points
(𝑹1 , 𝑹2 ).
2 Requirements to be Satisfied by Conjugate Contact Points
1) The conjugate contact point 𝑃𝑑 (𝑹1𝑝 ) of rigid body I must coincide with the conjugate
contact point 𝑃𝑑 (𝑹2𝑝 ) of rigid body II, as shown in figure 1.3.7-1, that is,
𝑹1𝑝 = 𝑹2𝑝 + 𝑙𝒑 (1.3.7-1)
2) At conjugate contact point 𝑃𝑑 , the unit normal 𝑵1𝑝 to conjugate surface 𝐴 of rigid body
I must be aligned with the unit normal 𝑵2𝑝 to conjugate surface 𝐴̅ of rigid body II but in
opposite direction, that is,
𝑵1𝑝 = −𝑵2𝑝 (1.3.7-2)
3) Relative velocity 𝒗12

𝑝 at conjugate contact point 𝑃𝑑 must have no component in
~ 43~
direction of common normal vector to a pair of conjugate surfaces (𝐴, ̅𝐴), that is,
𝒗12
𝑝 ∙ 𝑵1𝑝 = 0 (1.3.7-3)
4) No interference in differential region of the conjugate contact point 𝑃𝑑 , that is, in any
tangent direction 𝝉 through the conjugate contact point 𝑃𝑑 , normal curvature 𝐾1𝜏 of
conjugate surface 𝐴 on rigid body I and normal curvature 𝐾2𝜏 of conjugate surface 𝐴̅ on
rigid body II must satisfy
𝐾1𝜏 + 𝐾2𝜏 ≥ 0 (1.3.7-4)
𝑵1𝑝
𝒗12
𝑝
𝒌 = 𝝎1
𝐴̅ 𝝉
𝑃𝑑
𝐴
′
𝑹1𝑝 𝒌
𝛼 𝑵2𝑝
𝑂 𝑹2𝑝 𝒋
𝑙𝒑
𝑂′
𝒋′
𝒊′ 𝝎2
Figure 1.3.7-1 Requirements of Conjugate Contact Point
1.3.8 Instantaneous Contact Line and Contact Line

1 Definition
~ 44 ~
In the case of line contact, a pair of conjugate surfaces (𝐴, ̅𝐴) contact to each other in one or
several lines at any instant. Such lines are defined as instantaneous contact lines at instant 𝜀1 .
At other instant, due to conjugate motion, original instantaneous contact lines will be
separated to each other and become a pair of lines lying on conjugate surfaces (𝐴, ̅𝐴)
respectively, such a pair of lines are called as a pair of conjugate contact lines.
2 Calculation of Instantaneous Contact Line

Given Condition:
1) The first conjugate surface 𝐴 and its unit normal in initial position (𝜀1 = 0), that is,
expressions (1.2.1-2) and (1.2.1-4):
𝑹1 (𝑢, 𝑣) = 𝑥(𝑢, 𝑣)𝒊 + 𝑦(𝑢, 𝑣)𝒋 + 𝑣(𝑢, 𝑣)𝒌,

𝜕𝑹1 𝜕𝑹1
𝜕𝑢
×
𝜕𝑣 } (1.3.8-1)
𝑵= 𝜕𝑹 𝜕𝑹 = 𝐴𝒊 + 𝐵𝒋 + 𝐶𝒌.
| × |
𝜕𝑢 𝜕𝑣
Where:
1 𝜕𝑦 𝜕𝑧 𝜕𝑧 𝜕𝑦 1 𝜕𝑧 𝜕𝑥 𝜕𝑥 𝜕𝑧 1 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥
𝐴 = 𝑄 (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣 ) , 𝐵 = 𝑄 (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) , 𝐶 = 𝑄 (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) ,
2 2 2
}
𝜕𝑦 𝜕𝑧 𝜕𝑧 𝜕𝑦 𝜕𝑧 𝜕𝑥 𝜕𝑥 𝜕𝑧 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥
𝑄 = ±√(𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣 ) + (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) + (𝜕𝑢 𝜕𝑣 − 𝜕𝑢 𝜕𝑣) .
Here: sign “ ± ” is decided by 𝑵 pointing from entity to void.
2) A pair of conjugate motion (𝜑1 , 𝜑2 ), that is,
At instant 𝜀1 , initial point 𝑹1 on the first conjugate surface 𝐴 reaches to conjugate contact
position decided by expression (1.3.4-1), that is,
𝜀2 = 𝜀2 (𝜀1 ), 𝜎1 = 𝜎1 (𝜀1 ), 𝜎2 = 𝜎2 (𝜀1 ),

} (1.3.8-2)
𝑓 = 𝑓(𝜀1 ), ℎ = ℎ(𝜀1 ).
Calculation Object:
1) Instantaneous contact line at instant 𝜀1 (𝜀1 is visualized as virtual time parameter)
Calculation Program:
Given an instant 𝜀1 , let 𝑹1 (𝑢, 𝑣) be any point on contact line of the first conjugate surface 𝐴 in
initial position corresponding to instant 𝜀1 , then, 𝑹1 (𝑢, 𝑣) reaches conjugate contact position at
instant 𝜀1 , that is,
~45 ~
𝑹1𝑝 = (𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 = (𝜀1 𝒌) ⊗ 𝑹1 + 𝜎1 𝒌 = 𝑥𝑝 𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌,
𝑥𝑝 = 𝑥 cos 𝜀1 − 𝑦 sin 𝜀1 ,
(1.3.8-3)
𝑦𝑝 = 𝑥 sin 𝜀1 + 𝑦 cos 𝜀1 ,
𝑧𝑝 = 𝑧 + 𝜎1 . }
And unit normal 𝑵1𝑝 to the first conjugate surface 𝐴 at conjugate contact position of instant 𝜀1
is as follow:
𝑵1𝑝 = (𝜀1 𝝎1 ) ⊗ 𝑵 = (𝜀1 𝝎1 ) ⊗ [𝐴(𝑢, 𝑣)𝒊 + 𝐵(𝑢, 𝑣)𝒋 + 𝐶(𝑢, 𝑣)𝒌]
(1.3.8-4)
= [𝐴(𝑢, 𝑣) cos 𝜀1 − 𝐵(𝑢, 𝑣) sin 𝜀1 ]𝒊 + [𝐴(𝑢, 𝑣) sin 𝜀1 + 𝐵(𝑢, 𝑣) cos 𝜀1 ]𝒋 + 𝐶(𝑢, 𝑣)𝒌
The relative velocity 𝒗12𝒑 of conjugate contact point 𝑃𝑑 (𝑹1𝑝 ) on rigid body I with respect to
rigid body II at instant 𝜀1 is defined in expression (1.3.5-3), that is,
𝒗12 1 2
𝑝 = (𝝎1 − 𝑀𝝎2 ) × 𝑹1𝑝 + 𝑑𝜀 𝝎1 + 𝑀𝝎2 × (𝑙𝒑) − 𝑑𝜀 𝝎2 −
1 1 𝑑𝜀1 (1.3.8-5)
12 12 12
= 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑧 𝒌
Where:
12 𝑑𝑓
1
𝑣𝑝𝑦 = (1 + 𝑀 cos 𝛼)𝑥𝑝 − 𝑀𝑓 cos 𝛼 + 𝑑𝜀 sin 𝛼 − 𝑑𝜀 , (1.3.8-6)
1 1
12 𝑑𝜎 𝑑𝜎
𝑣𝑝𝑧 = −𝑀𝑥𝑝 sin 𝛼 + 𝑀𝑓 sin 𝛼 + 𝑑𝜀 1 + 𝑑𝜀 2 cos 𝛼 . }
1 1
Due to 𝑃𝑑 (𝑹1𝑝 ) being a conjugate contact point at instant 𝜀1 , requirement of conjugate

contact, i.e., expression (1.3.7-3), is satisfied, then, and substitution of expressions (1.3.8-4) and
(1.3.8-5) into (1.3.5-3) results in
𝑈 cos 𝜀1 − 𝑉 sin 𝜀1 = 𝑊 (1.3.8-7)
Where:
𝑑𝑓 𝑑𝜎 𝑑ℎ
𝑈 = 𝐴 [𝑀ℎ cos 𝛼 + 𝑀(𝑧 + 𝜎1 ) sin 𝛼 − 𝑑𝜀 ] − 𝐵 (𝑀𝑓 cos 𝛼 − 𝑑𝜀 2 sin 𝛼 + 𝑑𝜀 ) − 𝐶𝑀𝑥 sin 𝛼 ,
1 1 1
𝑑𝜎2 𝑑ℎ 𝑑𝑓
𝑉 = 𝐴 (𝑀𝑓 cos 𝛼 − 𝑑𝜀 sin 𝛼 + 𝑑𝜀 ) + 𝐵 [𝑀(𝑧 + 𝜎1 ) sin 𝛼 + 𝑀ℎ cos 𝛼 − 𝑑𝜀 ] − 𝐶𝑀𝑦 sin 𝛼 ,
1 1 1
𝑑𝜎1 𝑑𝜎2
𝑊 = (1 + 𝑀 cos 𝛼)(𝑦𝐴 − 𝑥𝐵) − (𝑀𝑓 sin 𝛼 + 𝑑𝜀 + 𝑑𝜀 cos 𝛼) 𝐶. }
1 1
Given 𝜀1 , equation (1.3.8-7) includes two parameters 𝑢 and 𝑣 which are parameters for
instantaneous contact line corresponding to instant 𝜀1 . Thus, Instantaneous contact line at
instant 𝜀1 is derived as follow:
~ 46 ~
𝑹1𝑝 = 𝑥𝑝 𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌,
𝑥𝑝 = 𝑥(𝑢, 𝑣) cos 𝜀1 − 𝑦(𝑢, 𝑣) sin 𝜀1 ,
(1.3.8-8)
𝑦𝑝 = 𝑥(𝑢, 𝑣) sin 𝜀1 + 𝑦(𝑢, 𝑣) cos 𝜀1 ,
𝑧𝑝 = 𝑧(𝑢, 𝑣) + 𝜎1 . }
Where: 𝜀1 is prescribed. 𝑢 and 𝑣 are decided by expression (1.3.8-7).
1.3.9 Path of Contact and The Second Conjugate Surface

1 Path of Contact
Set of all conjugate contact points at different instant 𝜀1 constitutes a geometric configuration
in coordinate system (𝑂 − 𝒊, 𝒋, 𝒌). Such a geometric configuration is defined as path of contact.
Analytic formular of path of contact is expression (1.3.8-7).
Path of contact is a curve in the case of point contact for motion with single degree of freedom
and a surface in the case of line contact for motion with single degree of freedom.
2 Second Conjugate Surface

Because the second conjugate surface ̅𝐴 is in conjugate contact with the first conjugate surface
𝐴 under a pair of conjugate motion (𝜑1 , 𝜑2 ), the second conjugate surface ̅𝐴 can be
determined by expression (1.3.4-5) with geometric parameters of the first conjugate surface 𝐴
and motion parameters of conjugate motion (𝜑1 , 𝜑2 ) as follow
𝑹2 = 𝑥 ′ 𝒊′ + 𝑦 ′ 𝒋′ + 𝑧 ′ 𝒌′ = (−𝜀2 𝝎2 ) ⊗ (𝑹1𝑝 − 𝑙𝒑) − 𝜎2 𝝎2

= (−𝜀2 𝝎2 ) ⊗ [(𝜀1 𝝎1 ) ⊗ 𝑹1 + 𝜎1 𝝎1 − 𝑙𝒑] − 𝜎2 𝝎2 ,
𝑥(cos 𝜀1 cos 𝜀2 − cos 𝛼 sin 𝜀1 sin 𝜀2 ) − 𝑦(sin 𝜀1 cos 𝜀2 + cos 𝛼 cos 𝜀1 sin 𝜀2 )
𝑥′ = { },
+(𝑧 + 𝜎1 ) sin 𝛼 sin 𝜀2 − 𝑓 cos 𝜀2 + ℎ cos 𝛼 sin 𝜀2 (1.3.8-8)
𝑥(cos 𝜀1 sin 𝜀2 + cos 𝛼 sin 𝜀1 cos 𝜀2 ) + 𝑦(cos 𝛼 cos 𝜀1 cos 𝜀2 − sin 𝜀1 sin 𝜀2 )
𝑦′ = { },
−(𝑧 + 𝜎1 ) sin 𝛼 cos 𝜀2 − 𝑓 sin 𝜀2 − ℎ cos 𝛼 cos 𝜀2
𝑧 ′ = 𝑥 sin 𝛼 sin 𝜀1 + 𝑦 sin 𝛼 cos 𝜀1 + (𝑧 + 𝜎1 ) cos 𝛼 − ℎ sin 𝛼 + 𝜎2 . }
Where: 𝜎1 , 𝜎2 , 𝑓, ℎ and 𝜀2 are all functions of 𝜀1 and surface parameters (𝑢, 𝑣) of the first
conjugate surface 𝐴 are calculated by expression (1.3.8-6).
~ 47 ~
Chapter 4
Pitch Surface and Surface of Screw Axis
1.4.1 Definition of Pitch Surface

Pitch surfaces on both rigid body I and rigid body II are defined as surfaces constituted by points
with relative velocity 𝒗12
𝑝 = 𝟎. Application of expression (1.3.8-5) gives
𝒗12 1 2
𝑝 = (𝝎1 − 𝑀𝝎2 ) × 𝑹1𝑝 + 𝑑𝜀 𝝎1 + 𝑀𝝎2 × (𝑙𝒑) − 𝑑𝜀 𝝎2 − =𝟎 (1.4.1-1)
1 1 𝑑𝜀1
1.4.2 Existent Condition of Pitch Surfaces

12 12 12
Let 𝑣𝑝𝑥 = 𝑣𝑝𝑦 = 𝑣𝑝𝑧 = 0 in expression (1.3.8-5), and eliminating 𝑥𝑝 in last two formulae gives
existent condition of pitch surfaces as follow
𝑑𝜎 𝑑ℎ 𝑑𝜎 𝑑𝜎
𝑀 sin 𝛼 (𝑀𝑓 cos 𝛼 − 𝑑𝜀 2 sin 𝛼 + 𝑑𝜀 ) = (1 + 𝑀 cos 𝛼) (𝑀𝑓 sin 𝛼 + 𝑑𝜀 1 + 𝑑𝜀 2 cos 𝛼) (1.4.2-1)
1 1 1 1
1.4.3 Equation of Pitch Surfaces

Relative velocity calculated by expression (1.4.1-1) shows that any point 𝑹1𝑝 + 𝑠(𝝎1 − 𝑀𝝎2 )
can satisfy the requirement defined by expression (1.4.1-1) if point 𝑹1𝑝 can satisfy expression
(1.4.1-1). Therefore, pitch surfaces are ruled surfaces.
1 Equation of First Pitch Surface

With aid of expression (1.3.8-3), application of first two formulae in expression (1.3.8-6) yields
equation of first pitch surface in initial position with respect to coordinate system (𝑂 − 𝒊, 𝒋, 𝒌)
as follow:
𝑹0 = 𝑥0 𝒊 + 𝑦0 𝒋 + 𝑧0 𝒌 (1.4.3-1)
Where: 𝑧0 and 𝜀1 are independent parameters and

[𝑀(𝑧0 +𝜎1 ) sin 𝛼+𝑀ℎ cos 𝛼− ] sin 𝜀1 +(𝑀𝑓 cos 𝛼− 2 sin 𝛼+ ) cos 𝜀1
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1
𝑥0 = ,
1+𝑀 cos 𝛼
[𝑀(𝑧0 +𝜎1 ) sin 𝛼+𝑀ℎ cos 𝛼− ] cos 𝜀1 −(𝑀𝑓 cos 𝛼− 2 sin 𝛼+ ) sin 𝜀1
𝑦0 = .}
1+𝑀 cos 𝛼
2 Path of Contact for Pitch Surface
~ 48 ~
Substitution of expressions (1.4.3-1) into (1.3.8-3) gives path of contact for pitch surface as
follow:
𝑹0𝑝 = (𝜀1 𝝎1 ) ⊗ 𝑹0 + 𝜎1 𝝎1 = (𝜀1 𝒌) ⊗ 𝑹0 + 𝜎1 𝒌 = 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋 + 𝑧0𝑝 𝒌,

𝑑𝜎2 𝑑ℎ
(𝑀𝑓 cos 𝛼−
𝑑𝜀1
sin 𝛼+
𝑑𝜀1
) 𝑀(𝑧0 +𝜎1 ) sin 𝛼+𝑀ℎ cos 𝛼−
𝑑𝑓 } (1.4.3-2)
𝑥0𝑝 = , 𝑦0𝑝 =
𝑑𝜀1
, 𝑧0𝑝 = 𝑧0 + 𝜎1 .
1+𝑀 cos 𝛼 1+𝑀 cos 𝛼
Where: 𝑧0 and 𝜀1 are two independent parameters.
3 Equation of Second Pitch Surface

Substitution of expression (1.4.3-1) into (1.3.8-8) results in equation of second pitch surface as
follow:
𝑹′0 = 𝑥0′ 𝒊′ + 𝑦0′ 𝒋′ + 𝑧0′ 𝒌′ = (−𝜀2 𝝎2 ) ⊗ (𝑹𝑝 − 𝑙𝒑) (1.4.3-3)
Where:
(−𝑓− sin 𝛼+ ) cos 𝜀2 −[𝑀(𝑧0 +𝜎1 ) sin 𝛼−ℎ− ] cos 𝛼 sin 𝜀2
𝑥0′ = + (𝑧0 + 𝜎1 ) sin 𝛼 sin 𝜀2 ,
1+𝑀 cos 𝛼
(−𝑓− sin 𝛼+ ) sin 𝜀2 +[𝑀(𝑧0 +𝜎1 ) sin 𝛼−ℎ− ] cos 𝛼 cos 𝜀2
𝑦0′ = − (𝑧0 + 𝜎1 ) sin 𝛼 cos 𝜀2 ,
1+𝑀 cos 𝛼
𝑑𝑓
𝑀(𝑧0 +𝜎1 ) sin 𝛼−ℎ−
𝑑𝜀1
𝑧0′ = sin 𝛼 + (𝑧0 + 𝜎1 ) cos 𝛼 + 𝜎2 . }
1+𝑀 cos 𝛼
𝑑𝜀
Where: 𝑧0 and 𝜀1 are two independent variables. 𝑀 = 𝑑𝜀2 .
1
1.4.4 Unit Normal to Pitch Surface at Instantaneous Contact Position

Let 𝑃0 be a conjugate contact point on first pitch surface 𝐴0 at instant 𝜀1 , relative velocity 𝒗12
𝑝 of
point 𝑃0 on first pitch surface 𝐴0 with respect to second pitch surface ̅̅̅
𝐴0 is decided by
expression (1.4.1-1).
Let 𝑃0′ be a point on the first pitch surface 𝐴0 adjacent to point 𝑃0 in differential region of point
𝑃0 as shown in figure 1.4.4-1. Point 𝑃0′ reaches conjugate contact position at instant 𝜀1 + 𝑑𝜀1 ,
and point vector of point 𝑃0′ in conjugate contact position at instant 𝜀1 + 𝑑𝜀1 is 𝑹0𝑝 + 𝑑𝒓0𝑝
with omitting second or higher order infinitesimal as follow:
𝑹0𝑝 + 𝑑𝒓0𝑝 = (𝑑𝜀1 𝝎1 ) ⊗ (𝑹0𝑝 + 𝑑𝑠0 𝝉0 ) + 𝑑𝜎1 𝝎1

(1.4.4-1)
= 𝑹0𝑝 + 𝑑𝑠0 𝝉0 + 𝑑𝜀1 𝝎1 × 𝑹0𝑝 + 𝑑𝜎1 𝝎1
~ 49 ~
𝑑𝑵0𝑝
𝑵0𝑝 + ( ) 𝑑𝑠0
𝑑𝑠0 𝜏0
𝑵0𝑝 𝑑𝒓0𝑝
𝝉′0 𝑃0′ 𝝉0
𝒌 𝑃̅0′ 𝑑𝑠0′ 𝐴0
̅̅̅
𝐴0 𝑃0 𝑑𝑠0
𝑑𝑵′0𝑝
𝑵′0𝑝 + ( ) 𝑑𝑠0′ 𝒌′
𝑑𝑠0′
𝜏0′
𝑵′0𝑝
𝑹0𝑝 𝑹0𝑝 − 𝑙𝒑 𝛼
𝑂 𝒋
𝑙𝒑
𝑂′
𝒊′ 𝒋′
Figure 1.4.4-1 Differential Quantities in a Differential Region at Conjugate Contact Point 𝑃0 on a

Pair of Pitch Surfaces (𝐴0 , ̅̅̅
𝐴0 )
Corresponding to point 𝑃0′ , conjugate point 𝑃̅0′ on the second pitch surface 𝐴
̅̅̅0 reaches
conjugate contact position at instant 𝜀1 + 𝑑𝜀1 and becomes conjugate contact point 𝑃0′′ , that is,
𝑹0𝑝 + 𝑑𝒓0𝑝 = (𝑑𝜀2 𝝎2 ) ⊗ (𝑹0𝑝 − 𝑙𝒑 + 𝑑𝑠0′ 𝝉′0 ) + 𝑑𝜎2 𝝎2 + 𝑙𝒑 + 𝑑( 𝑙𝒑)

(1.4.4-2)
= 𝑹0𝑝 + 𝑑𝑠0′ 𝝉′0 + 𝑀𝑑𝜀1 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) + 𝑑𝜎2 𝝎2 + 𝑑( 𝑙𝒑)
And 𝑑𝒓0𝑝 can be derived by expression (1.4.4-1) or (1.4.4-2) as follow:
𝑑𝒓0𝑝 = 𝑑𝑠0 𝝉0 + 𝑑𝜀1 𝝎1 × 𝑹0𝑝 + 𝑑𝜎1 𝝎1

(1.4.4-3)
= 𝑑𝑠0′ 𝝉′0 + 𝑀𝑑𝜀1 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) + 𝑑𝜎2 𝝎2 + 𝑑( 𝑙𝒑)
With help of expression (1.4.1-1), expression (1.4.4-3) becomes
~ 50 ~
𝑑𝑠0 𝝉0 = 𝑑𝑠0′ 𝝉′0
That is,
𝝉0 = 𝝉′0 ,
} (1.4.4-4)
𝑑𝑠0 = 𝑑𝑠0′ .
Expression (1.4.4-4) shows that through any conjugate contact point 𝑃0 on pitch surfaces, a pair
of any corresponding conjugate contact tangent directions (𝝉0 , 𝝉′0 ) and conjugate contact arc-
length (𝑑𝑠0 , 𝑑𝑠0′ ) on respective pitch surfaces (𝐴0 , ̅̅̅
𝐴0 ) are identical to each other which is
different from the case of regular conjugate contact point on a pair of conjugate surfaces
(𝐴, 𝐴̅). In the case of regular conjugate contact point, conjugate contact tangent directions
(𝝉, 𝝉′ ) and conjugate contact arc-length (𝑑𝑠1, 𝑑𝑠2 ) are usually different to each other.
By neglecting second or higher order infinitesimal, relative velocity of conjugate contact point
𝑃0′′ on 𝐴0 with respect to ̅̅̅
𝐴0 at instant 𝜀1 + 𝑑𝜀1 is
𝑑𝜎1 𝑑 2 𝜎1
𝝎1 × (𝑹0𝑝 + 𝑑𝒓0𝑝 ) + (
+ 𝑑𝜀 ) 𝝎1
𝑑𝜀1 𝑑𝜀12 1
𝑑𝑀 𝑑(𝑙𝒑)
𝒗12 12
𝑝 + 𝑑𝒗𝑝 = − (𝑀 + 𝑑𝜀1 ) 𝝎2 × [𝑹0𝑝 + 𝑑𝒓0𝑝 − 𝑙𝒑 − 𝑑𝜀1 ]
𝑑𝜀1 𝑑𝜀1
𝑑𝜎2 𝑑 2 𝜎2 𝑑(𝑙𝒑) 𝑑 2 (𝑙𝒑)
−( + 𝑑𝜀 ) 𝝎 − [ + 𝑑𝜀1 ]
𝑑𝜀12 1 2
{ 𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 }
𝑑𝜎1 𝑑𝜎2 𝑑(𝑙𝒑)
𝝎1 × 𝑹0𝑝 + 𝝎1 − 𝑀𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝝎2 −
2
𝑑 𝜎1 𝑑(𝑙𝒑)
= +𝝎1 × 𝑑𝒓0𝑝 + 2 𝑑𝜀1 𝝎1 − 𝑀𝝎2 × [𝑑𝒓0𝑝 − 𝑑𝜀 𝑑𝜀1 ] =𝟎
𝑑𝜀1 1
𝑑𝑀 𝑑 2 𝜎2 𝑑 2 (𝑙𝒑)
− 𝑑𝜀 𝝎 × (𝑹0𝑝 − 𝑙𝒑) − 𝑑𝜀 𝝎 − 𝑑𝜀1
{ 𝑑𝜀1 1 2 𝑑𝜀12 1 2 𝑑𝜀12 }
With help of expressions (1.4.1-1) and (1.4.4-4), expression above gives
𝑑2 𝜎1
(𝝎1 − 𝑀𝝎2 ) × (𝑑𝑠0 𝝉0 + 𝑑𝜀1 𝝎1 × 𝑹0𝑝 + 𝑑𝜎1 𝝎1 ) + 𝑑𝜀1 𝝎1
𝑑𝜀12
𝑑𝒗12
𝑝 ={ 𝑑𝑀 𝑑2 𝜎2 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)
}
− 𝑑𝜀 𝑑𝜀1 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝑑𝜀1 𝝎2 − 𝑑𝜀1 + 𝑀𝝎2 × 𝑑𝜀1
1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1
𝑑𝑠0 (𝝎1 − 𝑀𝝎2 ) × 𝝉0
𝑑𝜎1
(𝝎1 − 𝑀𝝎2 ) × (𝝎1 × 𝑹0𝑝 + 𝝎1 )
= 𝑑𝜀1 =0
+𝑑𝜀1 [ 𝑑2 𝜎1 𝑑𝑀 𝑑2 𝜎2 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)
]
+ 𝝎1 − 𝑑𝜀 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝝎2 − + 𝑀𝝎2 ×
{ 𝑑𝜀12 1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 }
~ 51 ~
Simplification of expression above gives
𝑑𝜀
( 𝑑𝑠1) 𝑱0 = (𝝎1 − 𝑀𝝎2 ) × 𝝉0 (1.4.4-5)
0 𝜏0
And
𝑑𝜎 𝑑2 𝜎1
−(𝝎1 − 𝑀𝝎2 ) × (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 ) −
𝝎1
1 𝑑𝜀12
𝑱0 = [ 𝑑𝑀 𝑑2 𝜎2 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)
] = 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋 + 𝐽0𝑧 𝒌 (1.4.4-6)
+ 𝑑𝜀 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) + 𝑑𝜀2 𝝎2 + 𝑑𝜀2 − 𝑀𝝎2 × 𝑑𝜀
1 1 1 1
Where:
𝑑𝑓
𝑑ℎ 𝑑𝜎1 𝑑𝜎2 𝑑ℎ 𝑑𝑀 [(ℎ+𝑑𝜀1 ) cos 𝛼+(𝑧0 +𝜎1 ) sin 𝛼] 𝑑2 𝑓
𝐽0𝑥 = 𝑀 [(𝑓 − ) cos 𝛼 − sin 𝛼] − sin 𝛼 + − + ,
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1+𝑀 cos 𝛼 𝑑𝜀12
𝑑𝜎2 𝑑ℎ
𝑑𝑓 𝑑𝑓 𝑑2 𝜎2 𝑑2 ℎ 𝑑𝑀 ( 𝑑𝜀1 sin 𝛼+𝑓−𝑑𝜀1 )
𝐽0𝑦 = 𝑀 [(𝑧0 + 𝜎1 ) sin 𝛼 + (ℎ + 𝑑𝜀 ) cos 𝛼] − 𝑑𝜀 − sin 𝛼 + 𝑑𝜀2 + cos 𝛼 ,
1 1 𝑑𝜀12 1 𝑑𝜀1 1+𝑀 cos 𝛼
𝑑𝜎 𝑑ℎ 𝑑𝑓
𝑑𝑀 (− 2 sin 𝛼+ −𝑓) (𝑧0 +𝜎1 ) sin 𝛼+(ℎ+ ) cos 𝛼 𝑑2 𝜎1 𝑑2 𝜎2
𝐽0𝑧 = 𝑑𝜀 sin 𝛼 − 𝑀2 sin 𝛼 − − cos 𝛼 . }
1 1+𝑀 cos 𝛼 1+𝑀 cos 𝛼 𝑑𝜀12 𝑑𝜀12
Dot product on both sides of expression (1.4.4-5) with 𝝉0 gives

𝑑𝜀
( 𝑑𝑠1) 𝑱0 ∙ 𝝉0 = 0 (1.4.4-7)
0 𝜏0
𝑑𝜀
( 𝑑𝑠1) is usually not equal to zero and 𝝉0 is an arbitrarily tangent vector, and therefore, 𝑱0 is
0 𝜏0
perpendicular to any tangent vector 𝝉0 , thus, unit normal 𝑵0𝑝 to the first pitch surface at
conjugate contact point 𝑃0 (𝑹0𝑝 ) is
𝑱
𝑵0𝑝 = ± |𝑱0| (1.4.4-8)
0
̅̅̅0 )
Let 𝒕𝜏0 be unit tangent vector to path of contact of a pair of pitch surfaces (𝐴0 , 𝐴
corresponding to unit tangent vector 𝝉0 to the first pitch surface 𝐴0 at instant 𝜀1 , and 𝑑𝑠 be arc-
length on path of contact as shown in figure 1.4.4-1.
Expression (1.4.4-3) can be re-written as follow:

𝑑𝑠 𝑑𝜀 𝑑𝜎 𝑑𝜀
(𝑑𝑠 ) 𝒕𝜏0 = 𝝉0 + (𝑑𝑠1) (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 ) = 𝝉0 + ( 𝑑𝑠1 ) 𝒗0𝑝 (1.4.4-9)
0 𝜏0 0 𝜏0 1 0 𝜏0
𝑑𝜎
Where: 𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 , and 𝒕𝜏0 is unit tangent to path of contact at conjugate
1
~ 52 ~
contact point 𝑃0 (𝑹0𝑝 ) corresponding to 𝝉0 .
1.4.5 Rate of Rotating Angular Increment with Respect to Arc-Length,

Ratio of Arc-Length on Path of Contact with Respect to Conjugate Arc-
Length on the First Pitch Surface and Unit Tangent to Path of Contact
1 Rate of Rotating Angular Increment with Respect to Arc-Length on the First
Pitch Surface
Application of expression (1.4.4-5) generates increment rate of rotating angle 𝜀1 of the first
pitch surface 𝐴0 about 𝝎1 with respect to arc-length 𝑠0 in tangent direction 𝝉0 as follow:
𝑑𝜀 [𝑱0 ×(𝝎1 −𝑀𝝎2 )]∙𝝉0
( 𝑑𝑠1) = |𝑱0 |2
(1.4.5-1)
0 𝜏0
Where: 𝑱0 is calculated by formular (1.4.4-6), 𝑵0𝑝 is decided by expression (1.4.4-8) and both
are uniquely decided by parameters of a pair of conjugate motion (𝜑1 , 𝜑2 ).
2 Ratio of Arc-Length on Path of Contact with Respect to Conjugate Arc-Length

on the First Pitch Surface and Unit Tangent to Path of Contact
𝑑𝑠 𝑑𝜀 𝑑𝜀 𝑑𝜀 2
(𝑑𝑠 ) = |𝝉0 + ( 𝑑𝑠1 ) 𝒗0𝑝 | = √1 + ( 𝑑𝑠1 ) [2(𝒗0𝑝 ∙ 𝝉0 ) + (𝑑𝑠1 ) |𝒗0𝑝 | ],
0 𝜏0 0 𝜏0 0 𝜏0 0 𝜏0
𝝉0 +(
𝑑𝜀1
) 𝒗 𝝉0 +(
𝑑𝜀1
) 𝒗 (1.4.5-2)
𝑑𝑠0 𝜏 0𝑝 𝑑𝑠0 𝜏 0𝑝
0 0
𝒕 𝜏0 = 𝑑𝑠 = .
( ) 𝑑𝜀 𝑑𝜀1 2
𝑑𝑠0 𝜏
0 √1+(𝑑𝑠1 ) [2(𝒗0𝑝 ∙𝝉0 )+( ) |𝒗0𝑝 | ]
𝑑𝑠0 𝜏
0 𝜏0 0 }
𝑑𝜀
Where: ( 𝑑𝑠1) is calculated by expression (1.4.5-1)
0 𝜏0
1.4.6 Unit Normal to Path of Contact Corresponding to a Pair of Pitch

Surfaces
Because any point 𝑃0 (𝑹0𝑝 ) on the first pitch surface satisfies requirement of pitch surface, i.e.,
expression (1.4.1-1), all points on straight line 𝑹0𝑝 + 𝑠(𝝎1 − 𝑀𝝎2 ) can satisfy expression
~ 53 ~
(1.4.1-1), that is, straight line 𝑹0𝑝 + 𝑠(𝝎1 − 𝑀𝝎2 ) is an instantaneous contact line between a
pair of pitch surfaces (𝐴0 , ̅̅̅
𝐴0 ) at instant 𝜀1 and (𝝎1 − 𝑀𝝎2 ) is parallel to tangent vector to an
instantaneous contact line at instant 𝜀1 .
Let 𝒆0 be unit tangent vector to instantaneous contact line at instant 𝜀1 , that is,
(𝝎 −𝑀𝝎 )
𝒆0 = |(𝝎1−𝑀𝝎2)| (1.4.6-1)
1 2
substitution of 𝒆0 for 𝝉0 in expression (1.4.5-1) gives increment rate of rotating angle 𝜀1 of the
first pitch surface 𝐴0 about 𝝎1 with respect to arc-length 𝑠0 in tangent direction 𝒆0 as follow:
𝑑𝜀 [𝑱0 ×(𝝎1 −𝑀𝝎2 )] [𝑱0 ×(𝝎1 −𝑀𝝎2 )] (𝝎 −𝑀𝝎 )
( 𝑑𝑠1) = |𝑱0 |2
∙ 𝒆0 = |𝑱0 |2
∙ |(𝝎1−𝑀𝝎2)| = 0 (1.4.6-2)
0 𝑒0 1 2
𝒕𝑒0 = 𝒆0 ,
= 1.} (1.4.6-3)
𝑑𝑠
(𝑑𝑠 )
0 𝑒0
𝑱0 ×𝒆0
Let 𝒈0 = 𝑵0𝑝 × 𝒆0 = ± |𝑱0 |
be unit tangent vector to the first pitch surface 𝐴0 corresponding
𝑑𝜀1
to the maximum value of ( 𝑑𝑠 ) , substitution of 𝒈0 for 𝝉0 in expression (1.4.5-1) gives
0 𝜏0
𝑑𝜀 [𝑱0 ×(𝝎1 −𝑀𝝎2 )]∙𝒈0

(𝑑𝑠1 ) = |𝑱0 |2
(1.4.6-4)
0 𝑔0
Tangent vector 𝒕𝑔0 to path of contact corresponding to tangent vector 𝝉0 = 𝒈0 = 𝑵0𝑝 × 𝒆0 is

derived by substituting 𝒈0 for 𝝉0 in expression (1.4.5-2) as follow:
𝑑𝜀1 𝑑𝜀1
𝒈0 +( ) 𝒗 𝒈0 +( ) 𝒗
𝑑𝑠0 𝑔 0𝑝 𝑑𝑠0 𝑔 0𝑝
0 0
𝒕𝑔0 = 𝑑𝜀1
= ,
|𝒈0 +( ) 𝒗 | 𝑑𝜀 𝑑𝜀 2
𝑑𝑠0 𝑔 0𝑝 √1+(𝑑𝑠1 ) [2(𝒗0𝑝 ∙𝒈0 )+(𝑑𝑠1 ) |𝒗0𝑝 | ]
0 0 𝑔0 0 𝑔0
2
(1.4.6-5)
𝑑𝑠 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1
( ) = |𝝉0 + ( ) 𝒗0𝑝 | = √1 + ( ) [2(𝒗0𝑝 ∙ 𝒈0 ) + ( ) |𝒗0𝑝 | ],
𝑑𝑠0 𝑔 𝑑𝑠0 𝜏 𝑑𝑠0 𝑔 𝑑𝑠0 𝑔
0 0 0 0
𝑑𝜀 [𝑱0 ×(𝝎1 −𝑀𝝎2 )]∙𝒈0

(𝑑𝑠1 ) = |𝑱0 |2
.
0 𝑔0 }
Unit normal vector 𝚷0 to path of contact is obtained by cross multiplication of both 𝒕𝑒0 and 𝒕𝑔0
as follow:
~ 54 ~
𝑑𝜀1
𝑵0𝑝 +( ) 𝒆0 ×𝒗0𝑝
𝒕𝑒0 ×𝒕𝑔0 𝑑𝑠0 𝑔
0
𝚷0 = |𝒕 = (1.4.6-6)
𝑒0 ×𝒕𝑔0 | |𝑵0𝑝 +(
𝑑𝜀1
) 𝒆0 ×𝒗0𝑝 |
𝑑𝑠0 𝑔
0
𝑑𝜀
Where: 𝑵0𝑝 = 𝒆0 × 𝒈0 , 𝒆0 is calculated by expression (1.4.6-1) and ( 𝑑𝑠1 ) is decided by
0 𝑔0
1.4.7 Relationship of Conjugate Curvatures at Pitch Point

With help of expression (1.2.1-6), unit normal to the first pitch surface 𝐴0 of point 𝑃0′ at instant
𝜀1 is as shown in figure 1.4.4-1
𝑑𝑵0𝑝
𝑵0𝑝 + ( ) 𝑑𝑠0 = 𝑵0𝑝 + [𝐾1𝜏0 𝝉0 + 𝐺1𝜏0 (𝑵0𝑝 × 𝝉0 ) ]𝑑𝑠0 (1.4.7-1)
𝑑𝑠0 𝜏0
Where: 𝐾1𝜏0 and 𝐺1𝜏0 are normal and torsional curvatures of the first pitch surface 𝐴0 in
tangent direction 𝝉0 at pitch point 𝑃0 .
At instant 𝜀1 + 𝑑𝜀1 , point 𝑃0′ arrives conjugate contact position and its unit normal is derived by
omitting second order infinitesimal as follow
𝑑𝑵0𝑝 𝑑𝑵0𝑝
(𝑑𝜀1 𝝎1 ) ⊗ [𝑵0𝑝 + ( ) 𝑑𝑠0 ] = 𝑵0𝑝 + ( ) 𝑑𝑠0 + 𝑑𝜀1 𝝎1 × 𝑵0𝑝
𝑑𝑠0 𝜏0 𝑑𝑠0 𝜏0 (1.4.7-2)
= 𝑵0𝑝 + [𝐾1𝜏0 𝝉0 + 𝐺1𝜏0 (𝑵0𝑝 × 𝝉0 ) ]𝑑𝑠0 + 𝑑𝜀1 𝝎1 × 𝑵0𝑝
𝐴0 of point 𝑃̅0′ at instant 𝜀1 is as shown in figure 1.4.4-1

Unit normal to the second pitch surface ̅̅̅
𝑑𝑵′0𝑝
𝑵′0𝑝 + ( ) 𝑑𝑠0′ = 𝑵′0𝑝 + [𝐾2𝝉′0 𝝉′0 + 𝐺2𝝉′0 (𝑵′0𝑝 × 𝝉′0 )]𝑑𝑠0′ (1.4.7-3)
𝑑𝑠0′
𝝉′0
At instant 𝜀1 + 𝑑𝜀1 , point 𝑃̅0′ arrives conjugate contact position and its unit normal is derived by
omitting second order infinitesimal as follow
𝑑𝑵′0𝑝 𝑑𝑵′0𝑝
(𝑀𝑑𝜀1 𝝎2 ) ⊗ [𝑵′0𝑝 + ( ) 𝑑𝑠0′ ] = 𝑵′0𝑝 + ( ) 𝑑𝑠0′ + 𝑀𝑑𝜀1 𝝎2 × 𝑵′0𝑝
𝑑𝑠0′ 𝑑𝑠0′
𝜏′ 𝝉′0 (1.4.7-4)
= 𝑵′0𝑝 + [𝐾2𝝉′0 𝝉′0 + 𝐺2𝝉′0 (𝑵′0𝑝 × 𝝉′0 )]𝑑𝑠0′ + 𝑀𝑑𝜀1 𝝎2 × 𝑵′0𝑝
With requirement of conjugate contact, i.e., expression (1.3.7-2), application of expressions

(1.4.7-2) and 1.4.7-4) results in
~ 55 ~
[𝐾1𝜏0 𝝉0 + 𝐺1𝜏0 (𝑵0𝑝 × 𝝉0 ) ]𝑑𝑠0 + 𝑑𝜀1 𝝎1 × 𝑵0𝑝
= −[𝐾2𝝉′0 𝝉′0 + 𝐺2𝝉′0 (𝑵′0𝑝 × 𝝉′0 ) ]𝑑𝑠0′ − 𝑀𝑑𝜀1 𝝎2 × 𝑵′0𝑝
Expression above can be simplified by application of expression (1.4.4-4) as follow:

𝑑𝜀
(𝐾1𝜏0 + 𝐾2𝜏0 )𝝉0 + (𝐺1𝜏0 − 𝐺2𝜏0 )(𝑵0𝑝 × 𝝉0 ) + ( 𝑑𝑠1) (𝝎1 − 𝑀𝝎2 ) × 𝑵0𝑝 = 𝟎 (1.4.7-5)
0 𝜏0
Dot multiplication on both sides of expression (1.4.7-5) with 𝝉0 and 𝑵0𝑝 × 𝝉0 respectively
results in
𝑑𝜀1
𝐾2𝜏0 = −𝐾1𝜏0 − ( ) [(𝝎1 − 𝑀𝝎2 ) × 𝑵0𝑝 ] ∙ 𝝉0 ,
𝑑𝑠0 𝜏
0
𝑑𝜀1
} (1.4.7-6)
𝐺2𝜏0 = 𝐺1𝜏0 − ( 𝑑𝑠 ) [(𝝎1 − 𝑀𝝎2 ) ∙ 𝝉0 ]
0 𝜏0
Expression (1.4.7-6) is relationship of conjugate curvatures at pitch point.
1.4.8 Curvatures of Pitch Surfaces

Let 𝐾1𝜏0 be normal curvature in tangent direction 𝝉0 on the first pitch surface 𝐴0 at pitch point
𝑃0 and point 𝑃0′ be any point along tangent direction 𝝉0 within differential region of point 𝑃0
with reservation of up to second order infinitesimal as shown in figure 1.4.8-1
Due to
̅̅̅̅̅
𝑃0 𝑇 = 𝑑𝑠0 𝝉0 ,
̅̅̅̅̅ 1 } (1.4.8-1)
𝑇𝑃0′ = − 2 𝐾1𝜏0 (𝑑𝑠0 )𝟐 𝑵0𝑝 .
Thus,
1
𝑃0 𝑇 + ̅̅̅̅̅
𝑑𝑹0𝑝 = ̅̅̅̅̅ 𝑇𝑃0′ = 𝑑𝑠0 𝝉0 − 𝐾1𝜏0 (𝑑𝑠0 )2 𝑵0𝑝
2
At instant 𝜀1 + 𝑑𝜀1 , point 𝑃0′ reaches to conjugate contact position 𝑹0𝑝 + 𝑑𝒓0𝑝 . With aid of
expression (1.1.1-2) and reservation of up to second order infinitesimal, 𝑹0𝑝 + 𝑑𝒓0𝑝 is
expressed as follow
𝑑𝜎 1 𝑑2 𝜎1
𝑹0𝑝 + 𝑑𝒓0𝑝 = (𝑑𝜀1 𝝎1 ) ⊗ (𝑹0𝑝 + 𝑑𝑹0𝑝 ) + [ 𝑑𝜀 1 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1
1 𝑑𝜀12
cos 𝑑𝜀1 (𝑹0𝑝 + 𝑑𝑹0𝑝 ) + (1 − cos 𝑑𝜀1 )[(𝑹0𝑝 + 𝑑𝑹0𝑝 ) ∙ 𝝎1 ]𝝎1 (1.4.8-2)
={ 𝑑𝜎 1 𝑑2 𝜎 }
+ sin 𝑑𝜀1 𝝎1 × (𝑹0𝑝 + 𝑑𝑹0𝑝 ) + [ 𝑑𝜀 1 𝑑𝜀1 + 2 𝑑𝜀21 (𝑑𝜀1 )2 ] 𝝎1
1 1
~ 56 ~
𝑵0𝑝 𝑵0𝑝
𝑑𝒓0𝑝
𝒌 𝑃0 𝑑𝑹0𝑝 𝑃0 𝑑𝑠0 𝑇 𝝉0
𝑹0𝑝 𝑃0′ 𝝉0 𝑑𝑹0𝑝 𝑃0′

1
𝑹0𝑝 + 𝑑𝑹0𝑝 𝐾1𝜏0
𝑜 𝒋
Figure 1.4.8-1 Differential Region at Pitch Point 𝑃0 with Reservation of up to Second Order
Infinitesimal
Due to
sin 𝑑𝜀1 = 𝑑𝜀1 ,

1 }
cos 𝑑𝜀1 = 1 − 2 (𝑑𝜀1 )2 .
Then, expression (1.4.8-2) is updated as follow:
𝑑𝜎 1 𝑑2 𝜎1
𝑹0𝑝 + 𝑑𝒓0𝑝 = (𝑑𝜀1 𝝎1 ) ⊗ (𝑹0𝑝 + 𝑑𝑹0𝑝 ) + [ 𝑑𝜀 1 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1
1 𝑑𝜀12
1 1
[1 − 2 (𝑑𝜀1 )2 ] (𝑹0𝑝 + 𝑑𝑹0𝑝 ) + 2 (𝑑𝜀1 )2 [(𝑹0𝑝 + 𝑑𝑹0𝑝 ) ∙ 𝝎1 ]𝝎1
={ 𝑑𝜎 1 𝑑2 𝜎1
}
+𝑑𝜀1 𝝎1 × (𝑹0𝑝 + 𝑑𝑹0𝑝 ) + [ 𝑑𝜀 1 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1 (1.4.8-3)
1 𝑑𝜀12
1 1 1
𝑹0𝑝 + 𝑑𝑠0 𝝉0 − 𝐾1𝜏0 (𝑑𝑠0 )𝟐 𝑵0𝑝 − 2 (𝑑𝜀1 )2 𝑹0𝑝 + 2 (𝑑𝜀1 )2 (𝑹0𝑝 ∙ 𝝎1 )𝝎1
2
={ 𝑑𝜎 1 𝑑2 𝜎1 }
+𝑑𝜀1 𝝎1 × 𝑹0𝑝 + 𝝎1 × 𝝉0 (𝑑𝑠0 )(𝑑𝜀1 ) + [ 𝑑𝜀 1 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1
1 𝑑𝜀12
And
1 1 1
𝑑𝑠0 𝝉0 − 𝐾1𝜏0 (𝑑𝑠0 )2 𝑵0𝑝 − (𝑑𝜀1 )2 𝑹0𝑝 + (𝑑𝜀1 )2 (𝑹0𝑝 ∙ 𝝎1 )𝝎1
2 2 2
𝑑𝒓0𝑝 = { 𝑑𝜎 1 𝑑2 𝜎 }
+𝑑𝜀1 𝝎1 × 𝑹0𝑝 + 𝝎1 × 𝝉0 (𝑑𝑠0 )(𝑑𝜀1 ) + [ 𝑑𝜀 1 𝑑𝜀1 + 2 𝑑𝜀21 (𝑑𝜀1 )2 ] 𝝎1
1 1
1 𝑑2 𝜎1 (1.4.8-4)
𝑑𝑠0 𝝉0 + 2 [ 𝑑𝜀2 𝝎1 + (𝑹0𝑝 ∙ 𝝎1 )𝝎1 − 𝑹0𝑝 ] (𝑑𝜀1 )2
1
=
𝑑𝜎1 𝑑𝜀 1
+ (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 𝝎1 ) 𝑑𝜀1 + [𝝎1 × 𝝉0 ( 𝑑𝑠1 ) − 𝐾1𝜏0 𝑵0𝑝 ] (𝑑𝑠0 )2
{ 1 0 𝜏 2 }
0
~ 57 ~
Velocity of conjugate contact point 𝑹0𝑝 + 𝑑𝒓0𝑝 on the first pitch surface 𝐴0 at instant 𝜀1 + 𝑑𝜀1
is derived by application of expression (1.3.5-1)
𝑑𝜎 𝑑2 𝜎1 1 𝑑3 𝜎1
𝒗𝑝 + 𝑑𝒗𝑝 = 𝝎1 × (𝑹0𝑝 + 𝑑𝒓0𝑝 ) + [ 𝑑𝜀 1 + 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1
1 𝑑𝜀12 𝑑𝜀13
𝑑2 𝜎 1 𝑑3 𝜎1
(1.4.8-5)
= 𝒗𝑝 + 𝝎1 × (𝑑𝒓0𝑝 ) + [ 𝑑𝜀21 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1
1 𝑑𝜀13
Velocity of conjugate contact 𝑹0𝑝 + 𝑑𝒓0𝑝 on the second pitch surface ̅̅̅
𝐴0 at instant 𝜀1 + 𝑑𝜀1 is
derived by application of expression (1.3.5-2) as follow
𝒗′𝒑 + 𝑑𝒗′𝒑
𝑑𝑀 𝑑2 𝑀 (𝑑𝜀1 )2 𝑑(𝑙𝒑) 𝑑2 (𝑙𝒑) (𝑑𝜀1 )2
[𝑀 + 𝑑𝜀 𝑑𝜀1 + ] 𝝎2 × [𝑹0𝑝 + 𝑑𝒓0𝑝 − 𝑙𝒑 − 𝑑𝜀1 − ]
1 𝑑𝜀12 2 𝑑𝜀1 𝑑𝜀12 2
={ 𝑑𝜎 𝑑2 𝜎2 1 𝑑3 𝜎2 𝑑(𝑙𝒑) 𝑑2 (𝑙𝒑) 1 𝑑3 (𝑙𝒑)
}
+ [ 𝑑𝜀 2 + 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎2 + + 𝑑𝜀1 + 2 (𝑑𝜀1 )2
1 𝑑𝜀12 𝑑𝜀13 𝑑𝜀1 𝑑𝜀12 𝑑𝜀13
𝑑𝑀
𝒗′𝒑 + 𝑀𝝎2 × 𝑑𝒓0𝑝 + 𝑑𝜀 𝝎2 × 𝑑𝒓0𝑝 𝑑𝜀1 (1.4.8-6)
1
𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 𝜎2 𝑑2 (𝑙𝒑)
+ [𝑑𝜀 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝑀𝝎2 × + 𝝎2 + ] 𝑑𝜀1
= 𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 𝑀
2 𝑑𝜀 𝝎2 × − 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
1 𝑑𝜀1 𝑑𝜀12 (𝑑𝜀1 )2
−[ 𝑑3 𝜎2 𝑑2 (𝑙𝒑) 𝑑3 (𝑙𝒑)
] 2
− 𝝎2 + 𝑀𝝎2 × −
{ 𝑑𝜀13 𝑑𝜀12 𝑑𝜀13 }
Relative velocity of conjugate contact point 𝑹0𝑝 + 𝑑𝒓0𝑝 at instant 𝜀1 + 𝑑𝜀1 is derived by
application of expressions (1.4.8-5) and (1.4.8-6) as follow:
𝒗12 12 ′ ′
𝑝 + 𝑑𝒗𝑝 = 𝒗𝑝 + 𝑑𝒗𝑝 − (𝒗𝒑 + 𝑑𝒗𝒑 )
𝑑2 𝜎 1 𝑑3 𝜎1
𝒗𝑝 + 𝝎1 × (𝑑𝒓0𝑝 ) + [ 𝑑𝜀21 𝑑𝜀1 + 2 (𝑑𝜀1 )2 ] 𝝎1
1 𝑑𝜀13
𝑑𝑀
−𝒗′𝒑 − 𝑀𝝎2 × 𝑑𝒓0𝑝 − 𝑑𝜀 𝝎2 × 𝑑𝒓0𝑝 𝑑𝜀1
1
= 𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 𝜎2 𝑑2 (𝑙𝒑)
− [𝑑𝜀 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝑀𝝎2 × + 𝝎2 + ] 𝑑𝜀1
𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 𝑀 𝑑3 𝜎2 𝑑2 (𝑙𝒑) 𝑑3 (𝑙𝒑) (𝑑𝜀1 )2
{+ [2 𝑑𝜀 𝝎2 ×1 𝑑𝜀1
− 𝑑𝜀12
𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝑑𝜀13
𝝎2 + 𝑀𝝎2 × 𝑑𝜀12
− 𝑑𝜀13
] 2 }
𝑑𝑀
𝒗12
𝑝 + (𝝎1 − 𝑀𝝎2 ) × (𝑑𝒓0𝑝 ) − 𝑑𝜀 𝝎2 × 𝑑𝒓0𝑝 𝑑𝜀1
1
𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 𝜎1 𝑑2 𝜎2 𝑑2 (𝑙𝒑)
− [𝑑𝜀 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝑀𝝎2 × − 𝝎1 + 𝝎2 + ] 𝑑𝜀1
1 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12
= 𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 𝑀
=𝟎
2 𝑑𝜀 𝝎2 × − 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
𝑑𝜀 𝑑𝜀12 (𝑑𝜀1 )2
+ [ 𝑑3 𝜎 1 1
𝑑3 𝜎2 𝑑2 (𝑙𝒑) 𝑑3 (𝑙𝒑)
]
1 2
+ 𝑑𝜀3 𝝎1 − 𝑑𝜀3 𝝎2 + 𝑀𝝎2 × 𝑑𝜀2 − 𝑑𝜀3
{ 1 1 1 1 }
~ 58 ~
Due to pitch point, 𝒗12
𝑝 = 𝟎, 𝑑𝒓0𝑝 is defined in expression (1.4.8-4).
With reservation up to second order infinitesimal, substitution of expressions 𝒗12

𝑝 =𝟎
and 𝑑𝒓0𝑝 into expression above results in
𝑑𝜎1 𝑑𝜀1 𝐾1𝜏0 𝑵0𝑝

(𝝎1 × 𝑹0𝑝 + 𝝎1 ) 𝑑𝜀1 + [𝝎1 × 𝝉0 ( ) − ] (𝑑𝑠0 )2
𝑑𝜀1 𝑑𝑠0 𝜏 2
(𝝎1 − 𝑀𝝎2 ) × 0
𝑑 2 𝜎1 (𝑑𝜀1 )2
{ +𝑑𝑠0 𝝉0 + [ 𝝎1 + (𝑹0𝑝 ∙ 𝝎1 )𝝎1 − 𝑹0𝑝 ] }
𝑑𝜀12 2
𝑑𝑀 𝑑𝜎1
− 𝝎2 × [𝑑𝑠0 𝝉0 + (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 𝝎1 ) 𝑑𝜀1 ] (𝑑𝜀1 )
𝑑𝜀1
𝑑𝒗12
𝑝 =
1
𝑑𝑀 𝑑(𝑙𝒑) 𝑑 2 (𝑙𝒑) 𝑑 2 𝜎1 𝑑 2 𝜎2
−[ 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) − 𝑀𝝎2 × + − 𝝎 +
1 𝝎2 ] 𝑑𝜀1
𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12
𝑑 3 𝜎1 𝑑 3 𝜎2 𝑑 2 (𝑙𝒑) 𝑑 3 (𝑙𝒑)
𝝎1 − 𝝎2 + 𝑀𝝎2 × −
𝑑𝜀13 𝑑𝜀13 𝑑𝜀12 𝑑𝜀13 (𝑑𝜀1 )2
+[ 𝑑𝑀 𝑑(𝑙𝒑) 𝑑2𝑀
]
2
+2 𝝎2 × − 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
{ 𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 }
𝑑𝑀
−(𝑑𝑠0 )(𝑑𝜀1 ) 𝝎2 × 𝝉0
𝑑𝜀1
𝑑𝜀1 𝐾1𝜏0 𝑵0𝑝

[(𝝎1 − 𝑀𝝎2 ) × 𝝉0 ]𝑑𝑠0 + (𝝎1 − 𝑀𝝎2 ) × [𝝎1 × 𝝉0 ( ) − ] (𝑑𝑠0 )2
𝑑𝑠0 𝜏 2
0
𝑑𝜎1 𝑑𝑀
−(𝝎1 − 𝑀𝝎2 ) × (𝝎1 × 𝑹0𝑝 + 𝝎1 ) + 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
𝑑𝜀1 𝑑𝜀1
−{ 𝑑(𝑙𝒑) 𝑑 2 (𝑙𝒑) 𝑑 2 𝜎1 𝑑 2 𝜎2
} 𝑑𝜀1
= −𝑀𝝎2 × + − 𝝎1 + 𝝎2 =𝟎
𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12
𝑑 2 𝜎1 𝑑 2 (𝑙𝒑)
−(𝝎1 − 𝑀𝝎2 ) × 𝑹0𝑝 − 𝑀𝝎2 × [ 𝝎1 + (𝑹0𝑝 ∙ 𝝎1 )𝝎1 − ]
𝑑𝜀12 𝑑𝜀12
𝑑 3 𝜎1 𝑑 3 𝜎2 𝑑 3 (𝑙𝒑) 𝑑2𝑀 (𝑑𝜀1 )2
+ + 𝝎1 − 𝝎2 − − 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
𝑑𝜀13 𝑑𝜀13 𝑑𝜀13 𝑑𝜀12 2
𝑑𝑀 𝑑𝜎1 𝑑(𝑙𝒑)
{ { −2 𝝎2 × (𝝎1 × 𝑹0𝑝 + 𝝎1 − ) } }
With help of expression (1.4.4-6), expression above leads to

𝑑𝑀
[(𝝎1 − 𝑀𝝎2 ) × 𝝉0 ]𝑑𝑠0 − 𝑱0 𝑑𝜀1 − 𝝎2 × 𝝉0 (𝑑𝑠0 )𝑑𝜀1
𝑑𝜀1
𝑑𝑀 𝑑(𝑙𝒑) 𝑑𝜎
2 𝑑𝜀 𝝎2 × [ 𝑑𝜀 − 𝝎1 × 𝑹0𝑝 − 𝑑𝜀 1 𝝎1 ]
1 1 1
𝑑2 𝜎1 𝑑2 (𝑙𝒑)
−𝑀𝝎2 × [( 𝑑𝜀2 + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ] (𝑑𝜀1 )2
+ 1 𝑑𝜀12
𝑑𝒗12
𝑝 = 2 =𝟎 (1.4.8-7)
−(𝝎1 − 𝑀𝝎2 ) × 𝑹0𝑝
𝑑3 𝜎1 𝑑3 𝜎2 𝑑3 (𝑙𝒑) 𝑑2 𝑀
[+ 𝑑𝜀13
𝝎1 − 𝑑𝜀13
𝝎2 − 𝑑𝜀13
− 𝑑𝜀12
𝝎2 × (𝑹0𝑝 − 𝑙𝒑)]
𝑑𝜀 1
+(𝝎1 − 𝑀𝝎2 ) × [𝝎1 × 𝝉0 ( 𝑑𝑠1) − 𝐾1𝜏0 𝑵0𝑝 ] (𝑑𝑠0 )2
{ 0 𝜏0 2 }
Due to
~ 59 ~
𝑑𝜀 1 𝑑2 𝜀
𝑑𝜀1 = (𝑑𝑠1) (𝑑𝑠0 ) + 2 ( 𝑑𝑠21) (𝑑𝑠0 )2 (1.4.8-8)
0 𝜏0 0 𝜏0
By reserving up to second order infinitesimal, substitution of expression (1.4.8-8) into

expression (1.4.8-7) gives
𝑑𝜀
[(𝝎1 − 𝑀𝝎2 ) × 𝝉0 − ( 𝑑𝑠1) 𝑱0 ] 𝑑𝑠0
0 𝜏0
𝑑 2 𝜀1
( 𝑑𝑠2 ) 𝑱0 + 𝐾1𝜏0 (𝝎1 − 𝑀𝝎2 ) × 𝑵0𝑝
0 𝜏0
𝑑𝑀 𝑑𝜀
−2 [(𝝎1 − 𝑀𝝎2 ) × (𝝎1 × 𝝉0 ) − 𝑑𝜀 𝝎2 × 𝝉0 ] ( 𝑑𝑠1)
1 0 𝜏0
𝑑2 𝜎1 𝑑2 (𝑙𝒑) =𝟎 (1.4.8-9)
𝑀𝝎2 × [( + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ] (𝑑𝑠0 )2
− 𝑑𝜀12 𝑑𝜀12
𝑑𝑀 𝑑𝜎 𝑑(𝑙𝒑) 𝟐
+2 𝑑𝜀 𝝎2 × (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 − ) 2
1 1 𝑑𝜀1 𝑑𝜀
+ 𝑑3 𝜎1 𝑑3 𝜎2 𝑑3 (𝑙𝒑)
(𝑑𝑠1 )
0
− 𝝎1 + 𝝎2 + 𝜏0
𝑑2 𝑀
)
{ { {+(𝝎1 − 𝑀𝝎2 × 𝑹0𝑝 + 𝑑𝜀12
𝝎2 × (𝑹0𝑝 − 𝑙𝒑)} } }
Due to 𝑑𝑠0 being not equal to zero, then coefficients of 𝑑𝑠0 and (𝑑𝑠0 )2 are equal to zero, that
is,
𝑑𝜀1
(𝝎1 − 𝑀𝝎2 ) × 𝝉0 − ( ) 𝑱 = 𝟎,
𝑑𝑠0 𝜏 0
0
𝑑2 𝜀
( 𝑑𝑠21 ) 𝑱0 + 𝐾1𝜏0 (𝝎1 − 𝑀𝝎2 ) × 𝑵0𝑝
0 𝜏0
𝑑𝑀 𝑑𝜀
−2 [(𝝎1 − 𝑀𝝎2 ) × (𝝎1 × 𝝉0 ) − 𝑑𝜀 𝝎2 × 𝝉0 ] ( 𝑑𝑠1 )
1 0 𝜏0
𝑑2 𝜎1 𝑑2 (𝑙𝒑) (1.4.8-10)
𝑀𝝎2 × [( + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ]
𝑑𝜀12 𝑑𝜀12 = 𝟎.
+2 𝑑𝜀 𝝎2 × (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 𝝎1 − ) 2
1 1 𝑑𝜀1 𝑑𝜀
+ 𝑑3 𝜎1 𝑑3 𝜎2 𝑑3 (𝑙𝒑)
( 𝑑𝑠1 )
0
− 𝝎1 + 𝝎2 + 𝜏0
𝑑2 𝑀
)
{ {+(𝝎1 − 𝑀𝝎2 × 𝑹0𝑝 + 𝑑𝜀12
𝝎2 × (𝑹0𝑝 − 𝑙𝒑)} } }
Dot product of both sides of the first formula in simultaneous equation (1.4.8-10) with 𝑱0 gives
𝑑𝜀 [(𝝎1 −𝑀𝝎2 )×𝝉0 ]∙𝑱0
( 𝑑𝑠1) =
0 𝜏0 𝑱0 ∙𝑱0
~ 60~
(𝝎 −𝑀𝝎 ) 𝑱
With help of 𝒆0 = |(𝝎1−𝑀𝝎2)| and 𝒈0 = 𝑵0𝑝 × 𝒆0 = ± |𝑱0 | × 𝒆0 , expression above is updated as
1 2 0
follow:
𝑑𝜀 [(𝝎1 −𝑀𝝎2 )×𝝉0 ]∙𝑱0 |𝝎1 −𝑀𝝎2 |(𝒆0 ×𝝉0 )∙𝑱0 |𝝎1 −𝑀𝝎2 |(𝒈0 ∙𝝉0 )
( 𝑑𝑠1) = = = |𝑱0 |
(1.4.8-11)
0 𝜏0 𝑱0 ∙𝑱0 𝑱0 ∙𝑱0
Dot product on both sides of second formula in simultaneous equation (1.4.8-10) with 𝑱0 gives
𝑑𝑀 𝑑𝜀
2 [|(𝝎1 − 𝑀𝝎2 )|𝒆0 × (𝝎1 × 𝝉0 ) − 𝑑𝜀 𝝎2 × 𝝉0 ] ( 𝑑𝑠1)
1 0 𝜏0
|(𝝎1 − 𝑀𝝎2 )|𝒆0 × 𝑹0𝑝
+2 𝝎2 × (𝝎1 × 𝑹0𝑝 + 𝝎1 − )
𝑑 2 𝜀1 𝑱
( 𝑑𝑠2 ) = 𝑑2 𝜎1 𝑑2 (𝑙𝒑) ∙ |𝑱 0|𝟐 (1.4.8-12)
0 𝜏0 +𝑀𝝎2 × [( + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ] 𝑑𝜀1 2 0
− 𝑑𝜀12 𝑑𝜀12 ( 𝑑𝑠 )
0 𝜏0
𝑑2 𝑀
+ 𝑑𝜀2 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
1
𝑑3 𝜎1 𝑑3 𝜎2 𝑑3 (𝑙𝒑)
{ { − 𝝎1 + 𝝎2 + } }
As shown in figure 1.4.8-2, due to
𝝉0 = cos 𝜃𝑒𝜏0 𝒆0 + sin 𝜃𝑒𝜏0 𝑵0𝑝 × 𝒆0 ,

}
𝒆0 ∙ 𝑱0 = 0, (𝑵0𝑝 × 𝒆0 ) ∙ 𝑱0 = 0.
𝒈0 = 𝑵0𝑝 × 𝒆0 𝝉0
𝜃𝑒𝜏0
𝑃0 𝒆0
Figure 1.4.8-2. Tangent Direction 𝝉0 at Point 𝑃0 on The First Pitch Surface
Then,
𝑑𝑀
[|(𝝎1 − 𝑀𝝎2 )|𝒆0 × (𝝎1 × 𝝉0 ) − 𝑑𝜀 𝝎2 × 𝝉0 ] ∙ 𝑱0
1
|(𝝎1 − 𝑀𝝎2 )|(𝝎1 ∙ 𝑱0 ) cos 𝜃𝑒𝜏0
={ 𝑑𝑀 }, (1.4.8-13)
+ 𝑑𝜀 [cos 𝜃𝑒𝜏0 (𝒈0 ∙ 𝝎2 ) − sin 𝜃𝑒𝜏0 (𝒆0 ∙ 𝝎2 )]|𝑱0 |
1
𝑑𝜀1 |(𝝎1 −𝑀𝝎2 )|(𝒈0 ∙𝝉0 ) |(𝝎1 −𝑀𝝎2 )| sin 𝜃𝑒𝜏0
( 𝑑𝑠 ) = |𝑱0 |
= |𝑱0 |
.
0 𝜏0 }
~ 61 ~
Substitution of expression (1.4.8-13) into expression (1.4.8-12) results in
𝑑2 𝜀
( 𝑑𝑠21)
0 𝜏0
2|(𝝎1 −𝑀𝝎2 )| cos 𝜃𝑒𝜏0 sin 𝜃𝑒𝜏0 𝑑𝑀
|𝑱0 |𝟑
[|(𝝎1 − 𝑀𝝎2 )|(𝝎1 ∙ 𝑱0 ) + 𝑑𝜀 (𝒈0 ∙ 𝝎2 )|𝑱0 |]
1
|(𝝎1 − 𝑀𝝎2 )|𝒆0 × 𝑹0𝑝
𝑑𝑀 𝑑𝜎 𝑑(𝑙𝒑)
+2 𝑑𝜀 𝝎2 × (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 − )
1 1 𝑑𝜀1
𝑑2 𝜎 𝑑2 (𝑙𝒑) (1.4.8-14)
= +𝑀𝝎2 × [( 𝑑𝜀21 + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ] ∙ 𝑱0
1 𝑑𝜀12 |(𝝎1 −𝑀𝝎2 )|2 sin2 𝜃𝑒𝜏0
|𝑱 |𝟐 0
− 𝑑2 𝑀
|𝑱0 |𝟐
+ 𝑑𝜀2 𝝎2 × (𝑹0𝑝 − 𝑙𝒑)
1
𝑑3 𝜎1 𝑑3 𝜎2 𝑑3 (𝑙𝒑)
{ − 𝝎1 + 𝝎2 + }
𝑑𝑀 (𝒆0 ∙𝝎2 )
{ { +2 𝑑𝜀 |(𝝎1 −𝑀𝝎2 )| } }
1
Dot production on both sides of the second formular in simultaneous equation (1.4.8-10) with
𝒈0 = 𝑵0𝑝 × 𝒆0 gives
1 𝑑𝑀
[ (𝝎2
|𝑱0 | 𝑑𝜀1
∙ 𝑵0𝑝 ) − |𝝎1 − 𝑀𝝎2 |(𝝎1 ∙ 𝒈0 )] sin 2𝜃𝑒𝜏0 +
2(𝝎1 ∙ 𝒆0 ) +
𝑑2 𝜎1 𝑑2 (𝑙𝒑)
𝑀𝝎2 × [( + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ]
𝑑𝑀 𝑑𝜎 𝑑(𝑙𝒑)
𝐾1𝜏0 = +2 𝑑𝜀 𝝎2 × (𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 − ) (1.4.8-15)
1 1 𝑑𝜀1 |𝝎1 −𝑀𝝎2 | sin2 𝜃𝑒𝜏0
𝑑3 𝜎1 𝑑3 𝜎2 𝑑3 (𝑙𝒑) 𝒈0
− 𝝎1 + 𝝎2 + ∙ |𝑱0 |
|𝑱0 |
+(𝝎1 − 𝑀𝝎2 ) × 𝑹0𝑝
𝑑2 𝑀
{{{ + 𝑑𝜀12
𝝎2 × (𝑹0𝑝 − 𝑙𝒑) } } }
Comparison of expression (1.2.1-23) with expression (1.4.8-15) generates curvatures of the first
pitch surface at point 𝑃0 in any tangent Direction 𝝉0 as follow
𝐾1𝜏0 = 𝐾1𝑒0 cos2 𝜃𝒆𝜏0 + 𝐾1𝑔0 sin2 𝜃𝒆𝜏0 + 𝐺1𝑒0 sin 2𝜃𝒆𝜏0 ,
} (1.4.8-16)
𝐺1𝜏0 = −(𝐾1𝑒0 − 𝐾1𝑔0 ) sin 𝜃𝒆𝜏0 cos 𝜃𝒆𝜏0 + 𝐺1𝑒0 (cos2 𝜃𝒆𝜏0 − sin2 𝜃𝒆𝜏0 ).
Where:
~ 62 ~
𝐾1𝑒0 = 0,
(𝝎1 − 𝑀𝝎2 ) × 𝑹0𝑝
𝑑2 𝜎 𝑑2 (𝑙𝒑)
+𝑀𝝎2 × [( 𝑑𝜀21 + 𝑹0𝑝 ∙ 𝝎1 ) 𝝎1 − ]
1 𝑑𝜀12
𝒈0
|𝝎1 −𝑀𝝎2 | ∙ 𝑑𝑀 𝑑𝜎 𝑑(𝑙𝒑) 𝑑3 𝜎1
𝐾1𝑔0 = |𝑱0 | +2 𝑑𝜀 𝝎2 × [𝝎1 × 𝑹0𝑝 + 𝑑𝜀 1 𝝎1 − ]− 𝝎1 ,
|𝑱0 | 1 1 𝑑𝜀1 𝑑𝜀13 (1.4.8-17)
𝑑3 𝜎2 𝑑3 (𝑙𝒑) 𝑑2 𝑀
{ + 𝝎2 + + 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) }
{ +2(𝒆0 ∙ 𝝎1 ) }
𝑑𝑀
[ (𝑵0𝑝 ∙𝝎2 )−|𝝎1 −𝑀𝝎2 |(𝒈0 ∙𝝎1 )]
𝑑𝜀1
𝐺1𝑒0 = −𝐺1𝑔0 = |𝑱0 | }
𝐾2𝑒0 = 0,
|(𝝎1 −𝑀𝝎2 )| |(𝝎1 −𝑀𝝎2 )|𝟐
𝐾2𝑔0 = −𝐾1𝑔0 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵0𝑝 ] ∙ 𝒈0 = −𝐾1𝑔0 + ,
|𝑱0 | |𝑱0 | (1.4.8-18)
𝑑𝑀
[ (𝑵0𝑝 ∙𝝎2 )−|(𝝎1 −𝑀𝝎2 )|(𝒈0 ∙𝝎1 )]
𝑑𝜀1
𝐺2𝑒0 = −𝐺2𝑔0 = 𝐺1𝑒0 = |𝑱0 | }
Curvatures 𝐾2𝜏0 and 𝐺2𝜏0 of the second pitch surface in any tangent direction 𝝉0 can be
calculate by expression (1.2.1-23).
1.4.9 Relationship of Curvatures between a Pair of Pitch Surfaces and

a Pair of Corresponding Conjugate Surfaces
1 Alternative Expression for Relative Linear Velocity of Common Contact Point
on Rigid Body I with Respect to Rigid Body II at an Instant Rotating Angle 𝜀1 .
Due to the third requirement for conjugate contact point, i.e., expression (1.3.7-3) 𝒗12 𝑝 ∙ 𝑵1𝑝 =
0, when existent condition of pitch surfaces, i.e., expression (1.4.2-1) is satisfied, contact point
𝑃(𝑹1𝑝 ) on the first conjugate surface 𝐴 at instant 𝜀1𝑝 can be expressed through pitch point
𝑃0 (𝑹0𝑝 ) as follow:
𝑹1𝑝 = 𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 (1.4.9-1)
Where: 𝑹0𝑝 is pitch point at instant 𝜀1𝑝 , 𝑵1𝑝 is unit normal to surface 𝐴 at contact point
𝑃(𝑹1𝑝 ) on the first conjugate surface 𝐴 at instant 𝜀1𝑝 and 𝑠𝑛 is distance from point 𝑃0 (𝑹0𝑝 ) to
point 𝑃(𝑹1𝑝 ) along unit normal 𝑵1𝑝 as shown in figure 1.4.9-1.
~ 63 ~
With help of expression (1.4.1-1), substitution of expression (1.4.9-1) into expression (1.3.5-3)
gives
12
𝒗12
𝑝 = 𝒗0𝑝 + (𝝎1 − 𝑀𝝎2 ) × (𝑠𝑛 𝑵1𝑝 ) (1.4.9-2)
Due to point 𝑃0 (𝑹0𝑝 ) being pitch point, thus, 𝒗12

0𝑝 = 𝟎, relative linear velocity of common
contact point 𝑃(𝑹1𝑝 ) on the first conjugate surface 𝐴 with respect to the second conjugate
surface 𝐴̅ at instant 𝜀1𝑝 is derived by updating expression (1.4.9-2) as follow:
𝒗12
𝑝 = (𝝎1 − 𝑀𝝎2 ) × (𝑠𝑛 𝑵1𝑝 ) (1.4.9-3)
2 Relationship of Curvatures between Pitch Surfaces and Conjugate Surfaces
A pair of conjugate surfaces (𝐴, 𝐴̅) contact with each other under a pair of conjugate motions
(𝜑1 , 𝜑2 ), that is, curvature of surface 𝐴 is decided by curvature of surface 𝐴̅ with parameters
of conjugate motion (𝜑1 , 𝜑2 ), while a pair of conjugate motions (𝜑1 , 𝜑2 ) uniquely decide a pair
of pitch surfaces (𝐴0 , ̅̅̅
𝐴0 ) if conjugate motions (𝜑1 , 𝜑2 ) satisfy existent condition of pitch
surfaces, i.e., expression (1.4.2-1). Therefore, pitch surfaces (𝐴0 , ̅̅̅
𝐴0 ) are geometric
representation of conjugate motions (𝜑1 , 𝜑2 ), and there exists relationship of curvatures
between pitch surfaces (𝐴0 , ̅̅̅ 𝐴0 ) and conjugate surfaces (𝐴, 𝐴̅) . Curvature of surface 𝐴 can be
determined by curvature of surface 𝐴̅ and curvatures of a pair of pitch surfaces (𝐴0 , ̅̅̅ 𝐴0 )
corresponding to a pair of conjugate motions (𝜑1 , 𝜑2 ).
In many engineering practice, initially given a pair of conjugate motions (𝜑1 , 𝜑2 ), then,
calculate a pair of pitch surfaces (𝐴0 , ̅̅̅
𝐴0 ) as geometric representation of conjugate motions
(𝜑1 , 𝜑2 ), a pair of corresponding conjugate surfaces (𝐴, 𝐴̅) which realize a pair of conjugate
motions (𝜑1 , 𝜑2 ) are formed by a pair of surfaces (𝐶, 𝐶̅ ) of cutters under conjugate motions
(𝜑1 , Σ1 ) or (𝜑2 , Σ2 ) . Here, Σ1 stands for motion of cutter surface 𝐶 which forms surface 𝐴 and
Σ2 stands for motion of cutter surface 𝐶̅ which forms surface 𝐴̅.
Then, through a proper manufacturing process, that is, selecting proper geometric properties of
surfaces (𝐶, 𝐶̅ ) of cutters and their corresponding pitch surfaces (𝐶0 , ̅̅̅
𝐶0 ) of cutters, machine
setting parameters, that is, conjugate motions (𝜑1 , Σ1 ) for a pair of conjugate surfaces (𝐴, 𝐶)
or conjugate motions (𝜑2 , Σ2 ) for a pair of conjugate surfaces (𝐴̅, 𝐶̅ ) are determined by
geometric properties of pitch surfaces of workpieces and pitch surfaces of cutters. Therefore,
in manufacturing process, initially given a pair of pitch surfaces (𝐴0 , 𝐶0 ) or (𝐴̅̅̅0 , ̅̅̅
𝐶0 ) for
workpiece and cutter, calculate a pair of corresponding conjugate motions (𝜑1 , Σ1 ) or
(𝜑2 , Σ2 ) , that is, machine setting parameters between workpiece and cutter. Finally, curvature
~ 64 ~
properties of surface 𝐴 or 𝐴̅ of workpiece are calculated by curvature properties of cutter
surface 𝐶 or 𝐶̅ and pitch surfaces (𝐴0 , 𝐶0 , ) or (𝐴
̅̅̅0 , ̅̅̅
𝐶0 ) of workpiece and cutter.
Assume curvatures (𝐾1𝜏0 , 𝐺1𝜏0 ) of pitch surface 𝐴0 and curvatures (𝐾2𝜏0 , 𝐺2𝜏0 ) of pitch
̅̅̅0 (for example pitch surface of cutter) are given. Point 𝑃0 is common contact point on
surface 𝐴
pitch surface at instant 𝜀1 . 𝑵0𝑝 and 𝑵′0𝑝 are unit normal to pitch surfaces 𝐴0 and ̅̅̅
𝐴0 at point 𝑃0
respectively as shown in figure 1.4.9-1. Point 𝑃0′ is within differential region of point 𝑃0 in any
tangent direction 𝝉0 to pitch surface and 𝑑𝑠0 is arc-length between point 𝑃0 and point 𝑃0′ .
By neglecting second or higher order infinitesimal, unit normal to pitch surface 𝐴0 at point 𝑃0′ is
as follow
𝑑𝑵0𝑝
𝑵0𝑝 + ( ) 𝑑𝑠0 = 𝑵0𝑝 + (𝐾1𝜏0 𝝉0 + 𝐺1𝜏0 𝑵0𝑝 × 𝝉0 )𝑑𝑠0 (1.4.9-4)
𝑑𝑠0 𝜏0
Likewise, unit normal to pitch surface ̅̅̅

𝐴0 at point 𝑃0′ is as follow
𝑑𝑵′0𝑝
𝑵′0𝑝 + ( ) 𝑑𝑠0 = 𝑵′0𝑝 + (𝐾2𝜏0 𝝉0 + 𝐺2𝜏0 𝑵′0𝑝 × 𝝉0 )𝑑𝑠0 (1.4.9-5)
𝑑𝑠0
𝜏0
𝑑𝑵0𝑝
At instant 𝜀1 + 𝑑𝜀1 , [𝑵0𝑝 + ( ) 𝑑𝑠0 ] reaches to direction of conjugate contact as follow
𝑑𝑠0 𝜏0
(𝑑𝜀1 𝝎1 ) ⊗ [𝑵0𝑝 + ( ) 𝑑𝑠0 ] = 𝑵0𝑝 + ( ) 𝑑𝑠0 + (𝑑𝜀1 𝝎1 ) × 𝑵0𝑝 (1.4.9-6)
𝑑𝑠0 𝜏0 𝑑𝑠0 𝜏0
𝑑𝑵′0𝑝
[𝑵′0𝑝 + ( ) 𝑑𝑠0 ] reaches to direction of conjugate contact as follow:
𝑑𝑠0
𝜏0
𝑑𝑵′0𝑝 𝑑𝑵′0𝑝
(𝑑𝜀2 𝝎2 ) ⊗ [𝑵′0𝑝 + ( ) 𝑑𝑠0 ] = 𝑵′0𝑝 + ( ) 𝑑𝑠0 + (𝑑𝜀2 𝝎2 ) × 𝑵′0𝑝 (1.4.9-7)
𝑑𝑠0 𝑑𝑠0
𝜏0 𝜏0
Due to point 𝑃0′ being a conjugate contact point at instant 𝜀1 + 𝑑𝜀1 , then,
𝑑𝑵0𝑝 𝑑𝑵′0𝑝
(𝑑𝜀1 𝝎1 ) ⊗ [𝑵0𝑝 + ( ) 𝑑𝑠0 ] = −(𝑑𝜀2 𝝎2 ) ⊗ [𝑵′0𝑝 + ( ) 𝑑𝑠0 ]
𝑑𝑠0 𝜏0 𝑑𝑠0
𝜏0
Substitution of expressions (1.4.9-6) and (1.4.9-7) into expression above results in
𝑵0𝑝 + ( ) 𝑑𝑠0 + (𝑑𝜀1 𝝎1 ) × 𝑵0𝑝 = − [𝑵′0𝑝 + ( ) 𝑑𝑠0 + (𝑑𝜀2 𝝎2 ) × 𝑵′0𝑝 ]
𝜏0
~ 65 ~
Due to 𝑵0𝑝 = −𝑵′0𝑝 , thus,
( ) 𝑑𝑠0 + (𝑑𝜀1 𝝎1 ) × 𝑵0𝑝 = − ( ) 𝑑𝑠0 + (𝑑𝜀2 𝝎2 ) × 𝑵0𝑝 ,
𝜏0
𝑂𝑅 (1.4.9-8)
𝑑𝑵0𝑝 𝑑𝑵′0𝑝 𝑑𝜀 𝑑𝜀
( ) +( ) + [( 1) 𝝎1 − ( 2 ) 𝝎2 ] × 𝑵0𝑝 = 0
𝑑𝑠0 𝑑𝑠0 𝑑𝑠 𝑑𝑠
𝜏0 𝜏0 0 𝜏0 0 𝜏0 }
𝑵1𝑝 𝝉′
a pair of conjugate surfaces 𝑑𝑠2 𝑃̅′ 𝑵1𝑝′
𝐴 𝑑𝑠1 𝐴̅
𝒌 𝑃 𝑵2𝑝̅̅̅′ 𝑃′ 𝝉
𝑵2𝑝
𝑹1𝑝 𝑠𝑛 𝑵0𝑝
𝐴0 𝑃0 𝑑𝑠0 ̅̅̅
𝐴0
𝑹0𝑝 𝑃0′ 𝝉0
𝑵′0𝑝
𝑂 𝒋
A pair of pitch surfaces (𝐴0 , ̅̅̅

𝐴0 )
Figure 1.4.9-1 Relationship of Curvatures between Pitch surfaces and Conjugate Surfaces
Point 𝑃 is a conjugate contact point between a pair of conjugate surfaces (𝐴, 𝐴̅) at instant 𝜀1𝑝 ,
points (𝑃′ , 𝑃̅′ ) are a pair of conjugate points within differential region of point 𝑃 on conjugate
surfaces (𝐴, 𝐴̅) respectively. 𝑵1𝑝 and 𝑵2𝑝 are a pair of unit normal vectors to conjugate
~ 66 ~
surfaces (𝐴, 𝐴̅) at point 𝑃 respectively. 𝑵1𝑝′ is unit normal to conjugate surface 𝐴 at point 𝑃′
and 𝑵2𝑝̅̅̅′ is unit normal to conjugate surface 𝐴̅ . Because unit normal to conjugate surface at
conjugate contact point passes through corresponding pitch point, i.e., expression (1.4.9-1),
thus, corresponding to conjugate surface 𝐴, following relationship is generated
⃗⃗⃗⃗⃗⃗⃗ 𝑃𝑃′ = ⃗⃗⃗⃗⃗⃗⃗⃗

𝑃0 𝑃 + ⃗⃗⃗⃗⃗⃗⃗ 𝑃0 𝑃0′ + ⃗⃗⃗⃗⃗⃗⃗⃗
𝑃0′ 𝑃′ (1.4.9-9)
Due to
𝑃𝑃′ = 𝑑𝑠1 𝝉, ⃗⃗⃗⃗⃗⃗⃗⃗

𝑃0 𝑃 = 𝑠𝑛 𝑵1𝑝 , ⃗⃗⃗⃗⃗⃗⃗
⃗⃗⃗⃗⃗⃗⃗ 𝑃0 𝑃0′ = 𝑑𝑠0 𝝉0 , ⃗⃗⃗⃗⃗⃗⃗⃗
𝑃0′ 𝑃′ = (𝑠𝑛 + 𝑑𝑠𝑛 )𝑵1𝑝′ ,
𝑑𝑵1𝑝 } (1.4.9-10)
𝑵1𝑝′ = 𝑵1𝑝 + ( ) 𝑑𝑠1 = 𝑵1𝑝 + (𝐾1𝜏 𝝉 + 𝐺1𝜏 𝑵1𝑝 × 𝝉)𝑑𝑠1 .
𝑑𝑠1 𝜏
By neglecting second or higher order infinitesimal, substitution of expression (1.4.9-10) into

expression (1.4.9-9) yields
𝑑𝑵1𝑝
𝑑𝑠1 𝝉 = 𝑑𝑠0 𝝉0 + 𝑠𝑛 ( ) 𝑑𝑠1 + 𝑑𝑠𝑛 𝑵1𝑝 (1.4.9-11)
𝑑𝑠1 𝜏
𝑑𝑵1𝑝
With consideration of 𝑵1𝑝 ∙ 𝝉 = 𝑵1𝑝 ∙ ( ) = 0 , dot product on both sides of expression
𝑑𝑠1 𝜏
(1.4.9-11) with 𝑵1𝑝 gives
𝑑𝑠𝑛
( ) = −𝝉0 ∙ 𝑵1𝑝 (1.4.9-12)
𝑑𝑠0 𝜏
0
Dot product on both sides of expression (1.4.9-11) with 𝝉 gives

𝑑𝑠 𝝉0 ∙𝝉 𝝉 ∙𝝉
(𝑑𝑠1 ) = 𝑑𝑵1𝑝 = 1−𝑠0 𝐾 (1.4.9-13)
0 𝜏0 1−𝑠𝑛 ( ) ∙𝝉 𝑛 1𝜏
𝑑𝑠1 𝜏
Likewise, with help of expression (1.4.4-4), following relationship is obtained as
⃗⃗⃗⃗⃗⃗⃗ 𝑃0 𝑃0′ = ⃗⃗⃗⃗⃗⃗⃗

𝑃𝑃0 + ⃗⃗⃗⃗⃗⃗⃗⃗ 𝑃𝑃̅′ + ⃗⃗⃗⃗⃗⃗⃗⃗
𝑃̅′ 𝑃0′ (1.4.9-14)
Due to
𝑃𝑃0 = 𝑠𝑛 𝑵2𝑝 , ⃗⃗⃗⃗⃗⃗⃗

⃗⃗⃗⃗⃗⃗⃗ 𝑃𝑃̅′ = 𝑑𝑠2 𝝉′ , ⃗⃗⃗⃗⃗⃗⃗⃗
𝑃̅′ 𝑃0′ = (𝑠𝑛 + 𝑑𝑠𝑛 )𝑵2𝑝̅̅̅′ ,
𝑑𝑵2𝑝 } (1.4.9-15)
𝑵2𝑝̅̅̅′ = 𝑵2𝑝 + ( ) 𝑑𝑠2 = 𝑵2𝑝 + (𝐾2𝜏 𝝉′ + 𝐺2𝜏 𝑵2𝑝 × 𝝉′ ).
𝑑𝑠2 𝜏′
~ 67 ~
𝑑𝑵2𝑝
𝑑𝑠0 𝝉0 = 𝑑𝑠2 𝝉′ + (𝑠𝑛 + 𝑑𝑠𝑛 )𝑵2𝑝̅̅̅′ = 𝑑𝑠2 𝝉′ + 𝑠𝑛 ( ) 𝑑𝑠2 + 𝑑𝑠𝑵2𝑝 (1.4.9-16)
𝑑𝑠2 𝜏′
With consideration of 𝑵2𝑝 ∙ 𝝉′ = 0 , dot product on both sides of expression (1.4.9-16) with 𝝉′
results in
𝑑𝑠 𝝉0 ∙𝝉′ 𝝉 ∙𝝉′
(𝑑𝑠2 ) = 𝑑𝑵2𝑝 = 1+𝑠0 (1.4.9-17)
0 𝜏0 1+𝑠𝑛 ( ) ∙𝝉′ 𝑛 𝐾2𝜏
𝑑𝑠2 𝜏′
At instant 𝜀1 + 𝑑𝜀1 , points 𝑃′ and 𝑃̅′ reach to conjugate contact position, and therefore, their
corresponding unit normal vectors are aligned but opposite in direction, that is,
(𝑑𝜀1 𝝎1 ) ⊗ [𝑵1𝑝 + ( ) 𝑑𝑠1 ] = −(𝑑𝜀2 𝝎2 ) ⊗ [𝑵2𝑝 + ( ) 𝑑𝑠2 ]
𝑑𝑠1 𝜏 𝑑𝑠2 𝜏′
With application of 𝑵1𝑝 = −𝑵2𝑝 and neglecting infinitesimal of second or higher order,
expanding expression above results in
( ) 𝑑𝑠1 + 𝑑𝜀1 𝝎1 × 𝑵1𝑝 = − ( ) 𝑑𝑠2 + 𝑑𝜀2 𝝎2 × 𝑵1𝑝 ,
𝑂𝑅 (1.4.9-18)
𝑑𝑵1𝑝 𝑑𝑠1 𝑑𝑵2𝑝 𝑑𝑠2 𝑑𝜀1 𝑑𝜀2
( ) (𝑑𝑠 ) +( ) (𝑑𝑠 ) + [( 𝑑𝑠 ) 𝝎1 − ( 𝑑𝑠 ) 𝝎2 ] × 𝑵1𝑝 = 𝟎.
𝑑𝑠1 𝜏 0 𝜏0 𝑑𝑠2 𝜏′ 0 𝜏0 0 𝜏0 0 𝜏0 }
Dot product on both sides of expression (1.4.9-8) with 𝑵1𝑝 yields
𝑑𝑵0𝑝 ′
[( ) + (𝑑𝑵0𝑝 ) ] ∙ 𝑵1𝑝 = − [(𝑑𝜀1 ) 𝝎1 − (𝑑𝜀2 ) 𝝎2 ] ∙ (𝑵0𝑝 × 𝑵1𝑝 ) (1.4.9-19)
𝑑𝑠0 𝑑𝑠
𝜏0 𝑑𝑠 0 𝑑𝑠 0 0
𝜏0 𝜏0 𝜏0
Dot product on both sides of expression (1.4.9-18) with 𝑵0𝑝 leads to
𝑑𝑵1𝑝 𝑑𝑠 𝑑𝑵2𝑝 𝑑𝑠 𝑑𝜀 𝑑𝜀
[( ) (𝑑𝑠1 ) +( ) (𝑑𝑠2 ) ] ∙ 𝑵0𝑝 = [( 𝑑𝑠1) 𝝎1 − ( 𝑑𝑠2) 𝝎2 ] ∙ (𝑵0𝑝 × 𝑵1𝑝 )
𝑑𝑠1 𝜏 0 𝜏0 𝑑𝑠2 𝜏′ 0 𝜏0 0 𝜏0 0 𝜏0
Substitution of expressions (1.4.9-13), (1.4.9-17) and (1.4.9-19) into expression above results
(𝝉0 ∙𝝉)( ) (𝝉0 ∙𝝉′ )( ) 𝑑𝑵0𝑝 ′
[
𝑑𝑠1 𝜏
+
𝑑𝑠2 𝜏′
] ∙ 𝑵0𝑝 = − [( ) + (𝑑𝑵0𝑝 ) ] ∙ 𝑵1𝑝 ,
𝑑𝑵1𝑝 𝑑𝑵2𝑝 𝑑𝑠0 𝜏0𝑑𝑠
1−𝑠𝑛 ( ) ∙𝝉 1+𝑠𝑛 ( ) ∙𝝉′ 0 𝜏0
𝑂𝑅 (1.4.9-20)
𝝉 ∙𝝉′ 𝑑𝑵0𝑝 ′
𝝉 ∙𝝉
[1−𝑠0 𝐾 (
𝑑𝑵1𝑝
) + 1+𝑠0 (
𝑑𝑵2𝑝
) ] ∙ 𝑵0𝑝 = − [( ) + (𝑑𝑵0𝑝 ) ] ∙ 𝑵1𝑝
𝑑𝑠1 𝑛 𝐾2𝜏 𝑑𝑠2 𝑑𝑠0 𝑑𝑠
𝑛 1𝜏 𝜏 𝜏′ 𝜏0 0 𝜏0 }
~ 68 ~
Expression (1.4.9-20) generates the curvature relationship between a pair of conjugate surfaces
(𝐴, 𝐴̅) and a pair of corresponding pitch surfaces (𝐴0 , ̅̅̅
𝐴0 ). ( 𝑑𝑠 ) and ( 𝑑𝑠 ) are curvatures
1 𝜏 2 𝜏′
of conjugate surfaces 𝐴 and 𝐴̅ respectively. ( 𝑑𝑠 ) and ( ) are curvatures of pitch
0 𝜏0 𝑑𝑠0
𝜏0
surfaces 𝐴0 and ̅̅̅
𝐴0 respectively.
1.4.10 Planar Case

In the case of parallel rotating axes, conjugate motion becomes planar relative motion due to
𝛼 = 0 or 𝛼 = 𝜋 and 𝜎1 = 𝜎2 = 0.
1 Dual Coordinate Systems

Substitution 𝛼 = 0 or 𝛼 = 𝜋 into expression (1.3.3-1) yields dual coordinate system as shown in
figure 1.4.10-1.
𝒊′ = 𝒊, 𝒋′ = ±𝒋, 𝒌′ = −𝝎2 = ±𝒌,

̅̅̅̅̅′ = 𝑓𝒊 + ℎ𝒋, } (1.4.10-1)
𝑙𝒑 = 𝑂𝑂
Where: for sign " ± " , upper sign is corresponding to external gearing transmission and lower
sign is corresponding to internal gearing transmission.
2 Equation of the First Pitch Surface

Equation of first pitch surface 𝐴0 with respect to coordinate system (𝑂 − 𝒊, 𝒋, 𝒌) is derived by
letting 𝛼 = 0 𝑜𝑟 𝜋 in expression (1.4.3-1) as follow:
𝑹0 = 𝑥0 𝒊 + 𝑦0 𝒋 (1.4.10-2)
Where: 𝜀1 is an independent parameter and

𝑑𝑓 𝑑ℎ
(±𝑀ℎ− ) sin 𝜀1 +(±𝑀𝑓+ ) cos 𝜀1
𝑑𝜀1 𝑑𝜀1
𝑥0 = ,
1±𝑀
𝑑𝑓 𝑑ℎ
(1.4.10-3)
(±𝑀ℎ− ) cos 𝜀1 −(±𝑀𝑓+ ) sin 𝜀1
𝑑𝜀1 𝑑𝜀1
𝑦0 = .}
1±𝑀
𝑑𝑀 𝑑𝑓
For the constant transmission ratio and fixed rotating axes, i.e., 𝑑𝜀 = 𝑑𝜀 = 0 and ℎ = 0
1 1
(through proper choice of coordinate system), then
~ 69 ~
±𝑀𝑓 cos 𝜀1
𝑥0 = ,
1±𝑀
∓𝑀𝑓 sin 𝜀1
} (1.4.10-4)
𝑦0 = .
1±𝑀
𝒌 = 𝝎1
𝒌′ = −𝝎2 (𝛼 = 0 )
𝑂 𝒋
𝑙𝒑 𝑓
ℎ 𝑂′ 𝒋′
𝒊′ 𝝎2
Figure 1.4.10-1 Relationship between Coordinate Systems (𝑂 − 𝒊, 𝒋, 𝒌) and (𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ )
3 Path of Contact for Pitch Surface

Path of contact for pitch surface is resulted from letting 𝛼 = 0 𝑜𝑟 𝜋 in expression (1.4.3-2) as
follow:
𝑹0𝑝 = 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋 (1.4.10-5)
Where: 𝜀1 is an independent parameter and

𝑑ℎ
±𝑀𝑓+
𝑑𝜀1
𝑥0𝑝 = ,
1±𝑀
𝑑𝑓 (1.4.10-6)
±𝑀ℎ−
𝑑𝜀1
𝑦0𝑝 = .}
1±𝑀
𝑑𝑀 𝑑𝑓
1 1
~ 70 ~
±𝑀𝑓
𝑥0𝑝 = 1±𝑀 ,
} (1.4.10-7)
𝑦0𝑝 = 0.
4 Equation of Second Pitch Surface
Equation of second pitch surface ̅̅̅

𝐴0 is derived by letting 𝛼 = 0 𝑜𝑟 𝜋 in expression (1.4.3-3) as
follow:
𝑹′0 = 𝑥0′ 𝒊′ + 𝑦0′ 𝒋′ (1.4.10-8)
Where: 𝜀1 is an independent variable and

𝑑ℎ 𝑑𝑓
(−𝑓+ ) cos 𝜀2 ±(ℎ+ ) sin 𝜀2
𝑑𝜀1 𝑑𝜀1
𝑥0′ = ,
1±𝑀
𝑑ℎ 𝑑𝑓 (1.4.10-9)
(−𝑓+ ) sin 𝜀2 ∓(ℎ+ ) sin 𝜀2
𝑑𝜀1 𝑑𝜀1
𝑦0′ = .}
1±𝑀
𝑑𝑀 𝑑𝑓
1 1
−𝑓 cos 𝜀2
𝑥0′ = ,
1±𝑀
−𝑓 sin 𝜀2
} (1.4.10-10)
𝑦0′ = .
1±𝑀
5 Unit Normal to Pitch Surface at Instantaneous Contact Point

Parameter 𝑱0 for the case of parallel axes is updated by letting 𝛼 = 0 𝑜𝑟 𝜋 in expression (1.4.4-
5) as follow:
−(𝝎1 − 𝑀𝝎2 ) × (𝝎1 × 𝑹0𝑝 )

𝑱0 = [ 𝑑𝑀 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)] = 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋 (1.4.10-11)
+ 𝑑𝜀 𝝎2 × (𝑹0𝑝 − 𝑙𝒑) + 𝑑𝜀2 − 𝑀𝝎2 × 𝑑𝜀
1 1 1
Where:
𝑑𝑓
𝑑ℎ 𝑑ℎ 𝑑𝑀 (ℎ+𝑑𝜀1 ) 𝑑2 𝑓
𝐽0𝑥 = ±𝑀 (𝑓 − 𝑑𝜀 ) + 𝑑𝜀 ∓ + ,
1 1 𝑑𝜀1 1±𝑀 𝑑𝜀12
𝑑ℎ
𝑑𝑓 𝑑𝑓 𝑑2 ℎ 𝑑𝑀 (𝑓−𝑑𝜀1 ) (1.4.10-12)
𝐽0𝑦 = ±𝑀 (ℎ + 𝑑𝜀 ) − 𝑑𝜀 + 𝑑𝜀2 ± ,
1 1 1 𝑑𝜀1 1±𝑀
|𝑱0 | = 2 2 .
√𝐽𝒐𝑥 + 𝐽𝒐𝑦 }
~ 71 ~
Unit normal 𝑵0𝑝 to the first pitch curve 𝐴0 at conjugate contact point is
𝑱
𝑵0𝑝 = ± |𝑱0| (1.4.10-13)
0
𝑑𝑀 𝑑𝑓
1 1
𝐽0𝑥 = ±𝑀𝑓, 𝐽0𝑦 = 0,

} (1.4.10-14)
|𝑱0 | = |𝑀𝑓|.
And
𝑵0𝑝 = ±𝒊 (1.4.10-15)
6 Rate of Angular Increment with Respect to Arc-Length on Pitch Surface

Increment rate of rotating angle 𝜀1 with respect to arc-length on the first pitch curve 𝐴0 at
conjugate contact point is derived by updating expression (1.4.5-1) as follow:
Due to
𝝎1 − 𝑀𝝎2 = (1 ± 𝑀)𝒌,
}
𝒆0 = 𝒌, 𝝉0 = 𝒈0 = 𝑵0𝑝 × 𝒆0 = 𝑵0𝑝 × 𝒌.
then
𝑑𝜀 [𝑱0 ×(𝝎1 −𝑀𝝎2 )]∙𝝉0 (1±𝑀)(𝑵0𝑝 ×𝒌)∙(𝑵0𝑝 ×𝒌) (1±𝑀)

( 𝑑𝑠1 ) = |𝑱0 |2
= |𝑱0 |
= |𝑱0 |
(1.4.10-16)
0 𝜏0
Where: |𝑱0 | is calculated by expression (1.4.10-12).
𝑑𝑀 𝑑𝑓
1 1
𝑑𝜀1 (1±𝑀)
( ) = |𝑀𝑓|
(1.4.10-17)
𝑑𝑠0 𝑔
0
Likewise, increment rate of rotating angle 𝜀2 with respect to arc-length on the second pitch
curve ̅̅̅
𝐴0 at conjugate contact point is
𝑑𝜀 𝑑𝜀
( 𝑑𝑠2 ) = 𝑀 ( 𝑑𝑠1 ) (1.4.10-18)
0 𝜏0 0 𝜏0
~ 72 ~
7 Ratio of Arc-Length on Path of Contact with Respect to Conjugate Arc-Length
on the First Pitch Surface and Unit Tangent to Path of Contact
Due to
𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 (1.4.10-19)
Substitution of expressions (1.4.10-16) and the above into expression (1.4.5-2) gives
𝑑𝑠 𝑑𝜀
(𝑑𝑠 ) = |𝝉0 + ( 𝑑𝑠1 ) (𝝎1 × 𝑹0𝑝 )|,
0 𝜏0 0 𝜏
0
𝝉0 +(
𝑑𝜀1
) (𝝎1 ×𝑹0𝑝 ) (1.4.10-20)
𝑑𝑠0 𝜏
0
𝒕 𝜏0 = 𝑑𝑠 .
( )
𝑑𝑠0 𝜏
0 }
𝑑𝑀 𝑑𝑓
1 1
𝑑𝑠
(𝑑𝑠 ) = 0,
0 𝜏0
𝑑𝜀1
𝝉0 +( ) 𝒗
𝑑𝑠0 𝜏 0𝑝
(1.4.10-21)
0
𝒕 𝜏0 = 𝑑𝑠 = 𝑖𝑛𝑑𝑒𝑓𝑖𝑛𝑖𝑡𝑦.
( )
𝑑𝑠0 𝜏
0 }
8 Unit Normal to Path of Contact Corresponding to a Pair of Pitch Surfaces

With help of expressions (1.4.10-13), (1.4.10-16) and (1.4.10-19), expression (1.4.6-6) gives
𝑑𝜀1 𝑑𝜀1
𝑵0𝑝 +( ) 𝒆 ×𝒗0𝑝 𝑵0𝑝 −( ) 𝑹0𝑝
𝑑𝑠0 𝑔 0 𝑑𝑠0 𝑔
0 0
𝚷0 = 𝑑𝜀1
= 𝑑𝜀1
(1.4.10-22)
|𝑵0𝑝 +( ) 𝒆 ×𝒗0𝑝 | |𝑵0𝑝 −( ) 𝑹0𝑝 |
𝑑𝑠0 𝑔 0 𝑑𝑠0 𝑔
0 0
𝑑𝑀 𝑑𝑓
1 1
𝑑𝜀1 𝑑𝜀1
𝑵0𝑝 −( ) 𝑹0𝑝 𝑵0𝑝 −( ) 𝑹0𝑝
𝑑𝑠0 𝑔 𝑑𝑠0 𝑔
0 0
𝚷0 = 𝑑𝜀1
= (1±𝑀)±𝑀𝑓 = 𝒊𝒏𝒅𝒆𝒇𝒊𝒏𝒊𝒕𝒚 (1.4.10-23)
|𝑵0𝑝 −( ) 𝑹0𝑝 | |±𝒊 − |𝑀𝑓| 𝒊|
𝑑𝑠0 𝑔 1±𝑀
0
9 Relationship of Conjugate Curvatures at Pitch Point
~ 73 ~
Due to 𝐺2𝜏0 = 𝐺1𝜏0 = 0 for planer case, substitution of expressions (1.4.10-13), (1.4.10-16) and
(1.4.10-18) into expression (1.4.7-5)
𝑑𝜀 (1±𝑀)
𝐾2𝜏0 = −𝐾1𝜏0 + (1 ± 𝑀) ( 𝑑𝑠1 ) = −𝐾1𝜏0 + (1 ± 𝑀) |𝑱0 |
0 𝜏0
𝑑𝜀 𝑑𝜀
= −𝐾1𝜏0 + ( 𝑑𝑠1 ) ± ( 𝑑𝑠2 ) ,
0 𝜏0 0 𝜏0 (1.4.10-24)
𝑂𝑅
1 1 (1±𝑀) (1±𝑀) (1±𝑀) 𝑑𝜀 𝑑𝜀
+ 𝜌 = (1 ± 𝑀) |𝑱0 |
= |𝑱 | ± 𝑀 |𝑱 | = ( 𝑑𝑠1) ± ( 𝑑𝑠2 ) .
𝜌10 20 0 0 0 𝜏0 0 𝜏0 }
1 1
Where: 𝜌10 = 𝐾 and 𝜌20 = 𝐾 are curvature radii for pitch surfaces 𝐴0 and ̅̅̅
𝐴0 respectively.
1𝜏0 2𝜏0
𝑑𝑀 𝑑𝑓
For the constant transmission Ratio and fixed rotating axes, i.e., 𝑑𝜀 = 𝑑𝜀 = 0 , |𝑱0 | = |𝑀𝑓|,
1 1
and ℎ = 0, (through proper choice of coordinate system), then
(1±𝑀) 𝑑𝜀 𝑑𝜀
𝐾2𝜏0 = −𝐾1𝜏0 + (1 ± 𝑀) |𝑀𝑓|
= −𝐾1𝜏0 + ( 𝑑𝑠1 ) ± ( 𝑑𝑠2 ) ,
0 𝜏0 0 𝜏0
𝑂𝑅 (1.4.10-25)
1 1 (1±𝑀) 𝑑𝜀1 𝑑𝜀2
+ 𝜌 = (1 ± 𝑀) |𝑀𝑓|
= ( 𝑑𝑠 ) ± ( 𝑑𝑠 ) .
𝜌10 20 0 𝜏0 0 𝜏0 }
10 Curvatures of Pitch Surfaces

Curvature of the first pitch surface 𝐴0 for the case of planar motion can be derived by
application of expression (1.4.8-17) as follow:
(1 ± 𝑀)𝒌 × 𝑹0𝑝 ± 2 𝑑𝑀 [𝑹0𝑝 + 𝒌 × 𝑑(𝑙𝒑)]

|1±𝑀| 𝒈 𝑑𝜀1 𝑑𝜀1
𝐾1𝑔0 = |𝑱0 |
{|𝑱 0| ∙ { 𝑑2 𝑀 𝑑2 (𝑙𝒑) 𝑑3 (𝑙𝒑)
} + 2} (1.4.10-26)
0
∓ 𝑑𝜀2 𝒌 × (𝑹0𝑝 − 𝑙𝒑) ± 𝑀𝒌 × 𝑑𝜀2 + 𝑑𝜀3
1 1 1
Where: |𝑱0 | is calculated by expression (1.4.10-12).

𝑑(𝑙𝒑)
For the case of fixed rotating axes, that is, = 𝟎 , ℎ = 0 (through proper selection of
𝑑𝜀1
coordinate system) and 𝑦0𝑝 = 0, expression (1.4.10-26) is updated as follow:
~ 74 ~
|1±𝑀| 𝑵0𝑝 ×𝒌 𝑑 𝑀 2
𝑑𝑀
𝐾1𝑔0 = |𝑱0 |
{ |𝑱0 |
∙ {(1 ± 𝑀)𝒌 × 𝑹0𝑝 ± 2 𝑑𝜀 𝑹0𝑝 ∓ 𝑑𝜀2 𝒌 × (𝑹0𝑝 − 𝑙𝒑)} + 2}
1 1
𝑑𝑀 𝑑2 𝑀
−(1±𝑀)𝑵0𝑝 ∙𝑹0𝑝 ±2 (𝑵0𝑝 ×𝒌)∙𝑹0𝑝 ± 2 𝑵0𝑝 ∙(𝑹0𝑝 −𝑙𝒑)
|1±𝑀| 𝑑𝜀1 𝑑𝜀1
= |𝑱0 |
[ |𝑱0 |
+ 2]
(1.4.10-27)
𝑑𝑀 𝑑2 𝑀
−(1±𝑀)𝑥0𝑝 𝑁0𝑝𝑥 ±2 𝑥 𝑁 ± 𝑁 (𝑥 −𝑓)
|1±𝑀| 𝑑𝜀1 0𝑝 0𝑝𝑦 𝑑𝜀2 0𝑝𝑥 0𝑝
1
= |𝑱0 |
[ |𝑱0 |
+ 2]
Application of expression (1.4.8-18) generates curvature of the second pitch surface ̅̅̅
𝐴0 as
follow:
|(𝝎1 −𝑀𝝎2 )|𝟐 (1±𝑀)𝟐

𝐾2𝑔0 = −𝐾1𝑔0 + |𝑱0 |
= −𝐾1𝑔0 + |𝑱0 |
(1.4.10-28)
𝑑𝑀 𝑑𝑓
For the constant transmission ratio and fixed rotating axes, i.e., 𝑑𝜀 = 𝑑𝜀 = 0, |𝑱0 | = |𝑀𝑓| and
1 1
ℎ = 0, (through proper choice of coordinate system), then
(1±𝑀) 1
𝐾1𝜏0 = 𝐾1𝑔0 = |𝑀𝑓|
=𝜌 ,
10
(1±𝑀)𝟐 1 (1±𝑀)𝟐 (1±𝑀) 1
} (1.4.10-29)
𝐾2𝑔0 = −𝐾1𝑔0 + |𝑱0 |
= −𝜌 + |𝑀𝑓|
= =𝜌
10 𝑓 20
11 Relationship of Curvatures between Pitch Surfaces (𝐴0 , ̅̅̅

𝐴0 ) and
Corresponding Conjugate Surfaces (𝐴, 𝐴̅).
Due to 𝝉 = 𝝉′ in the case of parallel rotating axes as shown in figure 1.4.10-2, expression (1.4.9-
20) is updated as
𝝉 ∙𝝉 𝝉 ∙𝝉
[1−𝑠0 𝐾 𝐾1𝜏 + 1+𝑠0 𝐾 𝐾2𝜏 ] (𝝉 ∙ 𝑵0𝑝 ) = −(𝐾1𝜏0 +𝐾2𝜏0 )(𝝉0 ∙ 𝑵1𝑝 ) (1.4.10-30)
𝑛 1𝜏 𝑛 2𝜏
Let 𝜌1 and 𝜌2 be curvature radius for pitch surfaces 𝐴 and 𝐴̅ respectively.
Due to 𝝉 = 𝑵1𝑝 × 𝒌 and 𝑵0𝑝 = 𝒌 × 𝝉0 ,
then
𝝉 ∙ 𝑵0𝑝 = (𝑵1𝑝 × 𝒌) ∙ (𝒌 × 𝝉0 ) = −𝝉0 ∙ 𝑵1𝑝
Consequently, expression (1.4.10-30) can be rewritten as follow:
~75 ~
𝐾 𝐾
(1−𝑠1𝜏𝐾 + 1+𝑠2𝜏𝐾 ) (𝝉0 ∙ 𝝉) = 𝐾1𝜏0 +𝐾2𝜏0 ,
𝑛 1𝜏 𝑛 2𝜏
𝑂𝑅 (1.4.10-31)
1 1 1 1
(𝜌 +𝜌 ) (𝝉0 ∙ 𝝉) = 𝜌 + }
1 −𝑠𝑛 2 +𝑠𝑛 10 𝜌20
Where: 𝝉0 = 𝒈0 = 𝑵0𝑝 × 𝒆0
𝑂 𝒋
𝑹0𝑝 𝐴0 ̅̅̅
𝐴0
𝑃0 𝑠𝑛 𝐴̅
𝝉0 𝑵0𝑝 𝑃
𝐴 𝑵1𝑝
𝒊 𝝉 = 𝝉′
Figure 1.4.10-2. Curvature Relationship between Pitch Surfaces (𝐴0 , ̅̅̅

𝐴0 ) and Conjugate
Surfaces (𝐴, 𝐴̅)
𝑑𝑀 𝑑𝑓
For the constant transmission ratio and fixed rotating axes, i.e., 𝑑𝜀 = 𝑑𝜀 = 0, |𝑱0 | = |𝑀𝑓|,
1 1
𝒈0 = −𝒋, and ℎ = 0, (through proper choice of coordinate system), and 𝝉0 ∙ 𝝉 = cos ∅ , then,
expression (1.4.10-30) becomes as follow
1 1 1 1 1
+𝜌 = cos ∅ (𝜌 + 𝜌 ) (1.4.10-32)
𝜌1 −𝑠𝑛 2 +𝑠𝑛 10 20
Expression (1.4.10-31) is Euler-Savary Equation. ∅ is an intersecting angle between 𝒊 and unit

normal 𝑵1𝑝 to the first conjugate surface 𝐴 at conjugate contact point 𝑃.
12 Arc-length of Pitch Curves

Let 𝑆1 and 𝑆2 be whole arc-length of the first and second pitch curves 𝐴0 and ̅̅̅
𝐴0 respectively.
Assume that whole range of rotating angle for the first pitch curve 𝐴0 is 0 ≤ 𝜀1 ≤ 𝜀1𝑚𝑎𝑥 and is
𝜀1𝑚𝑎𝑥
equally divided as ∆𝜀1 = .
𝑛

𝜀 𝑑𝜀1 ∆𝜀1
𝑆1 = 𝑆2 = ∫0 1𝑚𝑎𝑥 𝑑𝜀1 = ∑𝑛−1
𝑖=0 𝑑𝜀1,𝑖 (1.4.10-33)
( ) ( )
𝑑𝑠0 𝜏 𝑑𝑠0 𝜏
0 0
~ 76 ~
Where: 𝑛 is total number of interpolating points of the first pitch curve 𝐴0 . 𝜀1,𝑖 = 𝜀1,𝑖−1 + ∆𝜀1
and 𝜀1,0 = 0.
1.4.11 Surfaces of Screw Axes

1 Definition
If conjugate motion satisfies following condition:
𝛀𝑝 × 𝒗12
𝑝 =𝟎 (1.4.11-1)
Where: 𝛀𝑝 = 𝝎1 − 𝑀𝝎2 is relative angular velocity which is defined in expression (1.3.6-1).
That is, surfaces composed of points whose relative velocities 𝒗12

𝑝 are parallel to relative
angular velocities 𝛀𝑝 are defined as surfaces of screw axes.
Substitution of expressions (1.3.5-3) and (1.3.6-1) into expression (1.4.11-1) results in screw axis
𝐑 𝑎𝑝 at instant rotating angle 𝜀1 as follow:
𝐑 𝑎𝑝 = 𝑥𝑎𝑝 𝒊 + 𝑦𝑎𝑝 𝒋 + 𝑧𝑎𝑝 𝒌 (1.4.11-2)
Where: 𝑥𝑎𝑝 and 𝑦𝑎𝑝 are linear function of 𝑧𝑎𝑝 at instant rotating angle 𝜀1 , and thus screw axis is
straight line, that is,
𝑑ℎ 𝑑𝜎 𝑑𝜎
𝑀𝑓(𝑀+cos 𝛼)+ (1+𝑀 cos 𝛼)+ 1 𝑀 sin 𝛼− 2 sin 𝛼
𝑥𝑎𝑝 = 𝐸 = (1+𝑀 cos 𝛼)2 +𝑀2 sin2 𝛼
,
𝑑𝑓
𝑀𝑧𝑎𝑝 sin 𝛼+𝑀ℎ cos 𝛼−
𝑑𝜀1
𝑦𝑎𝑝 = 𝐹 = . }
1+𝑀 cos 𝛼
2 Equation of Surface of Screw Axes

With help of expression (1.4.11-2), application of expression (1.3.4-2) gives equation of surface
of screw axis on body I, that is,
𝑹𝑎 = 𝑥𝑎 𝒊 + 𝑦𝑎 𝒋 + 𝑧𝑎 𝒌,
𝑥𝑎 = 𝐸 cos 𝜀1 + 𝐹 sin 𝜀1 , } (1.4.11-3)
𝑦𝑎 = −𝐸 sin 𝜀1 + 𝐹 cos 𝜀1 .
Where: 𝑧𝑎 and 𝜀1 are independent parameters
~ 77 ~
𝑀𝑓(𝑀+cos 𝛼)+ (1+𝑀 cos 𝛼)+ 1 𝑀 sin 𝛼− 2 sin 𝛼
𝐸= (1+𝑀 cos 𝛼)2 +𝑀2 sin2 𝛼
,
𝑑𝑓
(𝑧𝑎 +𝜎1 ) sin 𝛼+𝑀ℎ cos 𝛼−
𝑑𝜀1
𝐹= . }
1+𝑀 cos 𝛼
With help of expression (1.4.11-2), application of expression (1.3.5-8) yields equation of surface
of screw axis on body II as follow:
𝑹′𝑎 = 𝑥𝑎′ 𝒊′ + 𝑦𝑎′ 𝒋′ + 𝑧𝑎′ 𝒌′ (1.4.11-4)
Where: 𝜎1 , 𝜎2 , 𝑓, ℎ and 𝜀2 are all functions of 𝜀1 and
𝑥𝑎′ = 𝐸 cos 𝜀2 − 𝐹 cos 𝛼 sin 𝜀2 + (𝑧𝑎 + 𝜎1 ) sin 𝛼 sin 𝜀2 − 𝑓 cos 𝜀2 + ℎ cos 𝛼 sin 𝜀2 ,
𝑦𝑎′ = 𝐸 sin 𝜀2 + 𝐹 cos 𝛼 cos 𝜀2 − (𝑧𝑎 + 𝜎1 ) sin 𝛼 cos 𝜀2 − 𝑓 sin 𝜀2 − ℎ cos 𝛼 cos 𝜀2 ,}
𝑧𝑎′ = 𝐹 sin 𝛼 + (𝑧𝑎 + 𝜎1 ) cos 𝛼 − ℎ sin 𝛼 + 𝜎2 .
Example 1.4-1 Design a pair of non-circular gears to realize a function 𝑤 = 𝑘3 𝐷2 , where: 𝑘3 is a

constant.
Let rotating angles of driving and driven gears be 𝜀1 and 𝜀2 respectively which are proportional
to independent parameter 𝐷 and dependent parameter 𝑤 of function 𝑤 = 𝑘3 𝐷2 .
Initial condition of 𝜀1 and 𝜀2 are
𝜀1 = 0, 𝜀2 = 0, When 𝐷 = 𝐷𝑚𝑖𝑛 .
1 Given Condition:
𝐷𝑚𝑖𝑛 = 20, 𝐷𝑚𝑎𝑥 =100, 𝑘1 = 3.5, 𝑘2 = 125, 𝑘3 = 2.5 × 10−4 ,

𝑘2 𝑘3 𝜋
𝐸= , 𝐾 = 180 , 𝐾1 = 𝐾𝑘1 , 𝐾2 = 𝐾𝑘2 , }
𝑘1
𝜀1𝑚𝑖𝑛 = 0, 𝜀1𝑚𝑎𝑥 = 280𝐾(𝑟𝑎𝑑), 𝜀2𝑚𝑖𝑛 = 0, 𝜀2𝑚𝑎𝑥 = 300𝐾, 𝑓 = 50𝑚𝑚.
𝑑𝜀2
Transmission ratio = 𝑀 of gearing sets is calculated as follow:
𝑑𝜀1
2 𝜀
𝜀1 = 𝐾1 (𝐷 − 𝐷𝑚𝑖𝑛 ), 𝜀2 = 𝐾2 (𝑤 − 𝑤𝑚𝑖𝑛 ) = 𝐾2 𝑘3 (𝐷2 − 𝐷𝑚𝑖𝑛 ) = 𝐸𝜀1 ( 1 + 2𝐷𝑚𝑖𝑛 ) ,
𝐾 1
𝑑𝜀2 𝜀1 𝑑𝑀 2𝐸
}
= 𝑀 = 2𝐸 (𝐾 + 𝐷𝑚𝑖𝑛 ) , 𝑑𝜀1
= = 0.292325.
𝑑𝜀1 1 𝐾1
2 Calculation Object:
A. Pitch Curve
B. Arc-length 𝑆0 of pitch curve
~ 78 ~
3 Calculation Program:
Step 1:
Generate interpolate point of 𝜀1 and 𝜀2
Let whole range 𝜀1𝑚𝑎𝑥 of rotating angle for driving gear be equally divided by 𝑁 segments (𝑁 is
an integer), and then, the knot vector 𝑼 for 𝜀1 is as follow:
𝑼 = {0, 𝜀1,1 ⋯ 𝜀1,𝑖 𝜀1,𝑖+1 ⋯ 𝜀1,𝑁 }
𝜀1𝑚𝑎𝑥
Due to 𝜀1𝑚𝑎𝑥 being equally divided, the knot span at 𝑖𝑡ℎ knot 𝜀1,𝑖 is ∆𝜀1,𝑖 = ∆𝜀1 = 𝑁
the 𝑖𝑡ℎ knot 𝜀1,𝑖 of 𝜀1 is
𝜀1,𝑖 = 𝜀1,𝑖−1 + ∆𝜀1,𝑖−1
Where: 𝑖 = 1,2, ⋯ 𝑁 − 1, 𝑁 and 𝜀1,0 = 0. 𝜀1,𝑁 = 𝑁∆𝜀1 = 𝜀1𝑚𝑎𝑥
Likewise, the knot vector 𝑼′ for 𝜀2 is as follow:
𝑼′ = {0, 𝜀2,1 ⋯ 𝜀2,𝑖 𝜀2,𝑖+1 ⋯ 𝜀2,𝑁 }
the 𝑖𝑡ℎ knot 𝜀2,𝑖 of 𝜀2 is
𝜀2,𝑖 = 𝜀2,𝑖−1 + ∆𝜀2,𝑖−1
Where: 𝑖 = 1,2, ⋯ 𝑁 − 1, 𝑁 and 𝜀2,0 = 0. 𝜀2,𝑁 = 𝜀2𝑚𝑎𝑥
The knot span ∆𝜀2,𝑖 at 𝑖𝑡ℎ knot 𝜀2,𝑖 is

𝑑𝜀
∆𝜀2,𝑖 = (𝑑𝜀2 ) ∆𝜀1,𝑖 = 𝑀(𝜀1,𝑖 )∆𝜀1,𝑖
1 𝜀1,𝑖
Where: 𝑖 = 0,2, ⋯ 𝑁 − 1.
Step 2:
Calculation for coordinate of 𝑖th pitch point on pitch curve 𝐴0 for workpiece 𝐴 by application of
𝑀𝑖 𝑓 cos 𝜀1,𝑖
𝑥0,𝑖 = ,
1+𝑀𝑖
−𝑀𝑖 𝑓 sin 𝜀1,𝑖
} (1.4.10-4)
𝑦0,𝑖 = .
1+𝑀𝑖
~ 79 ~
𝜀
Where: 𝑀𝑖 = 2𝐸 ( 𝐾1,𝑖 + 𝐷𝑚𝑖𝑛 )
1
Step 3:
Calculation for coordinate of 𝑖th pitch point on pitch curve 𝐴̅0 for workpiece 𝐴̅ by application of
′ −𝑓 cos 𝜀2,𝑖
𝑥0,𝑖 = ,
1+𝑀𝑖
−𝑓 sin 𝜀2,𝑖
} (1.4.10-10)
′
𝑦0,𝑖 = .
1+𝑀𝑖
Step 4:
Chose another point, i.e., 𝜀1,𝑖+1 , repeat steps 2 and 3 until cover whole range of rotating angle
𝜀1 , that is, 𝜀1𝑚𝑖𝑛 ≤ 𝜀1 ≤ 𝜀1𝑚𝑎𝑥
Arc-length 𝑆0 of pitch curve

∆𝜀1
𝑆0 = ∑𝑛−1
𝑖=0 𝑑𝜀1,𝑖 = 123.438 (1.4.10-33)
( )
𝑑𝑠0 𝜏
0
𝐴0
𝑂′ 𝒋′
̅̅̅
𝐴0
Figure 1.4-1 a pair of pitch curves in example 1.4-1
~ 80 ~
1.4.12 Summary of Chapter 4
Formulas derived in chapter 4 are listed in table 1.4
Table 1.4 Formulas in Chapter 4
Spatial Case Planar Case

𝑹0 = 𝑥0 𝒊 + 𝑦0 𝒋 + 𝑧0 𝒌 𝑹0 = 𝑥0 𝒊 + 𝑦0 𝒋
Where: 𝑧0 and 𝜀1 are independent parameters and Where: 𝜀1 is an independent parameter and
𝑑𝑓 (±𝑀ℎ−
𝑑𝑓
) sin 𝜀1 +(±𝑀𝑓+
𝑑ℎ
) cos 𝜀1
[𝑀(𝑧0 + 𝜎1 ) sin 𝛼 + 𝑀ℎ cos 𝛼 − 𝑑𝜀 ] sin 𝜀1 𝑑𝜀1 𝑑𝜀1
1st pitch surface
{ 1
} 𝑥0 = ,
𝑑𝜎 𝑑ℎ 1±𝑀
+ (𝑀𝑓 cos 𝛼 − 2 sin 𝛼 + ) cos 𝜀1 𝑑𝑓 𝑑ℎ (1.4.10-3)
𝑑𝜀1 𝑑𝜀1 (±𝑀ℎ− ) cos 𝜀1 −(±𝑀𝑓+ ) sin 𝜀1
𝑥0 = , 𝑑𝜀1 𝑑𝜀1
1 + 𝑀 cos 𝛼 𝑦0 = .}
𝑑𝑓 1±𝑀
[𝑀(𝑧0 + 𝜎1 ) sin 𝛼 + 𝑀ℎ cos 𝛼 − 𝑑𝜀 ] cos 𝜀1 For the case of constant transmission ratio and fixed rotating axes
1
{ }
𝑑𝜎 𝑑ℎ
− (𝑀𝑓 cos 𝛼 − 2 sin 𝛼 + ) sin 𝜀1 ±𝑀𝑓 cos 𝜀1
𝑑𝜀1 𝑑𝜀1 𝑥0 = ,
𝑦0 = .} 1±𝑀
1 + 𝑀 cos 𝛼
∓𝑀𝑓 sin 𝜀1
} (1.4.10-4)
(1.4.3-1) 𝑦0 = .
1±𝑀
𝑹0𝑝 = 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋 + 𝑧0𝑝 𝒌, 𝑹0𝑝 = 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋

Path of contact
𝑑𝜎 𝑑ℎ Where: 𝜀1 is an independent parameter and

(𝑀𝑓 cos 𝛼− 2 sin 𝛼+ ) 𝑑ℎ
𝑑𝜀1 𝑑𝜀1 ±𝑀𝑓+𝑑𝜀
𝑥0𝑝 = , 𝑥0𝑝 = 1
,
1+𝑀 cos 𝛼
𝑑𝑓
(1.4.3-2) 1±𝑀
𝑑𝑓 (1.4.10-6)
𝑀(𝑧0 +𝜎1 ) sin 𝛼+𝑀ℎ cos 𝛼− ±𝑀ℎ−
𝑑𝜀1
𝑑𝜀1 𝑦0𝑝 = .}
𝑦0𝑝 = , 1±𝑀
1+𝑀 cos 𝛼
For the case of constant transmission ratio and fixed rotating axes
𝑧0𝑝 = 𝑧0 + 𝜎1 . } ±𝑀𝑓
Where: 𝑧0 and 𝜀1 are two independent parameters 𝑥0𝑝 = ,
1±𝑀 } (1.4.10-7)
𝑦0𝑝 = 0.
𝑹′0 = 𝑥0′ 𝒊′ + 𝑦0′ 𝒋′ + 𝑧0′ 𝒌′ (1.4.3-3) 𝑹′0 = 𝑥0′ 𝒊′ + 𝑦0′ 𝒋′
Where: 𝜀1 is an independent variable
𝑑𝜎 𝑑ℎ 𝑑ℎ 𝑑𝑓
(−𝑓− 2 sin 𝛼+ ) cos 𝜀2 (−𝑓+ ) cos 𝜀2 ±(ℎ+ ) sin 𝜀2
2nd pitch surface
𝑑𝜀1 𝑑𝜀1
{
𝑑𝜀1 𝑑𝜀1
𝑑𝑓
} 𝑥0′ = ,
−[𝑀(𝑧0 +𝜎1 ) sin 𝛼−ℎ−𝑑𝜀 ] cos 𝛼 sin 𝜀2 1±𝑀
(1.4.10-9)
𝑥0′ = 1
+ (𝑧0 + 𝜎1 ) sin 𝛼 sin 𝜀2 , (−𝑓+
𝑑ℎ
) sin 𝜀2 ∓(ℎ+
𝑑𝑓
) sin 𝜀2
1+𝑀 cos 𝛼 𝑑𝜀1 𝑑𝜀1
𝑑𝜎 𝑑ℎ 𝑦0′ = .}
(−𝑓− 2 sin 𝛼+ ) sin 𝜀2 1±𝑀
𝑑𝜀1 𝑑𝜀1
{ 𝑑𝑓
} For the case of constant transmission ratio and fixed rotating axes
+[𝑀(𝑧0 +𝜎1 ) sin 𝛼−ℎ− ] cos 𝛼 sin 𝜀2
𝑑𝜀1 −𝑓 cos 𝜀2
𝑦0′ = − (𝑧0 + 𝜎1 ) sin 𝛼 cos 𝜀2 , 𝑥0′ = ,
1+𝑀 cos 𝛼 1+𝑀
𝑑𝑓 −𝑓 sin 𝜀2 } (1.4.10-10)
𝑀(𝑧0 +𝜎1 ) sin 𝛼−ℎ−𝑑𝜀
𝑧0′ = sin 𝛼 + (𝑧 + 𝜎1 ) cos 𝛼 + 𝜎2 .
1 𝑦0′ = .
} 1±𝑀
1+𝑀 cos 𝛼
Where: 𝑧0 and 𝜀1 are two independent variables.
𝑱0 = 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋 + 𝐽0𝑧 𝒌, (1.4.4 − 5) 𝑱0 = 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋 (1.4.10-12)
Parameter 𝑱0 and unit normal to pitch surface 𝑑ℎ 𝑑𝜎1 𝑑𝜎2 𝑑ℎ
𝑀 [(𝑓 − ) cos 𝛼 − sin 𝛼] − sin 𝛼 + Where:
𝐽0𝑥 = 𝑑𝑓 , 𝑑𝑓
𝑑𝑀 [(ℎ + 𝑑𝜀1 ) cos 𝛼 + (𝑧0 + 𝜎1 ) sin 𝛼] 𝑑 2 𝑓 𝑑ℎ 𝑑ℎ 𝑑𝑀 (ℎ + 𝑑𝜀1 ) 𝑑 2 𝑓
− + 2 𝐽0𝑥 = ±𝑀 (𝑓 − )+ ∓ + 2,
{ 𝑑𝜀1 1 + 𝑀 cos 𝛼 𝑑𝜀1 } 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1 ± 𝑀 𝑑𝜀1
𝑑𝑓 𝑑𝑓 𝑑 2 ℎ 𝑑ℎ
𝑑𝑓 2
𝑑𝑓 𝑑 ℎ 𝑑𝑀 (𝑓 − )
𝑀 [(𝑧0 + 𝜎1 ) sin 𝛼 + (ℎ + ) cos 𝛼] − + 𝑑𝜀1
𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 𝐽0𝑦 = ±𝑀 (ℎ + )− + 2± ,
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1 ± 𝑀
𝐽0𝑦 = 𝑑𝜎2 𝑑ℎ ,
𝑑 2 𝜎2 𝑑𝑀 ( 𝑑𝜀1 sin 𝛼 + 𝑓 − 𝑑𝜀1 ) 𝑑𝑓 2
{
− 2 sin 𝛼 +
𝑑𝜀1 𝑑𝜀1 1 + 𝑀 cos 𝛼
cos 𝛼
} 𝑑ℎ 𝑑ℎ 𝑑𝑀 (ℎ + 𝑑𝜀1 ) 𝑑 2 𝑓
[±𝑀 (𝑓 − )+ ∓ + 2]
𝑑𝜎2 𝑑ℎ 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1 ± 𝑀 𝑑𝜀1
𝑑𝑀 (− 𝑑𝜀1 sin 𝛼 + 𝑑𝜀1 − 𝑓) 𝑑 2 𝜎2 |𝑱0 | = ± .
sin 𝛼 − cos 𝛼 𝑑ℎ 2
𝑑𝜀1 1 + 𝑀 cos 𝛼 𝑑𝜀12
𝐽0𝑧 = . 𝑑𝑓 𝑑𝑓 𝑑 2 ℎ 𝑑𝑀 (𝑓 − 𝑑𝜀1 )
𝑑𝑓 + [±𝑀 (ℎ + )− + ± ]
(𝑧0 + 𝜎1 ) sin 𝛼 + (ℎ + ) cos 𝛼 𝑑 2
𝜎 𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 𝑑𝜀1 1 ± 𝑀
𝑑𝜀1 1
𝑀2 sin 𝛼 − √ }
{ 1 + 𝑀 cos 𝛼 𝑑𝜀12 }
𝑱 𝐽0𝑥 = ±𝑀𝑓, 𝐽0𝑦 = 0, |𝑱0 | = 𝑀𝑓. (1.4.10-14)
𝑵0𝑝 = ± |𝑱0 | (1.4.4-7) 𝑵0𝑝 = ±𝒊 (1.4.10-15)
0
𝑑𝜀1 [𝑱0 ×(𝝎1 −𝑀𝝎2 )]∙𝝉0 𝑑𝜀1 (1±𝑀)

( ) = (1.4.5-1) ( ) = (1.4.10-16)
𝜏0
𝑑𝑠0 𝜏 |𝑱0 |
𝑑𝑠0 𝜏 |𝑱0 |2
)
0
0
1
0
And
𝑑𝑠
Parameter (𝑑𝜀
𝑑𝜀2 𝑑𝜀1
( ) = 𝑀( ) (1.4.10-18)
0 0
𝑑𝜀1 (1±𝑀)
( ) = (1.4.10-17)
𝑑𝑠0 𝜏
0
𝑀𝑓
𝑑𝑠 𝑑𝜀1 𝑑𝑠 𝑑𝜀
( ) = |𝝉0 + ( ) 𝒗0𝑝 | ( ) = |𝝉0 + ( 1 ) (𝝎1 × 𝑹0𝑝 )|,
Ratio of arc length
𝑑𝑠0 𝜏 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏 𝑑𝑠 0 𝜏0

0 0 0
, 𝑑𝜀
𝝉0 +( 𝑑𝑠1 ) (𝝎1 ×𝑹0𝑝) (1.4.10-20)
𝑑𝜀1 𝑑𝜀 2 0 𝜏0
= √1 + ( ) [2(𝒗0𝑝 ∙ 𝝉0 ) + ( 1 ) |𝒗0𝑝 | ] 𝒕𝜏0 = 𝑑𝑠 .
𝑑𝑠0 𝜏 𝑑𝑠 (1.4.5-2) ( )
0
0 𝜏0
0 } 𝑑𝑠0 𝜏
𝑑𝜀
𝝉0 +( 1 ) 𝒗0𝑝
𝑑𝜀
𝝉0 +( 1 ) 𝒗0𝑝 For the case of constant transmission ratio and fixed rotating axes
0 0 𝑑𝑠
𝒕𝜏0 = 𝑑𝑠 = . ( ) = 0,
( ) 2 𝑑𝑠0 𝜏
𝑑𝑠0 𝜏
0
𝑑𝜀
√1+( 𝑑𝑠1 ) [2(𝒗0𝑝∙𝝉0 )+( 𝑑𝑠1 )
𝑑𝜀
|𝒗0𝑝 | ] 0 } (1.4.10-21)
0 𝜏0 0 𝜏0 } 𝒕𝜏0 = 𝑖𝑛𝑑𝑒𝑓𝑖𝑛𝑖𝑡𝑦.
𝑑𝜀 𝑑𝜀
𝑵0𝑝 +( 1 ) 𝒆 ×𝒗0𝑝 𝑵0𝑝 −( 1 ) 𝑹
𝑑𝑠0 𝑔 0 𝑑𝑠0 𝑔 0𝑝
Unit normal
0 0
𝚷0 = 𝚷0 = (1.4.10-22)
to path of
contact
𝑑𝜀1 𝑑𝜀1
|𝑵0𝑝 +( ) 𝒆 ×𝒗0𝑝 | |𝑵0𝑝 −( ) 𝑹 |
𝑑𝑠0 𝑔 0 𝑑𝑠0 𝑔 0𝑝
0 0
(1.4.6-6) For the case of constant transmission ratio and fixed rotating axes
𝚷0 = 𝒊𝒏𝒅𝒆𝒇𝒊𝒏𝒊𝒕𝒚 (1.4.10-23)
𝑑𝜀1 (1±𝑀) 𝑑𝜀1 𝑑𝜀2
𝐾2𝜏0 = −𝐾1𝜏0 − ( ) [(𝝎1 − 𝑀𝝎2 ) × 𝑵0𝑝 ] ∙ 𝝉0 , 𝐾2𝜏0 = −𝐾1𝜏0 + (1 ± 𝑀) |𝑱0 |
= −𝐾1𝜏0 + ( ) ±( ) ,
𝑑𝑠0 𝜏 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏
0
Curvature relationship
0 0
}(1.4.7-5)
𝐺2𝜏0 = 𝐺1𝜏0 − (
𝑑𝜀1
) [(𝝎1 − 𝑀𝝎2 ) ∙ 𝝉0 ] 𝑂𝑅
𝑑𝑠0 𝜏 1 1 (1±𝑀) 𝑑𝜀1 𝑑𝜀2
0 + = (1 ± 𝑀) |𝑱0 |
=( ) ±( ) .
𝜌10 𝜌20 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏
} 0 0
(1.4.10-24)
(1±𝑀) 𝑑𝜀 𝑑𝜀
𝐾2𝜏0 = −𝐾1𝜏0 + (1 ± 𝑀) = −𝐾1𝜏0 + ( 1 ) ± ( 2 ) ,
|𝑀𝑓| 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏
0 0
𝑂𝑅
1 1 (1±𝑀) 𝑑𝜀1 𝑑𝜀2
+ = (1 ± 𝑀) |𝑀𝑓|
=( ) ±( ) .
𝜌10 𝜌20 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏
0 0 }
(1.4.10-25)
𝐾1𝑒0 = 0, (1 ± 𝑀)𝒌 × 𝑹0𝑝
𝐾1𝑔0 = 𝑑𝑀 𝑑(𝑙𝒑)
±2 [𝑹 + 𝒌 × ]
𝑑 3 𝜎2 𝑑𝜀1 0𝑝 𝑑𝜀1
(𝝎1 − 𝑀𝝎2 ) × 𝑹0𝑝 + 𝝎 (1 ± 𝑀) 𝒈0
𝑑𝜀13 2 𝐾1𝑔0 = ∙ 𝑑 2 (𝑙𝒑)
𝑑 3 (𝑙𝒑)
+2
|𝑱0 | |𝑱0 | ±𝑀𝒌 × +
𝑑 3 𝜎1 𝑑𝜀12 𝑑𝜀13
Curvature of pitch surfaces
−𝑀(𝑹0𝑝 ∙ 𝝎1 )(𝝎1 × 𝝎2 ) − 𝝎
𝑑𝜀13 1 𝑑2 𝑀
2
𝑑 𝜎1 𝑑 2 (𝑙𝒑) ∓ 2 𝒌 × (𝑹0𝑝 − 𝑙𝒑)
{ { 𝑑𝜀1 } }
𝒈0 +𝑀𝝎2 × [ 2 𝝎1 − ]
|(𝝎1 − 𝑀𝝎2 )| 𝑑𝜀 1 𝑑𝜀12 (1.4.10-26)
∙ 𝑑(𝑙𝒑)
|𝑱0 | 𝑑𝜎1 , For the case of fixed rotating axes, i.e., = 𝟎 and ℎ = 0, then
|𝑱0 | 𝝎1 × 𝑹0𝑝 + 𝝎 𝑑𝜀1
𝑑𝑀 𝑑𝜀1 1 𝑑𝑀 𝑑2 𝑀
+2 𝝎 × (1±𝑀)[−(1±𝑀)𝑥0𝑝 𝑁0𝑝𝑥 ±2𝑑𝜀 𝑥0𝑝𝑁0𝑝𝑦 ±
𝑑𝜀2
𝑁0𝑝𝑥(𝑥0𝑝 −𝑓)+2|𝑱0 |]
𝑑𝜀1 2 𝑑(𝑙𝒑) 𝐾1𝑔0 =
1 1
− |𝑱0 |𝟐
[ 𝑑𝜀1 ] (1.4.10-27)
𝑑 3 (𝑙𝒑) 𝑑 2 𝑀 (1+𝑀)𝟐 𝑑𝜀1 𝑑𝜀2
+ + 𝝎 × (𝑹0𝑝 − 𝑙𝒑) 𝐾2𝑔0 = −𝐾1𝑔0 + = −𝐾1𝑔0 + ( ) ±( ) (1.4.10-25)
{ 𝑑𝜀13 𝑑𝜀12 2 } |𝑱0 | 𝑑𝑠0 𝜏
0
𝑑𝑠0 𝜏
0
{ +2(𝒆0 ∙ 𝝎1 ) }
𝑑𝑀 For the case of constant transmission ratio and fixed rotating axes
[ ∙ 𝝎2 ) − |(𝝎1 − 𝑀𝝎2 )|(𝒈0 ∙ 𝝎1 )]
𝑑𝜀1 (𝑵0𝑝 (1 ± 𝑀) 1
𝐺 1𝑒0 = −𝐺1𝑔0 = . 𝐾1𝜏0 = 𝐾1𝑔0 = = ,
|𝑱0 | |𝑀𝑓| 𝜌10
(1.4.8-17) (1 ± 𝑀) 𝟐 (1 ± 𝑀) 1
𝐾2𝑔0 = −𝐾1𝑔0 + = =
|𝑱0 | 𝑓 𝜌20
(1.4.10-29)
𝝉0 ∙ 𝝉 𝑑𝑵1𝑝 𝝉0 ∙ 𝝉′ 𝑑𝑵2𝑝 𝐾 𝐾
( 1𝜏 + 2𝜏 ) (𝝉0 ∙ 𝝉) = 𝐾1𝜏0 +𝐾2𝜏0 ,
[ ( ) + ( ) ] ∙ 𝑵0𝑝 1−𝑠𝑛 𝐾1𝜏 1+𝑠𝑛 𝐾2𝜏
1 − 𝑠𝑛 𝐾1𝜏 𝑑𝑠1 𝜏 1 + 𝑠𝑛 𝐾2𝜏 𝑑𝑠2 𝜏′
Curvature relationship
𝑜𝑟 } (1.4.10-31)
between pitch and
conjugate surface
1 1 1 1
𝑑𝑵0𝑝 𝑑𝑵′ ( + ) (𝝉0 ∙ 𝝉) = 𝜌 +
= − [( ) + ( 0𝑝 ) ] ∙ 𝑵1𝑝 𝜌1 −𝑠𝑛 𝜌2 +𝑠𝑛 10 𝜌20
0 0
(1.4.9-21) For the case of constant transmission ratio and fixed rotating axes
1 1 1 1 1
+ = ( + ) (1.4.10-32)
𝜌1 −𝑠𝑛 𝜌2 +𝑠𝑛 cos ∅ 𝜌10 𝜌20
Equation (1.4.10-31) is called Euler-Savary Equation.

𝑹𝑎 = 𝑥𝑎 𝒊 + 𝑦𝑎 𝒋 + 𝑧𝑎 𝒌
𝑥𝑎 = 𝐸 cos 𝜀1 + 𝐹 sin 𝜀1 , } (1.4.11-3)
𝑦𝑎 = −𝐸 sin 𝜀1 + 𝐹 cos 𝜀1 .
𝑹′𝑎 = 𝑥𝑎′ 𝒊′ + 𝑦𝑎′ 𝒋′ + 𝑧𝑎′ 𝒌′ (1.4.11-4)
Surfaces of screw axes
𝑥𝑎′ = 𝐸 cos 𝜀2 − 𝐹 cos 𝛼 sin 𝜀2 + (𝑧𝑎 + 𝜎1 ) sin 𝛼 sin 𝜀2 − 𝑓 cos 𝜀2 + ℎ cos 𝛼 sin 𝜀2 ,
𝑦𝑎′ = 𝐸 sin 𝜀2 + 𝐹 cos 𝛼 cos 𝜀2 − (𝑧𝑎 + 𝜎1 ) sin 𝛼 cos 𝜀2 − 𝑓 sin 𝜀2 − ℎ cos 𝛼 cos 𝜀2 ,}
𝑧𝑎′ = 𝐹 sin 𝛼 + (𝑧𝑎 + 𝜎1 ) cos 𝛼 − ℎ sin 𝛼 + 𝜎2 .
𝑀𝑓(𝑀 + cos 𝛼) + (1 + 𝑀 cos 𝛼) + 1 𝑀 sin 𝛼 − 2 sin 𝛼
𝐸= ,
(1 + 𝑀 cos 𝛼)2 + 𝑀2 sin2 𝛼
𝑑𝑓
(𝑧𝑎 + 𝜎1 ) sin 𝛼 + 𝑀ℎ cos 𝛼 −
𝑑𝜀1
𝐹= . }
1 + 𝑀 cos 𝛼
~ 81~
Chapter 5
Curvature Parameters within Differential Region of Conjugate
Contact Point between a Pair of Line Conjugate Contact
Surfaces
Curvature parameters of a pair of conjugate surfaces can be calculated by curvature
parameters of a pair of corresponding pitch surfaces through relationship of curvatures
between pitch surfaces and conjugate surfaces, that is, expression (1.4.9-20), and curvature
parameters of pitch surfaces are uniquely decided by conjugate motion parameters, that is,
expressions (1.4.7-6) and (1.4.8-17). However, pitch surfaces exist only when conjugate motions
meet existent condition of pitch surfaces, that is, expression (1.4.2-1). In fact, a conjugate
surface 𝐴 is formed by its corresponding conjugate surface 𝐴̅ under a pair corresponding
conjugate motions (𝜑1 , 𝜑2 ), therefore, the curvature parameters of conjugate surface 𝐴 can
be determined by curvature parameters of its corresponding conjugate surface 𝐴̅ with motion
parameters of conjugate motions (𝜑1 , 𝜑2 ).
1.5.1 Three Basic Differential Quantities and Their Conjugate

Relationships
1 Three Basic Differential Quantities
Assume that a pair of conjugate surfaces (𝐴, 𝐴̅) contact each other along an instantaneous
contact line Γ𝜀1𝑝 at instant 𝜀1𝑝 and point 𝑃 is an any point on the instantaneous contact line
Γ𝜀1𝑝 .
1) The First Basic Differential Quantity 𝑑𝑠1
Because of line contact between a pair of conjugate surfaces (𝐴, 𝐴̅), contact lines cover all
differential regions of point 𝑃 on both conjugate surfaces 𝐴 and 𝐴̅ respectively. Λ 𝜀1𝑝 +𝑑𝜀1𝑝 is
contact line on surface 𝐴 corresponding to instant 𝜀1𝑝 + 𝑑𝜀1𝑝 . Point 𝑃′ is any point on contact
̅̅̅̅̅′ from point 𝑃 to point 𝑃′ is
line Λ 𝜀 +𝑑𝜀 . vector 𝑃𝑃
1𝑝 1𝑝
̅̅̅̅̅
𝑃𝑃′ = 𝑑𝑠1 𝝉 (1.5.1-1)
As 𝑑𝑠1 → 0, 𝝉 becomes unit tangent vector to surface 𝐴 at point 𝑃 as shown in figure 1.5.1-1.
2) The Second Basic Differential Quantity 𝑑𝑠2
~ 82 ~
̅ 𝜀 +𝑑𝜀 is a contact line on surface 𝐴̅ corresponding to Λ 𝜀 +𝑑𝜀 on surface 𝐴 which will
Λ 1𝑝 1𝑝 1𝑝 1𝑝
become an instantaneous contact line with Λ 𝜀 +𝑑𝜀 at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 . Point 𝑃̅′ is a point
1𝑝 1𝑝
̅ 𝜀 +𝑑𝜀 corresponding to point 𝑃′ on contact line Λ 𝜀 +𝑑𝜀 . Vector ̅̅̅̅̅

on contact line Λ 𝑃𝑃̅′ from
1𝑝 1𝑝 1𝑝 1𝑝
point 𝑃 to point 𝑃̅′ is
̅ 𝜀 +𝑑𝜀
Λ contact line on surface 𝐴̅ corresponding to instant 𝜀1𝑝 + 𝑑𝜀1𝑝
1𝑝 1𝑝
Γ𝜀1𝑝 +𝑑𝜀1𝑝 (Instantaneous contact line at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 )
Γ𝜀1 (Instantaneous contact line at instant 𝜀1𝑝 )
𝑃"
𝒌 𝑑𝑠𝒕 𝑵1𝑝
𝑵1𝑝′
𝑃̅′ 𝑑𝑠2 𝝉′ 𝑃′
𝐴 𝑃 𝑑𝑠1 𝝉
𝐴̅
𝑹1𝑝 𝑵2𝑃̅̅̅′ 𝑵2𝑝
𝑂 Λ 𝜀1𝑝 +𝑑𝜀1𝑝 contact line on surface 𝐴 corresponding to instant 𝜀1𝑝 + 𝑑𝜀1𝑝
𝑹2𝑝 𝛼 𝒌′
(𝑙𝒑)
𝑂′
𝒊(= 𝒊′ ) 𝒋′
Figure 1.5.1-1 Three Basic Differential Quantities
~ 83 ~
̅̅̅̅̅
𝑃𝑃̅′ = 𝑑𝑠2 𝝉′ (1.5.1-2)
As 𝑑𝑠2 → 0, 𝝉′ becomes unit tangent vector to surface 𝐴̅ at point 𝑃 as shown in figure 1.5.1-1.
3) The Third Basic Differential Quantity 𝑑𝑠
Point 𝑃 is conjugate contact point at instant 𝜀1𝑝 , therefore, point 𝑃 is on path of contact 𝐵.
Both point 𝑃′ and point 𝑃̅′ will contact each other at point 𝑃" on instantaneous contact line
Γ𝜀1𝑝 +𝑑𝜀1𝑝at instant 𝜀 + 𝑑𝜀 , therefore, point 𝑃" is on path of contact 𝐵. Vector ̅̅̅̅̅
1𝑝 1𝑝 𝑃𝑃" from
"
point 𝑃 to point 𝑃 is
̅̅̅̅̅
𝑃𝑃" = 𝑑𝑠𝒕 (1.5.1-3)
As 𝑑𝑠 → 0, 𝒕 becomes unit tangent vector to path of contact 𝐵 at point 𝑃 as shown in figure

1.5.1-1.
2 Conjugate Relationship among Three Differential Quantities.

Position vector of point 𝑃′ is as follow
̅̅̅̅̅
𝑂𝑃′ = 𝑹1𝑝 + 𝑑𝑠1 𝝉 (1.5.1-4)
Position vector of point 𝑃̅′ is
̅̅̅̅̅
𝑂𝑃̅′ = 𝑹1𝑝 + 𝑑𝑠2 𝝉′ = 𝑹2𝑝 + (𝑙𝒑) + 𝑑𝑠2 𝝉′ (1.5.1-5)
Position vector of point 𝑃" is
̅̅̅̅̅
𝑂𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕 (1.5.1-6)
1) The First Conjugate Relationship
Because point 𝑃′ reaches conjugate contact position ̅̅̅̅̅

𝑂𝑃" at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 , thus,
̅̅̅̅̅
𝑂𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕 = (𝑑𝜀1𝑝 𝝎1 ) ⊗ (𝑹1𝑝 + 𝑑𝑠1 𝝉 ) + 𝑑𝜎1 𝒌
Expression above is expanded and simplified by application of expression (1.1.1-7) and

neglecting second or higher order infinitesimal as follow
̅̅̅̅̅
𝑂𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕 = 𝑹1𝑝 + 𝑑𝑠1 𝝉 + (𝑑𝜀1𝑝 𝝎1 ) × 𝑹1𝑝 + 𝑑𝜎1 𝒌 (1.5.1-7)
The first relationship is resulted from expression (1.5.1-7) as shown in figure 1.5.1-2
~ 84 ~
𝑑𝑠𝒕 = 𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗𝑝 (1.5.1-8)
𝑑𝑹1𝑝 𝑑𝜎
Where: 𝒗𝑝 is defined in expression (1.3.5-1), that is, 𝒗𝑝 = = 𝝎1 × 𝑹1𝑝 + 𝑑𝜀 1 𝝎1 .
𝑑𝜀1 1
2) The Second Conjugate Relationship
Likewise, point 𝑃̅′ will also reach conjugate contact position ̅̅̅̅̅
𝑂𝑃" at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 , that is,
̅̅̅̅̅
𝑂𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕 = (𝑀𝑑𝜀1𝑝 𝝎2 ) ⊗ (𝑹2𝑝 + 𝑑𝑠2 𝝉′ ) + 𝑑𝜎2 𝝎2 + (𝑙𝒑) + 𝑑(𝑙𝒑)
Expression above is expanded and simplified by application of expression (1.1.1-7) and

neglecting second or higher order infinitesimal as follow
̅̅̅̅̅
𝑂𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕 = 𝑹2𝑝 + 𝑑𝑠2 𝝉′ + (𝑀𝑑𝜀1𝑝 𝝎2 ) × 𝑹2𝑝 + 𝑑𝜎2 𝝎2 + (𝑙𝒑) + 𝑑(𝑙𝒑) (1.5.1-9)
With application of expressions (1.1.1-7), (1.3.5-2) and neglecting second or higher order
infinitesimal, the expression (1.5.1-9) can be reduced as
𝑑𝑠𝒕 = 𝑑𝑠2 𝝉′ + 𝑑𝜀1𝑝 𝒗′𝒑 (1.5.1-10)
Where: 𝒗′𝒑 is defined in expression (1.3.5-2), that is, 𝒗′𝒑 = 𝑀𝝎2 × 𝑹2𝑝 + 𝑑𝜀 2 𝝎2 + .
1 𝑑𝜀1
With help of expression (1.3.5-3), combination of expressions (1.5.1-8) and (1.5.1-10) generates
the second relationship as shown in figure 1.5.1-2
𝑑𝑠2 𝝉′ = 𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗12

𝑝 (1.5.1-11)
3) The Third Conjugate Relationship
Let 𝑵1𝑝 and 𝑵2𝑝 be unit normal vectors to conjugate surfaces 𝐴 and 𝐴̅ at point 𝑃 at instant 𝜀1𝑝
respectively. Due to point 𝑃 being conjugate contact point at instant 𝜀1𝑝 , thus, 𝑵1𝑝 = −𝑵2𝑝 .
Unit normal 𝑵1𝑝′ to surface 𝐴 at point 𝑃′ of instant 𝜀1𝑝 is expressed by application of

expression (1.2.1-6) as follow:
𝑑𝑵1𝑝
𝑵1𝑝′ = 𝑵1𝑝 + ( ) 𝑑𝑠1 = 𝑵1𝑝 + 𝛀 1𝜏 × 𝑵1𝑝 𝑑𝑠1
𝑑𝑠 𝝉 (1.5.1-12)
= 𝑵1𝑝 + [𝐾1𝜏 𝝉 + 𝐺1𝜏 (𝑵1𝑝 × 𝝉) ]𝑑𝑠1
Likewise, unit normal 𝑵2𝑝̅̅̅′ to surface 𝐴̅ at point 𝑃̅′ of instant 𝜀1𝑝 is
~ 85 ~
𝑑𝑵2𝑝
𝑵2𝑝̅̅̅′ = 𝑵2𝑝 + ( ) 𝑑𝑠2 = 𝑵2𝑝 + 𝛀 2𝜏 × 𝑵2𝑝 𝑑𝑠2
𝑑𝑠 𝜏′ (1.5.1-13)
= 𝑵2𝑝 + [𝐾2𝜏 𝝉 + 𝐺2𝜏′ (𝑵2𝑝 × 𝝉′ )] 𝑑𝑠2
′
′
Because points 𝑃′ and 𝑃̅′ are a pair of conjugate points on a pair of conjugate surfaces (𝐴, 𝐴̅) at
instant 𝜀1𝑝 respectively and will become a pair of conjugate contact points at instant 𝜀1𝑝 +
𝑑𝜀1𝑝 , application of requirement of conjugate contact, i.e., expression (1.3.7-2), leads
(𝑑𝜀1𝑝 𝝎1 ) ⊗ 𝑵1𝑝′ = −(𝑀𝑑𝜀1𝑝 𝝎2 ) ⊗ 𝑵2𝑝̅̅̅′ (1.5.1-14)
𝑃"
𝑑𝜀1𝑝 𝒗′𝒑
𝑑𝑠𝒕
𝑃̅′ 𝑑𝜀1𝑝 𝒗12

𝑝 𝑑𝜀1𝑝 𝒗𝑝
𝑑𝑠2 𝝉′ 𝑑𝑠1 𝝉 𝑃′ 𝑂" = (𝑙𝒑) + 𝑑(𝑙𝒑)
𝑹2𝑝 𝑑(𝑙𝒑)
𝑹1𝑝 𝑂′
Common tangent plane at point 𝑃 (𝑙𝒑)
Figure 1.5.1-2 Relationship among Three Basic Differential Quantities
The third conjugate relationship is generated by substitution of expressions (1.5.1-12) and

(1.5.1-13) into (1.5.1-14) and neglecting second or higher order of infinitesimal as follow:
[𝐾2𝜏′ 𝝉′ − 𝐺2𝜏′ (𝑵1𝑝 × 𝝉′ )] 𝑑𝑠2

(1.5.1-15)
= −[𝐾1𝜏 𝝉 + 𝐺1𝜏 (𝑵1𝑝 × 𝝉) ]𝑑𝑠1 − 𝑑𝜀1𝑝 (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝
Combination of expressions (1.5.1-8), (1.5.1-11) and (1.5.1-15) as a whole is called conjugate
~86 ~
relationship of three basic differential quantities within differential region of conjugate contact
point as shown in figure 1.5.1-2
𝑇ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝:

𝑑𝑠 𝑑𝜀1𝑝
𝑑𝑠𝒕 = 𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗𝑝 𝑂𝑅 (𝑑𝑠 ) 𝒕 = 𝝉 + ( 𝑑𝑠 ) 𝒗𝑝
1 𝜏 1 𝜏
𝑇ℎ𝑒 𝑠𝑒𝑐𝑜𝑛𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝:
𝑝 𝑂𝑅 (𝑑𝑠2) 𝝉′ = 𝝉 + ( 𝑑𝑠 ) 𝒗12
𝑝
1 𝜏 1 𝜏
𝑇ℎ𝑒 𝑡ℎ𝑖𝑟𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝: (1.5.1-16)
[𝐾2𝜏′ 𝝉′ − 𝐺2𝜏′ (𝑵1𝑝 × 𝝉′ )] 𝑑𝑠2
= −[𝐾1𝜏 𝝉 + 𝐺1𝜏 (𝑵1𝑝 × 𝝉) ]𝑑𝑠1 − 𝑑𝜀1𝑝 (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝
𝑂𝑅
𝑑𝑠2 𝑑𝜀1𝑝
𝛀 2𝜏 × 𝑵2𝑝 𝑑𝑠2 (𝑑𝑠 ) = −𝛀 1𝜏 × 𝑵1𝑝 − ( 𝑑𝑠 ) (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝
1 𝜏 1 𝜏 }
1.5.2 Rate of Rotating Angular Increment

Given curvature parameters of the first conjugate surface 𝐴 and parameters of conjugate
motion (𝜑1 , 𝜑2 ), curvature parameters of the second conjugate surface 𝐴̅ can be calculated by
application of conjugate relationship of three basic differential quantities, i.e., expression
𝑑𝜀1𝑝 𝑑𝜀1𝑝
(1.5.1-16) when ( 𝑑𝑠 ) is able to be calculated. ( 𝑑𝑠 ) is called increment rate of rotating
1 𝜏 1 𝜏
angle with respect to arc-length.
1 Rate of Rotating Angular Increment per Unit Arc-Length

1) Definition
𝑑𝜀1𝑝
Ratio ( 𝑑𝑠 ) of increment of rotating angle 𝑑𝜀1𝑝 with respect to corresponding arc-length 𝑑𝑠1
1 𝜏
in tangent direction 𝝉 to the first conjugate surface 𝐴 at point 𝑃 is defined as rate of rotating
angular increment.
𝑑𝜀1𝑝
2) Calculation of ( )
𝑑𝑠1 𝜏
Point 𝑃′ on the first conjugate surface 𝐴 reaches conjugate contact position ̅̅̅̅̅
𝑂𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕
at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 . Velocity of point 𝑃′ at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 is decided by application of
expression (1.3.5-1), that is,
~ 87 ~
𝒗𝑝 + 𝑑𝒗𝑝 = 𝝎1 × (𝑹1𝑝 + 𝑑𝑠𝒕) + ( 𝑑𝜀 1 + 𝑑𝜀1𝑝 ) 𝝎1
1 𝑑𝜀12
Substitution of expression (1.5.1-8) into expression above leads
𝒗𝑝 + 𝑑𝒗𝑝 = 𝝎1 × (𝑹1𝑝 + 𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗𝑝 ) + (𝑑𝜀 1 + 𝑑𝜀1𝑝 ) 𝝎1
1 𝑑𝜀12
𝑑2 𝜎1
= 𝒗𝑝 + 𝝎1 × (𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗𝑝 ) + 𝑑𝜀1𝑝 𝝎1 (1.5.2-1)
𝑑𝜀12
𝑑2 𝜎1
= 𝒗𝑝 + 𝝎1 × (𝑑𝑠1 𝝉) + 𝑑𝜀1𝑝 (𝝎1 × 𝒗𝑝 + 𝝎1 )
𝑑𝜀12
Likewise, point 𝑃̅′ on the second conjugate surface 𝐴̅ reaches conjugate contact position
̅̅̅̅̅̅
𝑂" 𝑃" = 𝑹1𝑝 + 𝑑𝑠𝒕 − (𝑙𝒑) − 𝑑(𝑙𝒑) at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 . Velocity of point 𝑃̅′ at instant 𝜀1𝑝 +
𝑑𝜀1𝑝 is decided by application of expression (1.3.5-2), that is,
𝒗′𝒑 + 𝑑𝒗′𝒑
𝑑𝜎2 𝑑2 𝜎2 𝑑(𝑙𝒑) 𝑑 2 (𝑙𝒑)
= (𝑀 + 𝑑𝑀)𝝎2 × [𝑹1𝑝 + 𝑑𝑠𝒕 − (𝑙𝒑) − 𝑑(𝑙𝒑)] + ( + 𝑑𝜀 ) 𝝎2 + + 𝑑𝜀1𝑝
𝑑𝜀1 𝑑𝜀12 1𝑝 𝑑𝜀1 𝑑𝜀12
𝑑𝜎2 𝑑 2 𝜎2 𝑑(𝑙𝒑) 𝑑 2 (𝑙𝒑)
= (𝑀 + 𝑑𝑀)𝝎2 × [𝑹2𝑝 + 𝑑𝑠𝒕 − 𝑑(𝑙𝒑)] + ( + 𝑑𝜀 ) 𝝎 + + 𝑑𝜀1𝑝
𝑑𝜀12 1𝑝 2
Where: 𝑹2𝑝 = 𝑹1𝑝 − (𝑙𝒑).
By neglecting second or higher order infinitesimal, substitution of expression (1.5.1-8) into

expression above gives
𝒗′𝒑 + 𝑀𝝎2 × (𝑑𝑠1 𝝉)

𝒗′𝒑 + 𝑑𝒗′𝒑 ={ 𝑑(𝑙𝒑) 𝑑𝑀 𝑑2 𝜎 𝑑2 (𝑙𝒑) } (1.5.2-2)
+𝑑𝜀1𝑝 [𝑀𝝎2 × 𝒗𝑝 − 𝑀𝝎2 × 𝑑𝜀 + 𝑑𝜀 𝝎2 × 𝑹2𝑝 + 𝑑𝜀22 𝝎2 + 𝑑𝜀2 ]
1 1 1 1
Where: 𝒗′𝒑 = 𝑀𝝎2 × 𝑹2𝑝 + 𝑑𝜀 2 𝝎2 + .
1 𝑑𝜀1
Relative velocity of the first conjugate surface 𝐴 with respect to the second conjugate surface 𝐴̅
at contact point 𝑃" of instant 𝜀1𝑝 + 𝑑𝜀1𝑝 is
𝒗12 12 ′ ′
𝑝 + 𝑑𝒗𝑝 = (𝒗𝑝 + 𝑑𝒗𝑝 ) − (𝒗𝒑 + 𝑑𝒗𝒑 )
𝑑(𝑙𝒑)
(𝝎1 − 𝑀𝝎2 ) × 𝒗𝑝 + 𝑀𝝎2 × (1.5.2-3)
𝑑𝜀1
= 𝒗12
𝑝 + (𝝎1 − 𝑀𝝎2 ) × (𝑑𝑠1 𝝉) + 𝑑𝜀1𝑝 [ 𝑑𝑀 𝑑2 𝜎1 𝑑2 𝜎2 𝑑2 (𝑙𝒑)
]
− 𝑑𝜀 𝝎2 × 𝑹2𝑝 + 𝝎1 − 𝝎2 −
1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12
~88 ~
then
𝑑(𝑙𝒑)
(𝝎1 − 𝑀𝝎2 ) × 𝒗𝑝 + 𝑀𝝎2 ×
𝑑𝜀1
𝑑𝒗12
𝑝 = (𝝎1 − 𝑀𝝎2 ) × (𝑑𝑠1 𝝉) + 𝑑𝜀1𝑝 [ 𝑑𝑀 𝑑2 𝜎1 𝑑2 𝜎2 𝑑2 (𝑙𝒑)
] (1.5.2-4)
− 𝑑𝜀 𝝎2 × 𝑹2𝑝 + 𝝎1 − 𝝎2 −
1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12
Unit normal 𝑵1𝑝′ to surface 𝐴 at point 𝑃′ of instant 𝜀1𝑝 defined in (1.5.1-12) reaches conjugate
contact position 𝑵1𝑝′′ at instant 𝜀1𝑝 + 𝑑𝜀1𝑝 as follow:
𝑑𝑵1𝑝
𝑵1𝑝′′ = (𝑑𝜀1𝑝 𝝎1 ) ⊗ [𝑵1𝑝 + ( ) 𝑑𝑠1 ]
𝑑𝑠 𝝉
By neglecting second or higher order infinitesimal, expression above is simplified as fellow:

𝑑𝑵1𝑝
𝑵1𝑝′′ = 𝑵1𝑝 + ( ) 𝑑𝑠1 + (𝑑𝜀1𝑝 𝝎1 ) × 𝑵1𝑝 (1.5.2-5)
𝑑𝑠 𝝉
Application of requirement for conjugate contact, i.e., expression (1.3.7-3), gives

𝑑𝑵1𝑝
(𝒗12 12 12 12
𝑝 + 𝑑𝒗𝑝 ) ∙ 𝑵1𝑝′′ = (𝒗𝑝 + 𝑑𝒗𝑝 ) ∙ [𝑵1𝑝 + ( ) 𝑑𝑠1 + (𝑑𝜀1𝑝 𝝎1 ) × 𝑵1𝑝 ] = 0
𝑑𝑠 𝝉
With aid of 𝒗12𝑝 ∙ 𝑵1𝑝 = 0 and neglecting second or higher order infinitesimal, expression above
is simplified as fellow:
𝑑𝑵1𝑝 𝑑𝜀1𝑝
𝑑𝒗12 12
𝑝 ∙ 𝑵1𝑝 + 𝑑𝑠1 𝒗𝑝 ∙ [( ) + ( 𝑑𝑠 ) 𝝎1 × 𝑵1𝑝 ] = 0
𝑑𝑠 𝝉 1 𝜏
With help of expression (1.5.2-4), expression above is updated as follow
𝑑(𝑙𝒑)
(𝝎1 − 𝑀𝝎2 ) × 𝒗𝑝 + 𝑀𝝎2 ×
𝑑𝜀1𝑝 𝑑𝜀1
(𝝎1 − 𝑀𝝎2 ) × 𝝉 + ( ) 2 2 ∙ 𝑵1𝑝
𝑑𝑠1 𝜏 𝑑𝑀 𝑑 𝜎1 𝑑 𝜎2 𝑑 2 (𝑙𝒑)
− 𝝎2 × 𝑹2𝑝 + 𝝎1 − 𝝎2 −
{ [ 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12 ]}
𝑑𝑵1𝑝 𝑑𝜀1𝑝
+𝒗12
𝑝 ∙ [( ) +( ) 𝝎 × 𝑵1𝑝 ]
{ 𝑑𝑠 𝜏 𝑑𝑠1 𝜏 1 }
(𝝎1 − 𝑀𝝎2 ) × 𝝉
𝑑(𝑙𝒑) 𝑑 2 𝜎1
𝝎1 × 𝒗′𝑝 − 𝑀𝝎2 × [𝒗𝑝 − ]+ 𝝎 𝑑𝑵1𝑝
= 𝑑𝜀1𝑝 𝑑𝜀1 𝑑𝜀12 1 ∙ 𝑵1𝑝 + 𝒗12 𝑝 ∙( ) =0
+( ) 2 2 𝑑𝑠 𝜏
𝑑𝑠1 𝜏 𝑑𝑀 𝑑 𝜎2 𝑑 (𝑙𝒑)
− 𝝎2 × 𝑹2𝑝 − 2 𝝎2 −
{ [ 𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 ]}
89
𝑑𝜀1𝑝
( 𝑑𝑠 ) is obtained by solving equation above as follow:
1 𝜏
𝑑𝑵1𝑝
𝑑𝜀1𝑝 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙𝝉+𝒗𝟏𝟐
𝒑 ∙( )
𝑑𝑠 𝜏
( 𝑑𝑠 ) = (1.5.2-6)
1 𝜏 𝑱𝑝 ∙𝑵1𝑝
Where:
𝑑𝑀 𝑑2 𝜎1 𝑑2 𝜎2 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)
𝑱𝑝 = 𝑑𝜀 𝝎2 × 𝑹2𝑝 − 𝝎1 + 𝝎2 + − 𝝎1 × 𝒗′𝑝 + 𝑀𝝎2 × [𝒗𝑝 − ]
1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1
𝝎2 × (𝑹1𝑝 − 𝑙𝒑) − 𝝎1 + 𝝎2 + + 𝑀𝝎2 × [𝒗𝑝 − ]
𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 (1.5.2-7)
={ 𝑑𝜎2 𝑑(𝑙𝒑)
}
−𝝎1 × [𝑀𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + 𝑑𝜀 𝝎2 + ]
1 𝑑𝜀1
= 𝐽𝑝1 𝒊 + 𝐽𝑝2 𝒋 + 𝐽𝑝3 𝒌
Here:
𝑑ℎ 𝑑𝜎 𝑑ℎ 𝑑𝜎
𝑀 [(𝑓 − 𝑑𝜀 ) cos 𝛼 − 𝑑𝜀 1 sin 𝛼] + 𝑑𝜀 − 𝑑𝜀 2 sin 𝛼
1 1 1 1
𝐽𝑝1 = { 𝑑2 𝑓 𝑑𝑀
},
+ 𝑑𝜀2 + 𝑑𝜀 [(𝑦𝑝 − ℎ) cos 𝛼 − 𝑧𝑝 sin 𝛼]
1 1
𝑑𝑓 𝑑𝑀
𝑀 [(ℎ + 𝑑𝜀 ) cos 𝛼 + 𝑧𝑝 sin 𝛼] − 𝑑𝜀 (𝑥𝑝 − 𝑓) cos 𝛼
1 1
𝐽𝑝2 ={ 𝑑𝑓 𝑑2 𝜎2 𝑑2 ℎ
}
− 𝑑𝜀 − 𝑑𝜀2 sin 𝛼 + 𝑑𝜀2
1 1 1
𝑑𝑓 𝑑𝑀 𝑑2 𝜎1 𝑑2 𝜎2
𝐽𝑝3 = −𝑀 (𝑦𝑝 + 𝑑𝜀 ) sin 𝛼 + 𝑑𝜀 (𝑥𝑝 − 𝑓) sin 𝛼 − − cos 𝛼 .}
1 1 𝑑𝜀12 𝑑𝜀12
With help of expression (1.2.1-28), expression (1.5.2-6) is modified as follow:

𝑑𝑵1𝑝
𝑑𝜀1𝑝 |𝒗𝟏𝟐
𝒑 |( ) −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]
𝑑𝑠 𝜆
( 𝑑𝑠 ) = ∙𝝉
𝒗𝟏𝟐
𝒑
Where: 𝝀 = |𝒗𝟏𝟐| .
𝒑
𝑑𝑵
Due to expression (1.2.1-10), i.e., ( 𝑑𝑠 ) = 𝛀𝜏 × 𝑵, expression above is further updated as
𝜏
follow:
𝒑 |𝛀𝜆 ×𝑵1𝑝 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]
( 𝑑𝑠 ) = ∙𝝉 (1.5.2-8)
2 Some Special Tangent Directions
~ 90 ~
𝒗12
𝑝
1) Direction of Linear Velocity of Relative Motion |𝒗12 |
𝑝
Because point 𝑃 is a conjugate contact point at instant 𝜀1𝑝 , the relative linear velocity 𝒗12
𝑝 at
point 𝑃 on the first conjugate surface 𝐴 with respect to the second conjugate surface 𝐴̅ is
perpendicular to common unit normal 𝑵1𝑝 to both surfaces (𝐴, 𝐴̅) at point 𝑃, that is, 𝑵1𝑝 ∙
𝒗12
𝑝 = 0.
𝒗12
𝒑
Substitution of 𝝉 = |𝒗12| into the second conjugate relationship in expression (1.5.1-16) gives
𝒑
𝒗12
𝒑
𝝉′ = 𝝉 = |𝒗12| ,
𝒑
} (1.5.2-9)
(𝑑𝑠 ) = 1 + |𝒗12
𝑝 | ( 𝑑𝑠 ) .
1 𝜆 1 𝜆
2) Direction with Maximum Increment Rate of Rotating Angle 𝒈
Let 𝑼𝑝 be 𝑼𝑝 = |𝒗𝟏𝟐
𝒑 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ]. Due to 𝑼𝑝 ⊥ 𝑵1𝑝 , thus, 𝑼𝑝 is a
𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑
tangent vector. Let 𝑼𝑝 be resolved in directions |𝒗𝟏𝟐 | and 𝑵1𝑝 × |𝒗𝟏𝟐 | as follow:
𝒑 𝒑
𝒑 𝒑 𝒗𝟏𝟐 𝒗𝟏𝟐 𝒑 𝒑 𝒗𝟏𝟐 𝒗𝟏𝟐

𝑼𝑝 = (𝑼𝑝 ∙ |𝒗𝟏𝟐 |) |𝒗𝟏𝟐 | + [𝑼𝑝 ∙ (𝑵1𝑝 × |𝒗𝟏𝟐 |) (𝑵1𝑝 × |𝒗𝟏𝟐 |)]
𝒑 𝒑 𝒑 𝒑
(1.5.2-10)
𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑
= 𝐷𝑝 |𝒗𝟏𝟐 | + 𝐸𝑝 (𝑵1𝑝 × |𝒗𝟏𝟐|)
𝒑 𝒑
Where:
𝒗12
𝑝
𝐷𝑝 = {|𝒗12
𝑝 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ]} ∙ |𝒗12 |
𝑝
𝒗𝟏𝟐
𝒑
= 𝐾1𝜆 |𝒗12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ |𝒗𝟏𝟐
,
𝒑 |
(1.5.2-11)
𝒗12
𝑝
𝐸𝑝 = {|𝒗12
𝑝 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ]} ∙ (𝑵1𝑝 × |𝒗12|)
𝑝
𝒗12
𝑝
= |𝒗12
𝑝 |𝐺1𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12 | .
𝑝 }
𝑑𝜀1𝑝
Then, ( 𝑑𝑠 ) is expressed in the form as follow:
1 𝜏
𝑑𝜀1𝑝 𝑼𝑝
( 𝑑𝑠 ) = 𝑱 ∙𝝉 (1.5.2-12)
1 𝜏 𝑝 ∙𝑵1𝑝
~ 91~
𝑼𝑝
When 𝝉 = 𝒈 = |𝑼 |, expression (1.5.2-8) becomes
𝑝
𝒑 |𝛀𝜆 ×𝑵1𝑝 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ] 𝑼𝑝 𝑼𝑝 |𝑼𝑝 |
( 𝑑𝑠 ) = ∙𝝉=𝑱 ∙ |𝑼 | = 𝑱 =𝑔 (1.5.2-13)
1 𝑔 𝑱𝑝 ∙𝑵1𝑝 𝑝 ∙𝑵1𝑝 𝑝 𝑝 ∙𝑵1𝑝
𝑑𝜀1𝑝 𝑼𝑝 𝑼𝑝
That is, ( 𝑑𝑠 ) = 𝑱 ∙ 𝝉 reaches maximum value when 𝝉 = 𝒈 = |𝑼 |. Therefore, 𝒈 is defined
1 𝜏 𝑝 ∙𝑵1𝑝 𝑝
as direction of maximum increment rate of rotating angle.
𝑼𝑝 𝐷𝑝 𝒗12
𝑝 𝐸𝑝 𝒗12
𝒈 = |𝑼 | = + (𝑵1𝑝 × |𝒗𝑝12|) (1.5.2-14)
|𝒗12 |
𝑝 √𝐷𝑝2 +𝐸𝑝2 𝑝 √𝐷𝑝2 +𝐸𝑝2 𝑝
𝒗𝟏𝟐
𝒑
𝒈 is also expressed through rotating |𝒗𝟏𝟐 | by an angle 𝜃𝜆𝑔 about 𝑵1𝑝 as follow:
𝒑
𝒑 𝒑 𝒗𝟏𝟐 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐

𝒈 = (𝜃𝜆𝑔 𝑵1𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑔 + (𝑵1𝑝 × |𝒗𝟏𝟐 |) sin 𝜃𝜆𝑔 (1.5.2-15)
𝒑 𝒑 𝒑
Where:
𝐸𝑝
sin 𝜃𝜆𝑔 = ,
√𝐷𝑝2 +𝐸𝑝2
𝐷𝑝
cos 𝜃𝜆𝑔 = .
}
3) Direction of Instantaneous Contact Line 𝒆
when 𝝉 = 𝒆 = 𝒈 × 𝑵1𝑝 , expression (1.5.2-8) becomes
𝒑 |𝛀𝜆 ×𝑵1𝑝 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ] 𝑼𝑝 𝑼𝑝
( 𝑑𝑠 ) = ∙𝝉=𝑱 ∙ (|𝑼 | × 𝑵1𝑝 ) = 0
1 𝜏 𝑱𝑝 ∙𝑵1𝑝 𝑝 ∙𝑵1𝑝 𝑝
That is, 𝒆 = 𝒈 × 𝑵1𝑝 is direction of instantaneous contact line. Then,
𝑼𝑝 𝐷𝑝 𝒗12 𝐸𝑝 𝒗12
(𝑵1𝑝 × |𝒗𝑝12 |) + 𝑝
𝒆 = 𝒈 × 𝑵1𝑝 = |𝑼 | × 𝑵1𝑝 = − |𝒗12
(1.5.2-16)
𝑝 √𝐷𝑝2 +𝐸𝑝2 𝑝 √𝐷𝑝2 +𝐸𝑝2 𝑝 |
𝒗𝟏𝟐
𝒑
𝒆 is also expressed through rotating |𝒗𝟏𝟐 | by an angle 𝜃𝜆𝑒 about 𝑵1𝑝 as follow:
𝒑
𝒑 𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐
𝒆 = (𝜃𝜆𝑒 𝑵1𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑒 + (𝑵1𝑝 × |𝒗𝟏𝟐|) sin 𝜃𝜆𝑒 (1.5.2-17)
𝒑 𝒑 𝒑
~92 ~
Where:
𝐷𝑝
sin 𝜃𝜆𝑒 = − ,
𝐸𝑝
cos 𝜃𝜆𝑒 = .
}
1.5.3 Calculation of Relative Curvature

1 In Direction of 𝒆
Because 𝒆 is direction of instantaneous contact line, thus,
̅ 𝑒 = 0,
𝛀
̅𝑒 = 0, }
𝐾 (1.5.3-1)
𝐺𝑒̅ = 0.
𝒗𝟏𝟐
𝒑
2 In Direction of 𝝀 =
|𝒗𝟏𝟐
𝒑 |
𝒗𝟏𝟐
𝒑
When 𝝉 = 𝝀 = |𝒗𝟏𝟐 |, expression (1.5.2-12) becomes
𝒑
𝑑𝜀1𝑝 𝑼𝑝 𝑼𝑝 𝒗𝟏𝟐
𝒑 𝐷𝑝
( 𝑑𝑠 ) = 𝑱 ∙𝝉=𝑱 ∙ |𝒗𝟏𝟐 | = 𝑱 (1.5.3-2)
1 𝜆 𝑝 ∙𝑵1𝑝 𝑝 ∙𝑵1𝑝 𝒑 𝑝 ∙𝑵1𝑝
With help of expression (1.5.2-9), application of the third conjugate relationship in expression
(1.5.1-16) gives
𝑑𝑠 1𝑝 𝑑𝜀
𝛀 2𝜆 × 𝑵1𝑝 (𝑑𝑠2) = 𝛀 1𝜆 × 𝑵1𝑝 + ( 𝑑𝑠 ) (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝
1 𝜆 1 𝜆
̅ 𝜏 = 𝛀1𝝉 − 𝛀2𝜏 , expression above is modified as

Due to expression (1.2.1-34), i.e., 𝛀
̅ 𝜆 × 𝑵1𝑝 (𝑑𝑠2 ) = 𝛀 1𝜆 × 𝑵1𝑝 [(𝑑𝑠2 ) − 1] − (𝑑𝜀1𝑝 ) (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝

𝛀 𝑑𝑠 1 𝜆 𝑑𝑠 𝑑𝑠 1 𝜆 1 𝜆
Substitution of expression (1.5.2-9) into expression above results in

12
|−(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]𝐷𝑝
̅ 𝜆 × 𝑵1𝑝 = [(𝛀 1𝜆 ×𝑵1𝑝 )|𝒗𝒑 12
𝛀 =𝐷
𝐷𝑝 𝑼𝑝
12 (1.5.3-3)
𝐷 |𝒗 |+𝑱 ∙𝑵 𝑝 𝒑 𝑝 1𝑝 𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝
~ 93 ~
̅ 𝜆 × 𝑵1𝑝 ) = 𝐷𝑝 (𝑵
̅ 𝜆 = 𝑵1𝑝 × (𝛀
𝛀
1𝑝 ×𝑼𝑝 )
,
𝐷 |𝒗12 |+𝑱 ∙𝑵𝑝 𝒑 𝑝 1𝑝
𝐷𝑝2
̅𝜆 =
𝐾 12 , (1.5.3-4)
𝐷 𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝
𝐷𝑝 𝐸𝑝
𝐺𝜆̅ = 𝐷 12 .
𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝 }
3 In Direction of 𝒈
Due to expression (1.2.1-40), that is
̅𝑡 = 𝛀
𝛀 ̅ 𝑢 (𝒖 ∙ 𝒕) + 𝛀
̅ 𝑣 (𝒗 ∙ 𝒕)
𝒗𝟏𝟐
𝒑
Let 𝒕 = 𝝀 = ,𝒖 = 𝒆 and 𝒗 = 𝒈. Substitution of expression (1.5.3-1) into
|𝒗𝟏𝟐
𝒑 |
expression above leads
𝟏𝟐
𝛀 ̅ 𝑔 (𝒈 ∙ 𝒗𝒑𝟏𝟐 ) = 𝛀
̅𝜆 = 𝛀 ̅ 𝑔 cos 𝜃𝜆𝑔
| 𝒗𝒑 |
Substitution of expressions (1.5.2-15) and (1.5.3-4) into expression above gives
̅ (𝑵1𝑝 ×𝑼𝑝 )√𝐷𝑝2 +𝐸𝑝2

̅ 𝑔 = 𝛀𝜆
𝛀 = (1.5.3-5)
cos 𝜃 𝜆𝑔 𝐷𝑝 |𝒗12
𝒑 |+𝑱𝑝 ∙𝑵1𝑝
Where: 𝑼𝑝 , 𝐷𝑝 and 𝐸𝑝 are defined in expressions (1.5.2-10) and (1.5.2-11).
̅𝑔 and relative torsional curvature 𝐺𝑔̅ in 𝒈 direction are

Therefore, relative normal curvature 𝐾
yielded follow:
𝐷𝑝2 +𝐸𝑝2
̅𝑔 = 𝛀
𝐾 ̅ 𝑔 ∙ (𝑵1𝑝 × 𝒈) = −𝛀
̅𝑔 ∙ 𝒆 = 12 ,
𝐷 𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝 } (1.5.3-6)
𝐺𝑔̅ = −𝛀
̅ 𝑔 ∙ 𝒈 = 0.
4 In Any Tangent Direction 𝝉

Any tangent direction 𝝉 is expressed as follow:
𝝉 = (𝜃𝑒𝜏 𝑵1𝑝 ) ⊗ 𝒆 = cos 𝜃𝑒𝜏 𝒆 + sin 𝜃𝑒𝜏 𝒈 (1.5.3-7)
̅ 𝑒 = 0, relative geometric
Let 𝒕 = 𝝉 , 𝒖 = 𝒆 and 𝒗 = 𝒈 in expression (1.2.1-40), due to 𝛀
angular velocity in direction of 𝝉 is derived as
~ 94 ~
̅𝜏 = 𝛀
𝛀 ̅ 𝑔 (𝒈 ∙ 𝝉) = 𝛀
̅ 𝑔 sin 𝜃𝑒𝜏
(𝑵1𝑝 ×𝑼𝑝 )√𝐷𝑝2 +𝐸𝑝2

̅𝜏 =
𝛀 sin 𝜃𝑒𝜏 (1.5.3-7)
𝐷𝑝 |𝒗12
Where: 𝑼𝑝 is defined in expression (1.5.2-10).
̅𝜏 and relative torsional curvature 𝐺𝜏̅ in any direction of 𝝉

Thus, the relative normal curvature 𝐾
are as follow:
2 2 2
̅ 𝜏 ∙ (𝑵1𝑝 × 𝝉) = (𝐷𝑝 +𝐸12𝑝 ) sin 𝜃𝑒𝜏 ,
̅𝜏 = 𝛀
𝐾 𝐷 |𝒗 |+𝑱 ∙𝑵𝑝 𝒑 𝑝 1𝑝
} (1.5.3-8)
(𝐷𝑝2 +𝐸𝑝2 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏
𝐺𝜏̅ = −𝛀
̅𝜏 ∙ 𝝉 = .
𝐷𝑝 |𝒗12
1.5.4 Calculation of Some Conjugate Parameters

1 Curvature of the Second Conjugate Surface
Application of expressions (1.2.1-34) and (1.5.3-7) generates geometric angular velocity 𝛀 2𝜆 of
the second conjugate surface in direction of 𝝉 as follow:
(𝑵1𝑝 ×𝑼𝑝 )√𝐷𝑝2 +𝐸𝑝2

𝛀 2𝜏 ̅ 𝜏 = 𝛀 1𝜏 −
= 𝛀 1𝜏 − 𝛀 sin 𝜃𝑒𝜏 (1.5.4-1)
𝐷𝑝 |𝒗12
The normal and torsional curvatures of the second conjugate surface in direction of 𝝉 are
derived by application of expressions (1.2.1-31) and (1.5.3-8)
(𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏

̅𝜏 − 𝐾1𝜏 =
𝐾2𝜏 = 𝐾 − 𝐾1𝜏 ,
𝐷𝑝 |𝒗12
2 2 } (1.5.4-2)
(𝐷𝑝 +𝐸𝑝 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏
𝐺2𝜏 = 𝐺1𝜏 − 𝐺𝜏̅ = 𝐺1𝜏 − 𝐷 |𝒗12|+𝑱 ∙𝑵 .
𝑝 𝒑 𝑝 1𝑝
When 𝝉 = 𝒆, due to sin 𝜃𝑒𝜏 = 0 , then
𝐾2𝑒 = −𝐾1𝑒 ,
} (1.5.4-3)
𝐺2𝑒 = 𝐺1𝑒 .
𝒗12
𝑝
When 𝝉 =
|𝒗12
, application of expression (1.5.2-17) gives
𝑝 |
~ 95 ~
𝐷𝑝2
𝐾2𝜆 = 𝐷 12 − 𝐾1𝜆 ,
𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝
𝐷𝑝 𝐸𝑝
} (1.5.4-4)
𝐺2𝜆 = 𝐺1𝜆 − 𝐷 12 .
When 𝝉 = 𝒈, expression (1.5.4-2) becomes
(𝐷𝑝2 +𝐸𝑝2 )
𝐾2𝑔 = 𝐷 12 − 𝐾1𝑔 ,
𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝 } (1.5.4-5)
𝐺2𝑔 = 𝐺1𝑔 .
2 Intersection Angle between a Pair of Conjugate Direction (𝝉, 𝝉′ )

Tangent directions (𝝉, 𝝉′ ) in figure 1.5.1-2 are called a pair of mutually conjugate tangent
directions at conjugate contact point 𝑃.
Tangent vector 𝝉′ is derived through rotating tangent vector 𝝉 by an angle 𝜃𝝉 𝜏′ about 𝑵1𝑝 as
an axis, that is,
𝝉′ = (𝜃𝝉 𝜏′ 𝑵1𝑝 ) ⊗ 𝝉 = cos 𝜃𝝉 𝜏′ 𝝉 + sin 𝜃𝜏 𝜏′ (𝑵1𝑝 × 𝝉)
Where: −𝜋 ≤ 𝜃𝝉 𝜏′ ≤ 𝜋.
Dot multiplication on both sides of the second conjugate relationship in expression (1.5.1-16)
with 𝝉 gives
(𝑑𝑠2) cos 𝜃𝝉 𝜏′ = 1 + ( 𝑑𝑠 ) |𝒗12
𝑝 | cos 𝜃𝜆𝜏 (1.5.4-6)
1 𝜏 1 𝜏
And dot product on both sides of the second conjugate relationship in expression (1.5.1-16)
with (𝑵1𝑝 × 𝝉) gives
𝑑𝑠 𝑑𝜀1𝑝 𝑑𝜀
(𝑑𝑠2) sin 𝜃𝝉 𝜏′ = (𝑵1𝑝 × 𝝉) ∙ 𝒗12 12
𝑝 ( 𝑑𝑠 ) = −|𝒗𝑝 | sin 𝜃𝜆𝜏 (
1𝑝
) (1.5.4-7)
1 𝜏 𝑑𝑠
1 𝜏 1 𝜏
Combination of expressions (1.5.2-12) and (1.5.2-13) results in

𝑑𝜀1𝑝
( 𝑑𝑠 ) = 𝑔(𝒈 ∙ 𝝉) = 𝑔 sin 𝜃𝑒𝜏 (1.5.4-8)
1 𝜏
With help of expression (1.5.4-8), combination of expressions (1.5.4-6) with (1.5.4-7) gives
~96 ~
𝑑𝜀1𝑝
|𝒗12
𝑝 | sin 𝜃𝜆𝜏 ( ) 𝑔|𝒗12
𝑑𝑠1 𝜏 𝑝 | sin 𝜃 sin 𝜃𝑒𝜏
tan 𝜃𝝉 𝜏′ = − 𝑑𝜀1𝑝 = − 1+𝑔|𝒗12 | cos 𝜆𝜏 (1.5.4-9)
1+( ) |𝒗12 | cos 𝜃𝜆𝜏 𝑝 𝜃 𝜆𝜏 sin 𝜃𝑒𝜏
𝑑𝑠1 𝜏 𝑝
where: 𝑔 is defined in (1.5.2-13) and
For: − 𝑔|𝒗12
𝑝 | sin 𝜃𝜆𝜏 sin 𝜃𝑒𝜏 > 0 , 0 < 𝜃𝝉 𝜏′ < 𝜋;
}
For: − 𝑔|𝒗12
𝑝 | sin 𝜃𝜆𝜏 sin 𝜃𝑒𝜏 < 0 , 0 > 𝜃𝝉 𝜏′ > −𝜋 .
3 Ratio of Conjugate Arc-Length

𝑑𝑠
The ratio (𝑑𝑠2) of arc-length 𝑑𝑠2 (prescribed as positive) in tangent direction 𝝉′ with arc-
1 𝜏
length 𝑑𝑠1 (prescribed as negative) in tangent direction 𝝉 in figure 1.5.1-2 is called as ratio of
conjugate arc-length at conjugate contact point 𝑃 in tangent direction 𝝉.
combination of expressions (1.5.4-6) with (1.5.4-7) gives
𝑑𝑠 2 𝑑𝜀1𝑝 2 𝑑𝜀1𝑝 2
(𝑑𝑠2) = 1 + 2 ( 𝑑𝑠 ) |𝒗12 12
𝑝 | cos 𝜃𝜆𝜏 + |𝒗𝑝 | ( 𝑑𝑠 )
1 𝜏 1 𝜏 1 𝜏
1−cos 2𝜃𝑒𝜏
Due to 𝜃𝜆𝜏 = 𝜃𝜆𝑒 + 𝜃𝑒𝜏 and sin2 𝜃𝑒𝜏 = , substitution of expression (1.5.4-8) into
2
expression above gives
𝑑𝑠 2
(𝑑𝑠2) = √1 + 2𝑔|𝒗12 2 12 2
𝑝 | sin 𝜃𝑒𝜏 cos 𝜃𝜆𝜏 + 𝑔 |𝒗𝑝 | sin 𝜃𝜏𝑒
1 𝜏
2
𝑔2 |𝒗12
𝑝 | (1.5.4-10)
1 − 𝑔|𝒗12
𝑝 | sin 𝜃𝜆𝑒 + 2
= √{ }
𝑔|𝒗12
𝑝 |
+𝑔|𝒗12
𝑝 | [cos 𝜃𝜆𝑒 sin 2𝜃𝑒𝜏 + (sin 𝜃𝜆𝑒 − ) cos 2𝜃𝑒𝜏 ]
2
Where: 𝑔 is defined in expression (1.5.2-13), cos 𝜃𝜆𝑒 and sin 𝜃𝜆𝑒 are defined in expression
(1.5.2-17).
1.5.5 Calculation of Some Parameters on Path of Contact

1 Unit Normal to Path of Contact
𝑑𝜀1𝑝
When 𝝉 = 𝒆, expression (1.5.4-8), i.e., ( 𝑑𝑠 ) = 0, then, the first conjugate relationship, i.e.,
1 𝑒
expression (1.5.1-16), leads
~ 97 ~
𝑑𝑠
(𝑑𝑠 ) 𝒕𝒆 = 𝒆
1 𝑒
that is,
𝒕𝒆 = 𝒆,
(𝑑𝑠 ) = 1.} (1.5.5-1)
𝑑𝑠
1 𝑒
𝑑𝜀1𝑝 𝑑𝜀1𝑝
When: When 𝝉 = 𝒈 , expression (1.5.4-8), i.e., ( 𝑑𝑠 ) = 𝑔, then, substitution of ( 𝑑𝑠 ) = 𝑔
1 𝑔 1 𝑔
into the first conjugate relationship, i.e., expression (1.5.1-16), yields
𝑑𝑠
(𝑑𝑠 ) 𝒕𝑔 = 𝒈 + 𝑔𝒗𝑝 (1.5.5-2)
1 𝜏
In general case, 𝒈 + 𝑔𝒗𝑝 ≠ 𝟎, application of expressions (1.5.5-1) and (1.5.5-2) generates the
unit normal 𝚷𝑝 to path of contact at conjugate contact point 𝑃 as follow:
𝒕𝒆 ×𝒕𝑔 𝒆×(𝒈+𝑔𝒗𝑝 ) 𝑵1𝑝 +𝑔(𝒆×𝒗𝑝 )

𝚷𝑝 = |𝒕 = |𝒆×(𝒈+𝑔𝒗 = |𝑵 (1.5.5-3)
𝒆 ×𝒕𝑔 | 𝑝 )| 1𝑝 +𝑔(𝒆×𝒗𝑝 )|
𝚷𝑝 is also derived through rotating 𝑵1𝑝 by an angle ∅𝑁Π about 𝒆 as an axis, that is,
𝚷𝑝 = (∅𝑁Π 𝒆 ) ⊗ 𝑵1𝑝 = cos ∅𝑁Π 𝑵1𝑝 − sin ∅𝑁Π 𝒈 (1.5.5-4)
Then,
𝑔(𝑵1𝑝 ∙𝒗𝑝 )
sin ∅𝑁Π = 𝚷𝑝 ∙ (−𝒈) = |𝑵 ,
1𝑝 +𝑔(𝒆×𝒗𝑝 )|
} (1.5.5-5)
1+𝑔(𝒈∙𝒗𝑝 )
cos ∅𝑁Π = 𝚷𝑝 ∙ 𝑵1𝑝 = |𝑵 )|
.
1𝑝 +𝑔(𝒆×𝒗𝑝
When 𝑵1𝑝 ∙ 𝒗𝑝 = 0, then, ∅𝑁Π = 0, therefore, 𝚷𝑝 is aligned with 𝑵1𝑝 and path of contact is
tangent to common tangent plane at contact point 𝑃 of a pair of conjugate surfaces. If in any
instant of whole process of conjugate motion, condition of 𝑵1𝑝 ∙ 𝒗𝑝 = 0 can be satisfied at any
conjugate contact point 𝑃 between a pair of conjugate surfaces, then, the conjugate surfaces
are in one side of path of contact, and such corresponding conjugate surface is called blank
pitch surface.
2 Relationship between Engagement Direction and Conjugate Direction

Because both 𝒕𝒆 = 𝒆 and 𝒕𝝉 are tangent to path of contact, then, 𝒕𝝉 can be derived through
rotating 𝒆 by an angle 𝜑𝑒τ about 𝚷𝑝 as an axis, that is,
~98 ~
𝒕𝝉 = (𝜑𝑒τ 𝚷𝑝 ) ⊗ 𝒆 = cos 𝜑𝑒τ 𝒆 + sin 𝜑𝑒τ 𝚷𝑝 × 𝒆
(1.5.5-6)
= cos 𝜑𝑒τ 𝒆 + sin 𝜑𝑒τ (cos ∅𝑁Π 𝒈 + sin ∅𝑁Π 𝑵1𝑝 )
With help of expressions (1.5.4-8), substitution of expression above into the first conjugate
relationship in expression (1.5.1-16) gives
𝑑𝑠
[cos 𝜑𝑒τ 𝒆 + sin 𝜑𝑒τ (cos ∅𝑁Π 𝒈 + sin ∅𝑁Π 𝑵1𝑝 )] (𝑑𝑠 ) = 𝝉 + 𝑔 sin 𝜃𝑒𝜏 𝒗𝑝 (1.5.5-7)
1 𝜏
Dot product on both sides of expression (1.5.5-7) with 𝒆, 𝒈 and 𝑵1𝑝 respectively gives
𝑑𝑠
cos 𝜑𝑒τ (𝑑𝑠 ) = cos 𝜃𝑒𝜏 + 𝑔 sin 𝜃𝑒𝜏 (𝒆 ∙ 𝒗𝑝 ),
1 𝜏
𝑑𝑠
sin 𝜑𝑒τ cos ∅𝑁Π (𝑑𝑠 ) = sin 𝜃𝑒𝜏 + 𝑔 sin 𝜃𝑒𝜏 (𝒈 ∙ 𝒗𝑝 ), (1.5.5-8)
1 𝜏
𝑑𝑠
sin 𝜑𝑒τ sin ∅𝑁Π (𝑑𝑠 ) = 𝑔 sin 𝜃𝑒𝜏 (𝑵1𝑝 ∙ 𝒗𝑝 ).
1 𝜏 }
|𝑵1𝑝 +𝑔(𝒆×𝒗𝑝 )| sin 𝜃𝑒𝜏

tan 𝜑𝑒τ = [cos 𝜃 (1.5.5-9)
𝑒𝜏 +𝑔 sin 𝜃𝑒𝜏 (𝒆∙𝒗𝑝 )]
Where: 𝑔 is calculated by expression (1.5.2-13).
3 Ratio of Engagement Arc-Length with Respect to Conjugate Arc-Length

𝑑𝑠
Ration of (𝑑𝑠 ) is derived by application of expression (1.5.5-7)
1 𝜏
𝑑𝑠
(𝑑𝑠 ) = |𝝉 + 𝑔 sin 𝜃𝑒𝜏 𝒗𝑝 | = √(𝝉 + 𝑔 sin 𝜃𝑒𝜏 𝒗𝑝 ) ∙ (𝝉 + 𝑔 sin 𝜃𝑒𝜏 𝒗𝑝 )
1 𝜏
(1.5.5-10)
2
= √1 + 2𝑔 sin 𝜃𝑒𝜏 (𝒈 ∙ 𝒗𝑝 ) + 𝑔2 sin2 𝜃𝑒𝜏 |𝒗𝑝 |
4 Some Special Unit Normal Directions

A. Gear Blank Surface
Expression (1.5.5-5) shows that ∅𝑁Π = 0, or 𝑵1𝑝 = ±𝚷𝑝 , that is, unit normal 𝑵1𝑝 to conjugate
surface is parallel to unit normal to path of contact, when 𝑵1𝑝 ∙ 𝒗𝑝 = 0, i.e., 𝑵1𝑝 ⊥ 𝒗𝑝 . Due to
𝑵1𝑝 = −𝑵2𝑝 , then a pair of conjugate surfaces are tangent to and on both sides of path of
contact if unit normal 𝑵1𝑝 to conjugate surface is perpendicular to linear velocity 𝒗𝑝 of
~ 99~
instantaneous contact point 𝑃 in whole motion process.
Because transmission force is in direction of unit normal 𝑵1𝑝 to conjugate surface, a pair of
conjugate surfaces can not be used to transmit power if unit normal 𝑵1𝑝 to conjugate surface is
perpendicular to linear velocity 𝒗𝑝 of instantaneous contact point 𝑃 in whole motion process.
Their conjugate motion is achieved through friction between a pair of conjugate surfaces.
A pair of conjugate surfaces are defined as gear blank surfaces when unit normal to surface is
perpendicular to linear velocity at instantaneous contact point in whole process.
Due to unit normal 𝑵𝑏 to gear blank surface being also perpendicular to relative velocity 𝒗12
𝑝 ,
𝑵𝑏 is expressed as follow:
𝒗𝑝 ×𝒗12
𝑝 𝒗𝑝 ×𝒗′𝑝 𝒗′𝑝 ×𝒗12
𝑝
𝑵𝑏 = ± |𝒗 12 = ± |𝒗 12 = ± |𝒗 12 (1.5.5-11)
𝑝 ×𝒗𝑝 | 𝑝 ×𝒗𝑝 | 𝑝 ×𝒗𝑝 |
B. Limit Unit Normal
Let point 𝑃 be conjugate contact point on conjugate surface 𝐴 at instant rotating angle 𝜀1𝑝 ,
contact arc-length (𝑑𝑠1 )𝜏 through point 𝑃 on conjugate surface 𝐴 in any tangent direction 𝝉
after rotating angle 𝑑𝜀1𝑝 is decided by application of expression (1.5.2-8) as follow:
𝑑𝜀1𝑝 𝑱𝑝 ∙𝑵1𝑝
(𝑑𝑠1 )𝜏 = 𝑑𝜀1𝑝 = |𝒗𝟏𝟐 |𝛀 𝑑𝜀1𝑝
( ) 𝒑 𝜆 ×𝑵1𝑝 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙𝝉
𝑑𝑠1 𝜏
When 𝑱𝑝 ∙ 𝑵1𝑝 = 0, the contact arc-length (𝑑𝑠1 )𝜏 in any tangent direction 𝝉 is zero. Conjugate
point with unit normal 𝑵1𝑝 perpendicular to 𝑱𝑝 is referred to as conjugate stagnant point. Unit
normal 𝑵1𝑝 perpendicular to 𝑱𝑝 is defined as limit unit normal 𝑵𝑜 . Due to 𝑵𝑜 being also
perpendicular to relative velocity 𝒗12
𝑝 , limit unit normal 𝑵𝑜 is expressed as follow:
𝒗12
𝑝 ×𝑱𝑝
𝑵𝑜 = |𝒗12×𝑱 (1.5.5-12)
𝑝 𝑝|
Where: 𝑱𝑝 is calculated by expression (1.5.2-7).
1.5.6 Planar Case

1 Rate of Rotating Angular Increment
In planar case, 𝛼 = 0 or 𝛼 = 𝜋, 𝜎1 = 𝜎2 = 0.
1) Unit tangent to instantaneous contact line is 𝒆, that is,
~ 100 ~
𝒆=𝒌 (1.5.6-1)
2) Unit normal 𝑵1𝑝 to the first conjugate curve at contact point 𝑃(𝑹1𝑝 ) of instant 𝜀1𝑝 is
expressed as follow:
𝑵1𝑝 = cos ∅ 𝒊 + sin ∅ 𝒋 (1.5.6-2)
Where: ∅ is intersection angle between 𝑵1𝑝 and 𝒊 as shown in figure 1.5.6-1.
3) Direction of maximum increment rate of rotating angle is 𝒈, that is,
𝒈 = 𝑵1𝑝 × 𝒆 = sin ∅ 𝒊 − cos ∅ 𝒋 (1.5.6-3)
Contact point 𝑃(𝑹1𝑝 ) on the first conjugate curve at instant 𝜀1𝑝 can be expressed by
application of expression (1.4.9-1), that is,
𝑹1𝑝 = 𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 (1.5.6-4)
Where: 𝑹0𝑝 is defined by expression (1.4.10-5).
With help of expression (1.5.6-4), the velocity 𝒗𝑝 of conjugate contact point 𝑃 on the first
conjugate curve is
𝒗𝑝 = 𝝎1 × 𝑹1𝑝 = 𝝎1 × (𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 ) = 𝒗0𝑝 + 𝑠𝑛 𝝎1 × 𝑵1𝑝 (1.5.6-5)
Where: 𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 is velocity of pitch point on the first conjugate curve.
With aid of expression (1.5.6-1), the velocity 𝒗′𝑝 of conjugate contact point 𝑃 on the second
conjugate curve is calculated by expression (1.3.5-2), that is,
𝑑(𝑙𝒑) 𝑑(𝑙𝒑)
𝒗′𝑝 = 𝑀𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + = 𝑀𝝎2 × (𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 − 𝑙𝒑) +
𝑑𝜀1 𝑑𝜀1 (1.5.6-6)
= 𝒗′0𝑝 + 𝑠𝑛 𝑀𝝎2 × 𝑵1𝑝
Where: 𝒗′0𝑝 is velocity of pitch point on the second conjugate curve, that is,
𝑑(𝑙𝒑)
𝒗′0𝑝 = 𝑀𝝎2 × (𝑹0𝑝 − 𝑙𝒑) + (1.5.6-7)
𝑑𝜀1
Due to 𝒗′0𝑝 − 𝒗′0𝑝 = 0, the relative velocity 𝒗12

𝑝 is derived by application of expression (1.4.9-3),
that is,
𝒗12 ′
𝑝 = 𝒗𝑝 − 𝒗𝑝 = (𝝎1 − 𝑀𝝎2 ) × (𝑠𝑛 𝑵1𝑝 ) = −𝑠𝑛 (1 ± 𝑀)𝒈 (1.5.6-8)
~101 ~
Due to 𝐺1𝜆 = 0 and (𝝎1 − 𝑀𝝎2 ) ⊥ 𝒗12
𝑝 , then, with help of expression (1.5.6-8), expression
(1.5.2-10) is updated as follow:
𝑼𝑝 = |𝒗12 12
𝑝 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] = 𝐾1𝜆 𝒗𝑝 + (1 ± 𝑀)𝒈
𝒗12
𝑝 𝒗12
𝑝 (1.5.6-9)
= 𝐷𝑝 |𝒗12| + 𝐸𝑝 (𝑵1𝑝 × |𝒗12 |) = (1 − 𝑠𝑛 𝐾1𝜆 )(1 ± 𝑀)𝒈,
𝑝 𝑝
Where:
𝒗12
𝑝
𝐷𝑝 = 𝑼𝑝 = 𝑼𝑝 ∙ |𝒗12| ,
𝑝 }
𝐸𝑝 = 0.
𝑂 𝒋
The first pitch curve 𝐴0
𝑹0𝑝 the second pitch curve 𝐴̅0
𝑃0 𝑹1𝑝 the first tooth curve 𝐴
∅ 𝑠𝑛 𝑃 the second tooth curve 𝐴̅
𝑑𝑠1 𝑑𝑠2 𝑑𝑠 𝑵1𝑝
𝑃′ 𝑃̅′
𝒊 𝝉 = 𝝉′ 𝑃′′
Figure 1.5.6-1 Three Basic Differential Quantities
Parameter 𝑱𝑝 is updated from expression (1.5.2-6) as follow:
𝑑𝑀 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)
𝑱𝑝 = 𝑑𝜀 𝝎2 × 𝑹2𝑝 + − 𝝎1 × 𝒗′𝑝 + 𝑀𝝎2 × [𝒗𝑝 − ]
1 𝑑𝜀12 𝑑𝜀1
𝑑𝑀 𝑑2 (𝑙𝒑)
𝝎2 × (𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 − 𝑙𝒑) + − 𝝎1 × (𝒗′0𝑝 + 𝑠𝑛 𝑀𝝎2 × 𝑵1𝑝 )
={ 𝑑(𝑙𝒑)
} (1.5.6-10)
+𝑀𝝎2 × [𝒗0𝑝 + 𝑠𝑛 𝝎1 × 𝑵1𝑝 − ]
𝑑𝜀1
𝑑𝑀 𝑑(𝑙𝒑) 𝑑2 (𝑙𝒑)
= 𝝎2 × (𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 − 𝑙𝒑) + 𝑀𝝎2 × [𝒗0𝑝 − ] − 𝝎1 × 𝒗′0𝑝 +
~ 102 ~
𝑑𝑀 𝑑𝑓
For the case of constant transmission ratio and fixed rotating axes, that is, 𝑑𝜀 = 𝑑𝜀 = 0, and
1 1
ℎ = 0 (through proper selection of coordinate system), expression (1.5.6-10) is simplified as
follow:
𝑱𝑝 = −𝑀𝑓(𝝎1 ∙ 𝝎2 )𝒊 = ±𝑀𝑓𝒊 (1.5.6-11)
4) Rate of Rotating Angular Increment
𝒑 |𝛀𝜆 ×𝑵1𝑝 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ] (1−𝑠𝑛 𝐾1𝜆 )(1±𝑀)
( 𝑑𝑠 ) = ∙𝝉= (1.5.6-12)
1 𝜏 𝑱𝑝 ∙𝑵1𝑝 𝑱𝑝 ∙𝑵1𝑝
Where: 𝝉 = 𝒈. 𝑵1𝑝 is calculated by expression (1.5.6-2). 𝑱𝑝 is decided by expression (1.5.6-

10).
𝑑𝑀 𝑑𝑓
1 1
ℎ = 0 (through proper selection of coordinate system), expression (1.5.6-12) is simplified as
follow:
𝑑𝜀1𝑝 (1−𝑠𝑛 𝐾1𝜆 )(1±𝑀)
( 𝑑𝑠 ) = =𝑔 (1.5.6-13)
1 𝜏 ±𝑀𝑓 cos ∅
2 Three Conjugate Relationships

1) The First Conjugate Relationship
The first conjugate relationship, i.e., expression (1.5.1-8), becomes
𝑑𝑠𝒕 = 𝑑𝑠1 𝒈 + 𝑑𝜀1𝑝 𝒗𝑝 = 𝑑𝑠1 𝒈 + 𝑑𝜀1𝑝 (𝒗0𝑝 − 𝑠𝑛 𝒈),

𝑂𝑅 } (1.5.6-14)
𝒕 = 𝒈 + ( ) (𝒗 0𝑝 − 𝑠𝑛 𝒈).
𝑑𝑠 1 𝑑𝑠 1 𝜏
𝑑𝜀1𝑝
Where: 𝒈 is decided by expression (1.5.6-3) and 𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 . 𝑔 = ( 𝑑𝑠 ) is calculated by
1 𝜏
2) The Second Conjugate Relationship
The Second Conjugate Relationship is derived by expression (1.5.1-11), that is,
~ 103 ~
𝑑𝑠2 𝝉 = 𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗12
𝑝 = 𝑑𝑠1 𝝉 − 𝑑𝜀1𝑝 𝑠𝑛 (1 ± 𝑀)𝒈,
𝑂𝑅 } (1.5.6-15)
= 1 − ( 𝑑𝑠 ) 𝑠𝑛 (1 ± 𝑀).
𝑑𝑠 1 1 𝜏
𝑑𝜀1𝑝
Where: 𝒈 is decided by expression (1.5.6-3). 𝑔 = ( 𝑑𝑠 ) is calculated by expression (1.5.6-13).
1 𝜏
3) The Third Conjugate Relationship
Due to 𝐺1𝜏 = 𝐺2𝜏′ = 0 and 𝝎1 = ±𝝎2 = 𝒌 in planar case, the third conjugate relationship, i.e.,
expression (1.5.1-15), is updated as
𝐾2𝜏 𝑑𝑠2 = −𝐾1𝜏 𝑑𝑠1 + 𝑑𝜀1𝑝 (1 ± 𝑀),

𝑂𝑅 } (1.5.6-16)
𝐾2𝜏 = −𝐾1𝜏 + ( ) (1 ± 𝑀).
𝑑𝑠1 𝑑𝑠1 𝜏
Where: “+" is corresponding to external gearing and " − " is corresponding to internal gearing.
Therefore, conjugate relationships among three basic differential quantities in planar case are
𝑇ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝

𝑑𝑠𝒕 = 𝑑𝑠1 𝒈 + 𝑑𝜀1𝑝 (𝒗0𝑝 − 𝑠𝑛 𝒈), 𝑂𝑅 𝒕 = 𝒈 + ( 𝑑𝑠 ) (𝒗0𝑝 − 𝑠𝑛 𝒈),
𝑑𝑠1 1 𝜏
𝑇ℎ𝑒 𝑠𝑒𝑐𝑜𝑛𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝
𝑑𝑠2 = 𝑑𝑠1 − 𝑑𝜀1𝑝 𝑠𝑛 (1 ± 𝑀), 𝑂𝑅
= 1 − ( 𝑑𝑠 ) 𝑠𝑛 (1 ± 𝑀), (1.5.6-17)
𝑑𝑠1 1 𝜏
𝑇ℎ𝑒 𝑡ℎ𝑖𝑟𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝
𝑑𝑠 1𝑝 𝑑𝜀
𝐾2𝜏 𝑑𝑠2 = −𝐾1𝜏 𝑑𝑠1 + 𝑑𝜀1𝑝 (1 ± 𝑀), 𝑂𝑅 𝐾2𝜏 𝑑𝑠2 = −𝐾1𝜏 + ( 𝑑𝑠 ) (1 ± 𝑀).
1 1 𝜏 }
𝑑𝜀1𝑝
Where: 𝒈 is decided by expression (1.5.6-3) and 𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 . 𝑔 = ( 𝑑𝑠 ) is calculated by
1 𝜏
3 Relative Curvature
Relative curvature is derived by updating expression (1.5.3-8)
𝐷𝑝2 (𝑠𝑛 𝐾1𝜆 −1)𝟐 (1±𝑀)𝟐

̅𝜏 =
𝐾 12 = (𝑠 𝟐 𝑠 +𝑱 ∙𝑵
= 𝐾1𝜆 + 𝐾2𝜆 (1.5.6-18)
𝐷 𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝 𝑛 𝐾1𝜆 −1)(1±𝑀) 𝑛 𝑝 1𝑝
Where: |𝒗12
𝒑 | is defined in expression (1.5.6-8). 𝑵1𝑝 is expressed in expression (1.5.6-2). 𝐷𝑝 is
~ 104 ~
1
calculated by expression (1.5.6-9) and 𝑱𝑝 is formulated in expression (1.5.6-10). 𝐾1𝜆 = 𝜌
1
1
and𝐾2𝜆 = 𝜌 .
2
Expanding expression (1.5.6-18) generates relationship between 𝜌1 and 𝜌2 as follow:
(1±𝑀)𝟐 1 1
= (𝜌 + (𝜌 (1.5.6-19)
(𝑱𝑝 ∙𝑵1𝑝 ) 1 −𝑠𝑛 ) 2 +𝑠𝑛 )
𝑑𝑀 𝑑𝑓
1 1
ℎ = 0 (through proper selection of coordinate system), 𝑱𝑝 is decided by expression (1.5.6-11),
then,
𝑱𝑝 ∙ 𝑵1𝑝 = ±𝑀𝑓 cos ∅ (1.5.6-20)
(1±𝑀)𝟐 1 1
= (𝜌 + (𝜌 (1.5.6-21)
±𝑀𝑓 cos ∅ 1 −𝑠𝑛 ) 2 +𝑠𝑛 )
For the case of external gear transmission with constant transmission ratio and fixed rotating
𝑀𝑓 𝑓
axes, radius of the first pitch circle is 𝜌10 = 1+𝑀 , radius of the second pitch circle is 𝜌20 = 1+𝑀
and 𝑓 = 𝜌10 + 𝜌20 , then,
(1±𝑀)𝟐 (1+𝑀)𝟐 𝑓(1+𝑀)(1+𝑀) 𝑓 1 1

= = =𝜌 =𝜌 +𝜌
±𝑀𝑓 𝑀𝑓 𝑀𝑓𝑓 10 𝜌20 10 20
Substitution of expression above into expression (1.5.6-21) gives Euler-Savary equation as

follow:
1 1 1 1 1
(𝜌1 −𝑠𝑛 )
+ (𝜌 = cos ∅ (𝜌 + 𝜌 ) (1.5.6-22)
2 +𝑠𝑛 ) 10 20
4 Ratio of Conjugate Arc-Length

𝜋 𝜋
Due to 𝜃𝑒𝜏 = 2 and 𝜃𝜆𝑒 = 2 , with help of expression (1.5.6-8), application of expression (1.5.4-
10) results in
𝑑𝑠 2
(𝑑𝑠2) = √1 + 2𝑔|𝒗12 2 12 2
𝑝 | sin 𝜃𝑒𝜏 cos 𝜃𝜆𝜏 + 𝑔 |𝒗𝑝 | sin 𝜃𝜏𝑒
1 𝜏 (1.5.6-23)
= √1 − 2𝑔|𝑠𝑛 (1 ± 𝑀)| + 𝑔2 𝑠𝑛2 (1 ± 𝑀)2 = |1 − 𝑔|𝑠𝑛 (1 ± 𝑀)||
~ 105 ~
Where: 𝑔 is calculated by expression (1.5.6-13).
5 Ratio of Engagement Arc-Length with Respect to Conjugate Arc-Length

𝜋
Due to 𝜃𝑒𝜏 = 2 , Application of expression (1.5.5-10) gives
𝑑𝑠
(𝑑𝑠 ) = |𝝉 + 𝑔 sin 𝜃𝑒𝜏 𝒗𝑝 | = |𝝉 + 𝑔𝒗𝑝 | = √1 + 2𝑔(𝝉 ∙ 𝒗𝑝 ) + 𝑔2 (𝒗𝑝 ∙ 𝒗𝑝 )
1 𝜏
(1.5.6-24)
2
= √1 + 2𝑔(𝒈 ∙ 𝒗0𝑝 − 𝑠𝑛 ) + 𝑔2 [|𝒗 0𝑝 | − 2𝑠𝑛 (𝒈 ∙ 𝒗0𝑝 ) + 𝑠𝑛2 ]
Where: 𝒈 is decided by expression (1.5.6-3) and 𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 . 𝑔 is calculated by expression

(1.5.6-13).
6 Unit Tangent to Path of Contact

With help of expressions (1.5.6-23) and (1.5.6-24), application of expression (1.5.6-14) gives
𝑑𝜀1𝑝
𝒈+( ) 𝒗
𝑑𝑠1 𝜏 𝑝 (1−𝑔𝑠𝑛 )𝒈+𝑔𝒗0𝑝
𝒕= 𝑑𝑠 = 2
(1.5.6-25)
( ) 2]
√1+2𝑔(𝒈∙𝒗0𝑝 −𝑠𝑛 )+𝑔2 [|𝒗0𝑝 | −2𝑠𝑛 (𝒈∙𝒗0𝑝 )+𝑠𝑛
𝑑𝑠1 𝜏
Where: 𝒈 is decided by expression (1.5.6-3) and 𝒗0𝑝 = 𝝎1 × 𝑹0𝑝 . 𝑔 is calculated by expression

(1.5.6-13).
1.5.7 Summary of Chapter 5

Formulas derived in chapter 5 are listed in table 1.5
~ 125 ~
Table 1.5 Formulas in Chapter 5
Spatial Case Planar Case

𝑇ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝: 𝑇ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝
𝑑𝑠𝒕 = 𝑑𝑠1 𝝉 + 𝑑𝜀1𝑝 𝒗𝑝 𝑂𝑅 ( ) 𝒕= 𝝉+( ) 𝒗𝑝 𝑑𝑠𝒕 = 𝑑𝑠1 𝒈 + 𝑑𝜀1𝑝 (𝒗0𝑝 − 𝑠𝑛 𝒈),
𝑑𝑠1 𝜏 𝑑𝑠1 𝜏 𝑂𝑅
𝑇ℎ𝑒 𝑠𝑒𝑐𝑜𝑛𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝: 𝑑𝑠 𝑑𝜀
Three Conjugate Relationships
𝑑𝑠2 𝑑𝜀1𝑝 𝒕 = 𝒈 + ( 1𝑝 ) (𝒗0𝑝 − 𝑠𝑛 𝒈)

𝑑𝑠1 𝑑𝑠1
𝑝 𝑂𝑅 ( ) 𝝉′ = 𝝉 + ( ) 𝒗12
𝑝 𝑔
𝑑𝑠1 𝜏 𝑑𝑠1 𝜏 𝑇ℎ𝑒 𝑠𝑒𝑐𝑜𝑛𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝
𝑇ℎ𝑒 𝑡ℎ𝑖𝑟𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝:
𝑑𝑠2 = 𝑑𝑠1 − 𝑑𝜀1𝑝 𝑠𝑛 (1 ± 𝑀),
[𝐾2𝜏′ 𝝉′ − 𝐺2𝜏′ (𝑵1𝑝 × 𝝉′ )] 𝑑𝑠2 𝑂𝑅 (1.5.6-17)
= −[𝐾1𝜏 𝝉 + 𝐺1𝜏 (𝑵1𝑝 × 𝝉) ]𝑑𝑠1 − 𝑑𝜀1𝑝 (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 𝑑𝑠2 𝑑𝜀
= 1 − ( 1𝑝 ) 𝑠𝑛 (1 ± 𝑀),
𝑑𝑠1 𝑑𝑠1
𝑂𝑅 𝑔
𝑑𝑠 𝑇ℎ𝑒 𝑡ℎ𝑖𝑟𝑑 𝑐𝑜𝑛𝑗𝑢𝑔𝑎𝑡𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛𝑠ℎ𝑖𝑝
[𝐾2𝜏′ 𝝉′ − 𝐺2𝜏′ (𝑵1𝑝 × 𝝉′ )] ( 2 ) 𝑑𝑠1 𝜏 𝐾2𝜏 𝑑𝑠2 = −𝐾1𝜏 𝑑𝑠1 + 𝑑𝜀1𝑝 (1 ± 𝑀),
𝑑𝜀1𝑝
= −[𝐾1𝜏 𝝉 + 𝐺1𝜏 (𝑵1𝑝 × 𝝉) ] − ( ) (𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 𝑂𝑅
𝑑𝑠1 𝜏 } 𝑑𝑠 𝑑𝜀
𝐾2𝜏 2 = −𝐾1𝜏 + ( 1𝑝 ) (1 ± 𝑀).
𝑑𝑠1 𝑑𝑠1 𝑔 }
(1.5.1-16)
𝒗𝟏𝟐
𝑼𝑝 = 𝐷𝑝 |𝒗𝒑𝟏𝟐 | + 𝐸𝑝 (𝑵1𝑝 × |𝒗𝒑𝟏𝟐|)
𝒗𝟏𝟐
(1.5.2-10) 𝒆=𝒌 (1.5.6-1), 𝝉 = 𝝉′ = 𝒈 = −𝒌 × 𝑵1𝑝 (1.5.6-3),
𝒑 𝒑 𝑹1𝑝 = 𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 , 𝒗𝑝 = 𝒌 × 𝑹0𝑝 − 𝑠𝑛 𝒈 ,
𝒑 𝒗𝟏𝟐
𝐷𝑝 = 𝐾1𝜆 |𝒗𝟏𝟐
𝒑 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ |𝒗𝟏𝟐| , (1.5.6-4) (1.5.6-5)
𝒑
} (1.5.2-11) 𝒗12
𝑝 = −𝑠𝑛 (1 ± 𝑀)𝒈, 𝑼𝑝 = (1 ± 𝑀)(𝟏 − 𝑠𝑛 𝐾1𝜆 )𝒈,
Some Parameters
𝒑 𝒗𝟏𝟐
𝐸𝑝 = |𝒗𝟏𝟐
𝒑 |𝐺1𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗𝟏𝟐| . (1.5.6-8), (1.5.6-9),
𝒑
𝑑𝑀 𝑑2 (𝑙𝒑)
𝝎2 × (𝑹0𝑝 + 𝑠𝑛 𝑵1𝑝 − 𝑙𝒑) +
𝑼 𝒗𝟏𝟐 𝒗𝟏𝟐 𝑱𝑝 = { } (1.5.6-10)
𝒈 = |𝑼𝑝 | = 𝒑
|𝒗𝟏𝟐
cos 𝜃𝜆𝑔 + (𝑵1𝑝 × 𝒑
|𝒗𝟏𝟐
) sin 𝜃𝜆𝑔 (1.5.2-15) +𝑀𝝎2 × [𝒗0𝑝 −
𝑑(𝑙𝒑)
] − 𝝎1 × 𝒗′0𝑝
𝑝 𝒑 | 𝒑 | 𝑑𝜀1
𝟏𝟐
𝒗𝒑 𝟏𝟐
𝒗𝒑
𝒆 = 𝒈 × 𝑵1𝑝 = cos 𝜃𝜆𝑒 + (𝑵1𝑝 × ) sin 𝜃 𝜆𝑒 (1.5.2-17) For the case of constant transmission ratio and fixed
|𝒗𝟏𝟐
𝒑 | |𝒗𝟏𝟐
𝒑 | 𝑑𝑀 𝑑𝑓
𝑑𝑀 𝑑2 𝜎1 𝑑2 𝜎2 𝑑2 (𝑙𝒑) rotating axes, that is, = = 0, and ℎ = 0 (through
𝝎2 × 𝑹2𝑝 − 𝝎1 + 𝝎2 + − 𝝎1 × 𝒗′𝑝 𝑑𝜀1 𝑑𝜀1
𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12 proper selection of coordinate system
𝑱𝑝 = { 𝑑(𝑙𝒑)
} (1.5.2-7)
+𝑀𝝎2 × [𝒗𝑝 − ] 𝑱𝑝 = ±𝑀𝑓𝒊 (1.5.6-11)
𝑑𝜀1
𝑑𝜀1𝑝 𝑼𝑝 𝑑𝜀1𝑝 (1±𝑀)(1−𝑠𝑛 𝐾1𝜆 )

( ) = ∙𝝉 (1.5.2-12) ( ) = =𝑔 (1.5.6-12)
𝑑𝑠1 𝑱𝑝 ∙𝑵1𝑝 𝑑𝑠1 𝑱𝑝 ∙𝑵1𝑝
Rate of Angular
𝜏 𝜏
and For the case of constant transmission ratio and fixed
Increment
𝑑𝜀1𝑝 |𝑼𝑝 | 𝑑𝑀 𝑑𝑓
( ) = =𝑔 (1.5.2-13) rotating axes, that is, = = 0, and ℎ = 0 (through
𝑑𝑠1 𝑱𝑝 ∙𝑵1𝑝 𝑑𝜀1 𝑑𝜀1
𝑔
proper selection of coordinate system
𝑑𝜀1𝑝 𝑑𝜀1𝑝 (1±𝑀)(1−𝑠𝑛 𝐾1𝜆)
𝑔=( ) =( ) = (1.5.6-13)
𝑑𝑠1 𝜏 𝑑𝑠1 𝑔 ±𝑀𝑓 cos ∅
(𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏 1 𝟐

̅𝜏 = 𝛀
𝐾 ̅ 𝜏 ∙ (𝑵1𝑝 × 𝝉) = , (1±𝑀)𝟐 𝑠𝑛2 (𝐾1𝜆 − ) (1±𝑀)𝟐 1 1
12 |+𝑱 ∙𝑵
𝐷𝑝 |𝒗𝒑 𝑝 1𝑝 ̅𝜏 =
𝐾 1
𝑠𝑛
, = (𝜌 + (𝜌 .
} (1.5.3-8) (1±𝑀)𝟐 𝑠𝑛2 (𝐾1𝜆 − )+𝑱𝑝 ∙𝑵1𝑝 (𝑱𝑝 ∙𝑵1𝑝 ) 1 −𝑠𝑛 ) 2 +𝑠𝑛 )
Relative Curvature
(𝐷𝑝2 +𝐸𝑝2 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏 𝑠𝑛

𝐺𝜏̅ = −𝛀
̅𝜏 ∙ 𝝉 = . (1.5.6-18) (1.5.6-19)
𝐷𝑝 |𝒗12
For the case of constant transmission ratio and fixed
𝑑𝑀 𝑑𝑓
rotating axes, that is, = = 0, and ℎ = 0 (through
𝑑𝜀1 𝑑𝜀1
proper selection of coordinate system
1 1 1 1 1
(𝜌1 −𝑠𝑛 )
+ (𝜌 = ( + ) (1.5.6-22)
2 +𝑠𝑛 ) cos ∅ 𝜌10 𝜌20
𝑑𝑠2 2
( ) = √1 + 2𝑔|𝒗12 2 12 2
𝑝 | sin 𝜃𝑒𝜏 cos 𝜃𝜆𝜏 + 𝑔 |𝒗𝑝 | sin 𝜃𝜏𝑒 (1.5.4-10) 𝑑𝑠2
𝑑𝑠1 𝜏 ( ) = |1 − 𝑔|𝑠𝑛 (1 ± 𝑀)|| (1.5.6-23)
Conjugate Parameters
𝑑𝑠1 𝜏
𝑵 +𝑔(𝒆×𝒗𝑝 ) 𝑔|𝒗12
𝑝 | sin 𝜃𝜆𝜏 sin 𝜃𝑒𝜏
𝚷𝑝 = |𝑵1𝑝 , tan 𝜃𝝉 𝜏′ = − ,
+𝑔(𝒆×𝒗 )|
1𝑝 𝑝 1+𝑔|𝒗12
𝑝 | cos 𝜃𝜆𝜏 sin 𝜃𝑒𝜏
(1.5.5-3) (1.5.4-9) 𝑑𝑠
1 + 2𝑔(𝒈 ∙ 𝒗0𝑝 − 𝑠𝑛 )
𝒕𝜏 = cos 𝜑𝑒τ 𝒆 + sin 𝜑𝑒τ (cos ∅𝑁Π 𝒈 + sin ∅𝑁Π 𝑵1𝑝 ) (1.5.5-6) ( ) =√ 2 2
𝑑𝑠1 𝜏 +𝑔 [|𝒗0𝑝 | − 2𝑠𝑛 (𝒈 ∙ 𝒗0𝑝 ) + 𝑠𝑛2 ]
𝑑𝑠 2
( ) = √1 + 2𝑔 sin 𝜃𝑒𝜏 (𝒈 ∙ 𝒗𝑝 ) + 𝑔2 sin2 𝜃𝑒𝜏 |𝒗𝑝 | (1.5.5-10) (1.5.6-24)
𝑑𝑠1 𝜏 (1−𝑔𝑠𝑛 )𝒈+𝑔𝒗0𝑝
|𝑵 +𝑔(𝒆×𝒗𝑝 )| sin 𝜃𝑒𝜏 𝒕= (1.5.6-25)
tan 𝜑𝑒τ = [cos1𝑝 (1.5.5-9) 2
√1+2𝑔(𝒈∙𝒗0𝑝 −𝑠𝑛 )+𝑔2 [|𝒗0𝑝 | −2𝑠𝑛 (𝒈∙𝒗0𝑝 )+𝑠𝑛2 ]
𝜃𝑒𝜏 +𝑔 sin 𝜃𝑒𝜏 (𝒆∙𝒗𝑝 )]
~107 ~
Chapter 6
Curvature Calculation of the First Conjugate Surface Generated by

Intersecting Curve as the Second Conjugate Surface
1.6.1 Curvature of the First Conjugate Surface generated by

Intersecting Curve as the Second Conjugate Surface
1 Given Parameters
𝑑𝜀2 𝑑𝜎1 𝑑𝜎2 𝑑𝑓 𝑑ℎ 𝑑𝑀 𝑑2 𝜎1 𝑑2 𝜎2 𝑑2 𝑓 𝑑2 ℎ
1) Value of 𝜀2 , 𝜎1 , 𝜎2 , 𝑓, ℎ, 𝑀 = , , , , , , , , , at
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12 𝑑𝜀12
instant 𝜀1 , and 𝛼 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡.
2) Any point 𝑃 on intersecting curve at instant 𝜀1 , that is,
𝑹2𝑝 = 𝑥𝑝′ 𝒊′ + 𝑦𝑝′ 𝒋′ + 𝑧𝑝′ 𝒌′
3) Unit tangent 𝜻 to intersecting curve at point 𝑃, that is,
𝜻 = 𝜁𝑥′ 𝒊′ + 𝜁𝑦′ 𝒋′ + 𝜁𝑧′ 𝒌′
4) Unit principal normal 𝝃 to intersecting curve at point 𝑃, and unit normal 𝑵𝐼 and 𝑵𝐼𝐼 to
surfaces of which intersecting curve is composed, that is,
𝝃 = 𝜉𝑥′ 𝒊′ + 𝜉𝑦′ 𝒋′ + 𝜉𝑧′ 𝒌′
5) Curvature 𝜅𝑐 of intersecting curve at point 𝑃.
2 Calculation of Curvature
1) Conjugate contact point 𝑃 on the first conjugate surface 𝐴 corresponding to 𝑹2𝑝 =
𝑥𝑝′ 𝒊′ + 𝑦𝑝′ 𝒋′ + 𝑧𝑝′ 𝒌′ on the second conjugate surface 𝐴̅.
Application of expression (1.3.4-3) yields point vector 𝑹1𝑝 for conjugate contact point 𝑃 on the
first conjugate surface 𝐴 as follow:
𝑹1𝑝 = 𝑹2𝑝 + 𝑙𝒑 = 𝑥𝑝 𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌 (1.6.1-1)
Where:
~ 108 ~
𝑥𝑝 = 𝑥𝑝′ + 𝑓,
𝑦𝑝 = 𝑦𝑝′ cos 𝛼 + 𝑧𝑝′ sin 𝛼 + ℎ,}
𝑧𝑝 = −𝑦𝑝′ sin 𝛼 + 𝑧𝑝′ cos 𝛼 .
Expression (1.3.5-3) gives relative velocity of point 𝑃 on the first conjugate surface 𝐴 with
respect to intersecting curve, that is,
𝒗12 ′ 12 12 12
𝑝 = 𝒗𝑝 − 𝒗𝑝 = 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑧 𝒌
𝑑𝜎 𝑑𝜎 𝑑(𝑙𝒑) (1.6.1-2)
= (𝝎1 − 𝑀𝝎2 ) × 𝑹1𝑝 + 𝑑𝜀 1 𝝎1 + 𝑀𝝎2 × (𝑙𝒑) − 𝑑𝜀 2 𝝎2 −
1 1 𝑑𝜀1
Where:
12 𝑑𝑓
1
𝑣𝑝𝑦 = (1 + 𝑀 cos 𝛼)𝑥𝑝 − 𝑀𝑓 cos 𝛼 + 𝑑𝜀 sin 𝛼 − 𝑑𝜀 ,
1 1
12 𝑑𝜎1 𝑑𝜎2
𝑣𝑝𝑧 = −𝑀𝑥𝑝 sin 𝛼 + 𝑀𝑓 sin 𝛼 + 𝑑𝜀 + 𝑑𝜀 cos 𝛼 . }
1 1
Expression (1.5.2-7) gives
𝝎2 × (𝑹1𝑝 − 𝑙𝒑) − 𝝎1 + 𝝎2 + + 𝑀𝝎2 × [𝒗𝑝 − ]
𝑱𝑝 = { 𝑑𝜎2 𝑑(𝑙𝒑)
}
−𝝎1 × [𝑀𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + 𝑑𝜀 𝝎2 + ]
1 𝑑𝜀1
2) Unit normal 𝑵1𝑝 = 𝐴𝑝 𝒊 + 𝐵𝑝 𝒋 + 𝐶𝑝 𝒌 to the first conjugate surface 𝐴 at conjugate

contact point 𝑃.
Because intersecting curve is always an instantaneous contact line with the first conjugate
surface 𝐴, that is, 𝜻 = 𝜁𝑥′ 𝒊′ + 𝜁𝑦′ 𝒋′ + 𝜁𝑧′ 𝒌′ = ±𝒆, and 𝜻 ⊥ 𝑵1𝑝 . Meanwhile, due to point 𝑃(𝑹1𝑝 )
being a conjugate contact point, thus, 𝒗12 𝑝 ⊥ 𝑵1𝑝 , therefore, unit normal 𝑵1𝑝 to the first
conjugate surface 𝐴 is
𝜻×𝒗12
𝑝
𝑵1𝑝 = ± |𝜻×𝒗12| (1.6.1-3)
𝑝
3) Normal curvature 𝐾1𝜁 of the first conjugate surface 𝐴 at point 𝑃(𝑹1𝑝 ) in direction 𝜻.
Due to intersecting curve being a curve on the first conjugate 𝐴, normal curvature 𝐾1𝜁 of the
first conjugate surface 𝐴 at point 𝑃(𝑹1𝑝 ) in direction 𝜻 is calculated by application of
~ 109 ~
𝐾1𝜁 = −𝜅𝑐 (𝑵1𝑝 ∙ 𝝃) (1.6.1-4)
4) Torsional curvature 𝐺1𝜁 of the first conjugate surface 𝐴 at point 𝑃(𝑹1𝑝 ) in direction 𝜻.
Application of expressions (1.2.1-27), (1.5.2-11) and (1.5.2-17) gives
𝒗𝟏𝟐
𝒑
𝐾1𝜆 |𝒗𝟏𝟐
𝒑 |−[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙ 𝟏𝟐
𝐾1𝜁 −𝐾1𝜆 𝐷𝑝 |𝒗𝒑 |
= tan 𝜃𝜆𝜁 = tan 𝜃𝜆𝑒 = − 𝐸 = − 𝒗𝟏𝟐
(1.6.1-5)
𝐺1𝜁 +𝐺1𝜆 𝑝 𝒑
|𝒗𝟏𝟐
𝒑 |𝐺1𝜆 +(𝝎1 −𝑀𝝎2 )∙ 𝟏𝟐
|𝒗𝒑 |
Expression (1.6.1-5) generates following two equations,
𝒗12
𝑝 𝒗12
𝑝
𝐸𝑝 [𝐾1𝜆 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ 2 ] = 𝐷𝑝 [𝐺1𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ 𝟐 ],
|𝒗12
𝑝 | |𝒗12
𝑝 | }
𝐸𝑝 (𝐾1𝜆 − 𝐾1𝜁 ) = 𝐷𝑝 (𝐺1𝜁 + 𝐺1𝜆 ).
Eliminating 𝐾1𝜆 and 𝐺1𝜆 by the first formula minus the second formula in simultaneous
equation above results in
𝒗12
𝑝 𝒗𝟏𝟐
𝐾1𝜁 −[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙ 𝒑
2 𝑵1𝑝 ∙( 𝟏𝟐 ×𝜻)
|𝒗12
𝑝 | 𝐷𝑝 sin 𝜃 |𝒗𝒑 |
𝒗12
= − 𝐸 = cos 𝜃𝜆𝑒 = 𝒗𝟏𝟐
(1.6.1-6)
𝑝 𝑝 𝜆𝑒 𝒑
𝐺1𝜁 −(𝝎1 −𝑀𝝎2 )∙ 𝟐 ∙𝜻
|𝒗12 |𝒗𝟏𝟐
𝒑 |
𝑝 |
𝐺1𝜁 is derived by expression (1.6.1-6) as follow
𝒗12
𝑝 ∙𝜻 𝒗12
𝑝 𝒗12
𝑝
𝐺1𝜁 = 𝑵 12 {𝐾1𝜁 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ 𝟐 } + (𝝎1 − 𝑀𝝎2 ) ∙ 𝟐 (1.6.1-7)
1𝑝 ∙(𝒗𝑝 ×𝜻) |𝒗12
𝑝 | |𝒗12
𝑝 |
5) Normal curvature 𝐾1𝑞 of the first conjugate surface 𝐴 at point 𝑃(𝑹1𝑝 ) in direction 𝒒 =
𝑵1𝑝 × 𝜻.
Normal curvature 𝐾2𝑞 of intersecting curve in direction 𝒒 = 𝑵1𝑝 × 𝜻 is 𝐾2𝑞 → ∞, therefore,

̅𝑞 = 𝐾
𝐾 ̅𝑔 = 𝐾1𝑞 + 𝐾2𝑞 → ∞ , application of expression (1.5.3-6) results in
𝒗12
𝑝
𝐷𝑝 |𝒗12
𝑝 | + 𝑱𝑝 ∙ 𝑵1𝑝 = [𝐾1𝜆 |𝒗12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ ] |𝒗12
𝑝 | + 𝑱𝑝 ∙ 𝑵1𝑝 = 0
|𝒗12
𝑝 |
Thus,
[(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙𝒗12

𝑝 −𝑱𝑝 ∙𝑵1𝑝
𝐾1𝜆 = 𝟐 (1.6.1-8)
|𝒗12
𝑝 |
~ 110 ~
Due to
𝐾1𝜆 = 𝐾1𝜁 cos 2 𝜃𝜁𝜆 + 𝐾1𝑞 sin2 𝜃𝜁𝜆 + 2𝐺1𝜁 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 (1.6.1-9)
Expression (1.6.1-1) leads
𝑵1𝑝 ∙(𝜻×𝒗𝟏𝟐
𝒑 )
sin 𝜃𝜁𝜆 = |𝒗𝟏𝟐
,
𝒑 |
𝟏
} (1.6.1-10)
cos 𝜃𝜁𝜆 = |𝒗𝟏𝟐 | (𝜻 ∙ 𝒗𝟏𝟐
𝒑 ).
𝒑
𝒗𝟏𝟐
𝒑
Where: 𝝀 = |𝒗𝟏𝟐| .
𝒑

2
(𝜻∙𝒗𝟏𝟐
𝒑 ) 2(𝜻∙𝒗𝟏𝟐
𝒑 ) [(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙𝒗𝟏𝟐
𝒑 −𝑱𝑝 ∙𝑵1𝑝
𝐾1𝑞 = − 2 𝐾1𝜁 − [𝑵 𝟏𝟐 𝐺1𝜁 + 2 (1.6.1-11)
[𝑵1𝑝 ∙(𝜻×𝒗𝟏𝟐
𝒑 )] 1𝑝 ∙(𝜻×𝒗𝒑 )] [𝑵1𝑝 ∙(𝜻×𝒗𝟏𝟐
𝒑 )]
6) Torsional curvature 𝐺1𝑞 of the first conjugate surface 𝐴 at point 𝑃(𝑹1𝑝 ) in direction
𝒒 = 𝑵1𝑝 × 𝜻.
𝐺1𝑞 = −𝐺1𝜁 (1.6.1-12)
Where: 𝐺1𝜁 is calculated in expression (1.6.1-7).
1.6.2 Calculation of Curvature for Conical Helicoids

1 Coordinate System
Relationship between coordinate systems 𝑂 − 𝒊, 𝒋, 𝒌 and 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ is resulted from
expression (1.3.3-1) by letting 𝛼 = 0 as shown in figure 1.6.2-1
𝒊′ = 𝒊, 𝒋′ = 𝒋, 𝒌′ = 𝒌,
̅̅̅̅̅′ = 𝑓𝒊 + ℎ𝒋, }
𝑙𝒑 = 𝑂𝑂
(1.6.2-1)
2 Conjugate Motion
1) Conjugate motion 𝜑1 of the first conjugate surface 𝐴
The first conjugate surface 𝐴 rotates about 𝒌 as an axis and translates along 𝒌 with a constant
𝑑𝜎
rate of axial leads 𝑏𝑎 , that is, 𝑑𝜀 1 = 𝑏𝑎 .
1
2) Conjugate motion 𝜑2 of the second conjugate surface 𝐴̅

~ 111 ~
The second conjugate surface 𝐴̅ (that is, cutting edge) is fixed to coordinate system 𝑂′ −
𝒊′ , 𝒋′ , 𝒌′ and relative motion of coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ with respect to coordinate
𝑑(𝑙𝒑)
systems 𝑂 − 𝒊, 𝒋, 𝒌 is = 𝑏𝑟 cos 𝛾 𝒊 + 𝑏𝑟 sin 𝛾 𝒋, where: 𝑏𝑟 is constant rate of radial lead.
𝑑𝜀1
Therefore, a pair of conjugate motion (𝜑1 , 𝜑2 ) corresponding to a pair conjugate

surfaces (𝐴, 𝐴̅ ) are as follow:
𝑑𝜎1 𝑑2 𝜎1 𝑑𝜎2 𝑑2 𝜎2
= 𝑏𝑎 , = 0, = = 0,
𝑑2 (𝑙𝒑) 𝑑𝑀
} (1.6.2-2)
𝑑(𝑙𝒑)
= 𝑏𝑟 cos 𝛾 𝒊 + 𝑏𝑟 sin 𝛾 𝒋, = 0, 𝑀 = 𝑑𝜀 = 0.
𝑑𝜀1 𝑑𝜀12 1
3) Calculation point 𝑃
Position vector 𝑹1𝑝 of point 𝑃 on generating edge, i.e., cutting edge, is expressed in coordinate
system 𝑂 − 𝒊, 𝒋, 𝒌 as
𝑹1𝑝 = 𝜂𝒓0 + 𝑧𝑝 𝒌 = 𝜂 cos 𝜇 𝒊 + 𝜂 sin 𝜇 𝒋 + 𝑧𝑝 𝒌 (1.6.2-3)
Where: 𝒓0 = cos 𝜇 𝒊 + sin 𝜇 𝒋 as shown in figure 1.6.2-1
𝒌 𝒌
𝜻 𝝃 𝒌′
𝛽 𝜈
𝑹1𝑝 𝒘0
𝑂 (𝑙𝒑) 𝑹2𝑝 𝒋
𝜂 𝑧𝑝 𝒌 𝑂′ 𝒋′
𝜇 𝜎 𝒘0
𝒊 𝒓0 𝒊′
Figure 1.6.2-1 coordinate system
4) Relative velocity 𝒗𝟏𝟐

𝒑 at point 𝑃
With help of expression (1.6.2-2), application of expression (1.6.1-2) yields 𝒗12

𝑝 as follow:
~ 112 ~
𝒗12 1 2
1 1 𝑑𝜀1
= 𝒌 × 𝑹1𝑝 + 𝑏𝑎 𝒌 − 𝑏𝑟 cos 𝛾 𝒊 − 𝑏𝑟 sin 𝛾 𝒋
(1.6.2-4)
= (−𝜂 sin 𝜇 − 𝑏𝑟 cos 𝛾)𝒊 + (𝜂 cos 𝜇 − 𝑏𝑟 sin 𝛾)𝒋 + 𝑏𝑎 𝒌,
|𝒗12 𝟐 2 2
𝑝 | = √𝜂 + 𝑏𝑟 + 𝑏𝑎 + 2𝜂𝑏𝑟 sin(𝜇 − 𝜇) . }
5) Parameter 𝑱𝑝
With help of expression (1.6.2-2), expression (1.5.2-7) gives
𝝎2 × (𝑹1𝑝 − 𝑙𝒑) − 𝝎1 + 𝝎2 + + 𝑀𝝎2 × [𝒗𝑝 − ]
𝑱𝑝 = { }
−𝝎1 × [𝑀𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + 𝑑𝜀 𝝎2 +
𝑑𝜎2 𝑑(𝑙𝒑)
] (1.6.2-5)
1 𝑑𝜀1
= −𝒌 × (𝑏𝑟 cos 𝛾 𝒊 + 𝑏𝑟 sin 𝛾 𝒋) = 𝑏𝑟 sin 𝛾 𝒊 − 𝑏𝑟 cos 𝛾 𝒋
3 Parameters of Cutting Edge

1) Unit tangent 𝜻 to cutting edge
Let 𝒘0 be as follow:
𝒘0 = (𝜎𝒌) ⊗ 𝒓0 = (𝜎𝒌) ⊗ (cos 𝜇 𝒊 + sin 𝜇 𝒋) = cos(𝜇 + 𝜎) 𝒊 + sin(𝜇 + 𝜎) 𝒋 (1.6.2-6)
Unit tangent 𝜻 to cutting edge is
𝜻 = (𝛽𝒘0 ) ⊗ 𝒌 = cos 𝛽 𝒌 + sin 𝛽 𝒘0 × 𝒌

(1.6.2-7)
= sin 𝛽 sin(𝜇 + 𝜎) 𝒊 − sin 𝛽 cos(𝜇 + 𝜎) 𝒋 + cos 𝛽 𝒌
2) Principal normal 𝝃 to cutting edge
𝝃 = (𝜈𝜻) ⊗ 𝒘0 = cos 𝜈 𝒘0 + sin 𝜈 𝜻 × 𝒘0

[cos 𝜈 cos(𝜇 + 𝜎) − sin 𝜈 cos 𝛽 sin(𝜇 + 𝜎)]𝒊 (1.6.2-8)
={ }
+[cos 𝜈 sin(𝜇 + 𝜎) + sin 𝜈 cos 𝛽 cos(𝜇 + 𝜎)]𝒋 + sin 𝜈 sin 𝛽 𝒌
4 Curvature of Surface Generated by Cutting Edge

1) Unit normal 𝑵1𝑝 to the first conjugate surface 𝐴
−[𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + cos 𝛽 (𝜂 cos 𝜇 − 𝑏𝑟 sin 𝛾)]𝒊

𝜻×𝒗12
𝑝 1
𝑵1𝑝 = = 𝑄 { −[𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + cos 𝛽 (𝜂 sin 𝜇 + 𝑏𝑟 cos 𝛾)]𝒋 } (1.6.2-9)
𝑄
+ sin 𝛽 [𝜂 sin 𝜎 − 𝑏𝑟 cos(𝜇 + 𝜎 − 𝛾)]𝒌
~ 113~
Where:
[𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + cos 𝛽 (𝜂 cos 𝜇 − 𝑏𝑟 sin 𝛾)]2

2
𝑄 = ±|𝜻 × 𝒗12
𝑝 | = ±√{+[[𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + cos 𝛽 (𝜂 sin 𝜇 + 𝑏𝑟 cos 𝛾)]] }
+[𝜂 sin 𝜎 − 𝑏𝑟 cos(𝜇 + 𝜎 − 𝛾)]2 sin2 𝛽
2) Normal curvature 𝐾1𝜁 of the first conjugate surface 𝐴 at point 𝑃 in direction 𝜻
𝜅𝑐 𝑏𝑎 sin 𝛽 cos 𝜈 − 𝜂(sin 𝜈 sin 𝜎 − cos 𝜈 cos 𝜎 cos 𝛽)

𝐾1𝜁 = −𝜅𝑐 (𝑵1𝑝 ∙ 𝝃) = { } (1.6.2-10)
𝑄 +𝑏𝑟 [sin 𝜈 cos(𝜇 + 𝜎 − 𝛾) + cos 𝛽 cos 𝜈 sin(𝜇 + 𝜎 − 𝛾)]
3) Torsional curvature 𝐺1𝜁 of the first conjugate surface 𝐴 at point 𝑃 in direction 𝜻
With help of expressions (1.6.2-2), (1.6.2-7) and (1.6.2-9), Expression (1.6.1-7) generates
𝒗𝟏𝟐
𝒑 ∙𝜻 𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑
𝐺1𝜁 = 𝑵 {𝐾1𝜁 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ 𝟏𝟐 𝟐
} + (𝝎1 − 𝑀𝝎2 ) ∙ 𝟐
∙(𝒗𝟏𝟐 ×𝜻) |𝒗𝒑 | |𝒗𝟏𝟐
1𝑝 𝒑 𝒑 |
𝒗𝟏𝟐
𝒑 ∙𝜻 𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑
=− [𝐾1𝜁 − (𝒌 × 𝑵1𝑝 ) ∙ 𝟐 ]+𝒌∙ 𝟐
𝑄 |𝒗𝟏𝟐 |𝒗𝟏𝟐
𝒑 | 𝒑 |
𝒗𝟏𝟐
𝒑 ∙𝜻 (𝒗𝟏𝟐 𝟏𝟐 𝟏𝟐
𝒑 ∙𝜻)(𝑵1𝑝 ×𝒗𝒑 )+𝑄𝒗𝒑
=− 𝐾1𝜁 + 𝒌 ∙ 𝟐
𝑄 𝑄|𝒗𝟏𝟐
𝒑 |
𝒗𝟏𝟐
𝒑 ∙𝜻 (𝒗𝟏𝟐 𝟏𝟐 𝟏𝟐 𝟏𝟐
𝒑 ∙𝜻)(𝑵1𝑝 ×𝒗𝒑 )−𝒗𝒑 [(𝑵1𝑝 ×𝒗𝒑 )∙𝜻] (1.6.2-11)
=− 𝐾1𝜁 + 𝒌 ∙ 𝟐
𝑄 𝑄|𝒗𝟏𝟐
𝒑 |
𝒗𝟏𝟐
𝒑 ∙𝜻 [𝒗𝟏𝟐 𝟏𝟐
𝒑 ×(𝑵1𝑝 ×𝒗𝒑 )]×𝜻 𝒗𝟏𝟐
𝒑 ∙𝜻 𝑵1𝑝 ×𝜻
=− 𝐾1𝜁 + 𝒌 ∙ 𝟐 =− 𝐾1𝜁 + 𝒌 ∙
𝑄 𝑄|𝒗𝟏𝟐 𝑄 𝑄
𝒑 |
𝐾1𝜁
− {𝑏𝑎 cos 𝛽 − [𝜂 cos 𝜎 + 𝑏𝑟 sin(𝜇 + 𝜎 − 𝛾)] sin 𝛽}
𝑄
={ sin 𝛽
}
+ {𝑏𝑎 sin 𝛽 + [𝜂 cos 𝜎 + 𝑏𝑟 sin(𝜇 + 𝜎 − 𝛾)] cos 𝛽}
𝑄2
Where: 𝑄 is calculated by expression (1.6.2-9) and 𝐾1𝜁 is decided by expression (1.6.2-10).
4) Normal curvature 𝐾1𝑞 of the first conjugate surface 𝐴 at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻
Expression (1.6.2-11) is rewritten as follow:

𝟐
(𝒗𝟏𝟐
𝒑 ∙𝜻) (𝒗𝟏𝟐
𝒑 ∙𝜻) (𝒗𝟏𝟐
𝒑 ∙𝜻)(𝑵1𝑝 ×𝜻)
− 𝐾1𝜁 − 𝐺1𝜁 = −𝒌 ∙
𝑄2 𝑄 𝑄2
With help of expressions (1.6.2-4), (1.6.2-5), (1.6.2-7) and (1.6.2-9), substitution of expression
~ 114 ~
above into expression (1.6.1-11) gives
2
(𝜻∙𝒗12
𝑝 ) 2(𝜻∙𝒗𝟏𝟐
𝒑 ) [(𝝎1 −𝑀𝝎2 )×𝑵1𝑝 ]∙𝒗12
𝑝 −𝑱𝑝 ∙𝑵1𝑝
𝐾1𝑞 = − 2 𝐾1𝜁 − 𝐺 +
[𝑵1𝑝 ∙(𝜻×𝒗𝟏𝟐
𝒑 )]
[𝑵 1𝑝 ∙(𝜻×𝒗𝟏𝟐 )] 1𝜁
𝒑 [𝑵1𝑝 ∙(𝜻×𝒗𝟏𝟐
𝒑 )]
2
2
(𝜻∙𝒗𝟏𝟐
𝒑 ) 2(𝜻∙𝒗𝟏𝟐
𝒑 ) (𝑵1𝑝 ×𝒗𝟏𝟐
𝒑 )∙𝒌−𝑱𝑝 ∙𝑵1𝑝
=− 𝐾1𝜁 − 𝐺1𝜁 +
𝑄2 𝑄 𝑄2
(𝜻∙𝒗𝟏𝟐
𝒑 ) (𝒗𝟏𝟐 𝟏𝟐
𝒑 ∙𝜻)(𝑵1𝑝 ×𝜻)−(𝑵1𝑝 ×𝒗𝒑 ) 𝑱𝑝 ∙𝑵1𝑝
=− 𝐺1𝜁 − 𝒌 ∙ −
𝑄 𝑄2 𝑄2
(𝜻∙𝒗𝟏𝟐
𝒑 ) 𝑵1𝑝 ×[𝜻(𝜻∙𝒗𝟏𝟐 𝟏𝟐
𝒑 )−𝒗𝒑 ] 𝑱𝑝 ∙𝑵1𝑝 (𝜻∙𝒗𝟏𝟐
𝒑 ) 𝑵1𝑝 ×[𝜻×(𝜻×𝒗𝟏𝟐
𝒑 )] 𝑱𝑝 ∙𝑵1𝑝 (1.6.2-12)
= 𝐺1𝜁 − 𝒌 ∙ − = 𝐺1𝜁 − 𝒌 ∙ −
𝑄 𝑄2 𝑄2 𝑄 𝑄2 𝑄2
(𝜻∙𝒗𝟏𝟐
𝒑 ) 𝑵1𝑝 ×[𝜻×𝑵1𝑝 ] 𝑱𝑝 ∙𝑵1𝑝 (𝜻∙𝒗𝟏𝟐
𝒑 )
𝜻 𝑱𝑝 ∙𝑵1𝑝
= 𝐺1𝜁 − 𝒌 ∙ − =
𝐺1𝜁 − 𝒌 ∙ 𝑄 −
𝑄 𝑄 𝑄2
𝑄 𝑄2
cos 𝛽+𝐺1𝜁 {𝑏𝑎 cos 𝛽−[𝜂 cos 𝜎+𝑏𝑟 sin(𝜇+𝜎−𝛾)] sin 𝛽}
− 𝑄
={ 𝑏𝑟 {𝑏𝑎 sin 𝛽 sin(𝜇+𝜎−𝛾)+cos 𝛽[𝜂 sin(𝜇−𝛾)+𝑏𝑟 ]}
}
− 𝑄3
5) Torsional curvature 𝐺1𝑞 of the first conjugate surface 𝐴 at point 𝑃 in direction 𝒒 =

𝑵1𝑝 × 𝜻
𝐺1𝑞 = −𝐺1𝜁 (1.6.2-13)
Where: 𝐺1𝜁 is calculated in expression (1.6.2-11).
~115 ~
Chapter 7
Motion Requirement for Generating Surface (Surface of Cutter) with

Respect to Group of Line Contact Conjugate Surfaces with
Interchangeability
1.7.1 Interchangeability of Conjugate Surfaces

Given a benchmark surface 𝑇0 and benchmark motion 𝜑0 , in addition, a series of conjugate
surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) and corresponding conjugate motions 𝜑𝑖 . Any surface 𝐴𝑖 can be in
line conjugate contact with benchmark surface 𝑇0 under a pair of conjugate motions (𝜑0 , 𝜑𝑖 ).
That is, conjugate surface 𝐴𝑖 can be calculated by benchmark surface 𝑇0 with a pair of
conjugate motions (𝜑0 , 𝜑𝑖 ). Within a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ), if any two
surfaces (𝐴𝑟 , 𝐴𝑠 ) can be in line conjugate contact to each other with corresponding conjugate
motions (𝜑𝑟 , 𝜑𝑠 ), then, a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) are called having
interchangeability with respect to benchmark surface 𝑇0 and benchmark motion 𝜑0 .
In manufacturing practice, surface of cutter is considered as benchmark surface 𝑇0 and used to

generate a pair of line contact conjugate surfaces (𝐴𝑟 , 𝐴𝑠 ) with specified conjugate motions
(𝜑𝑟 , 𝜑𝑠 ), if the motion of cutter, i.e., benchmark motion 𝜑0 , satisfies the requirement of
interchangeability.
1.7.2 Motion Requirement for Interchangeability of Conjugate

Surfaces
If benchmark surface 𝑇0 can contact with any surface 𝐴𝑖 within a series of conjugate surfaces 𝐴𝑖
(𝑖 = 1,2,3, ⋯ ) under corresponding conjugate motion (𝜑0 , 𝜑𝑖 ) along the same instantaneous
contact line in whole motion process, that is, any pair of surfaces (𝑇0 , 𝐴𝑖 ) have the same path of
contact 𝐸, then, any pair of two surfaces (𝐴𝑟 , 𝐴𝑠 ) within a series of conjugate surfaces 𝐴𝑖
(𝑖 = 1,2,3, ⋯ ) can be in line conjugate contact to each other under corresponding conjugate
motion (𝜑𝑟 , 𝜑𝑠 ) in the same instantaneous contact line. Therefore, requirement for
interchangeability within a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) is that any surface 𝐴𝑖
within a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) has the same common path of contact 𝐸
with benchmark surface 𝑇0 .
Assume that requirement for interchangeability of conjugate surfaces is satisfied and point 𝒓 is
any point on common path of contact 𝐸 as shown in figure 1.7.2-1, benchmark surface 𝑇0
~116 ~
reaches the position passing through point 𝒓 after rotating by an angle 𝜀0 under benchmark
motion 𝜑0 . Benchmark motion 𝜑0 is composed of rotation 𝜀0 𝝎0 about 𝝎0 as an axis with
translation 𝜎0 𝝎0 in direction 𝝎0 . Conjugate motion 𝜑𝑖 is composed of rotation 𝜀𝑖 𝝎𝑖 about 𝝎𝑖
as an axis with translation 𝜎𝑖 𝝎𝑖 in direction 𝝎𝑖 and translation (𝑙𝒑)𝑖 with respect to origin 𝑂 of
coordinate system 𝑂 − 𝒊, 𝒋, 𝒌.
Let 𝒏𝑡 be unit normal to benchmark surface 𝑇0 at the point corresponding to point 𝒓. Because
point 𝒓 is common conjugate contact point with any surface within a series of conjugate
surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ), requirement of conjugate contact, i.e., expression (1.3.7-3), must be
satisfied. Relative velocity 𝒗0𝑖
𝑝 of point 𝒓 on benchmark surface 𝑇0 with respect to common
point on any conjugate surface within a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) at instant
rotating angle 𝜀0 is derived by expression (1.3.5-3)
𝑑𝜎 𝑑𝜎 𝑑(𝑙𝒑)𝑖
𝒗0𝑖 0 𝑖
𝑝 = (𝝎0 − 𝑀𝑖 𝝎𝑖 ) × 𝒓 + 𝑑𝜀 𝝎0 + 𝑀𝑖 𝝎𝑖 × (𝑙𝒑)𝑖 − 𝑑𝜀 𝝎𝑖 −
0 0 𝑑𝜀0
𝑑𝜀
Where: 𝑀𝑖 = 𝑑𝜀 𝑖 .
0
𝒌(𝝎0 ) 𝐸
𝑇0
𝒓 𝐴𝑖
𝑂 𝛼𝑖 𝒌′
(𝑙𝒑)𝑖
𝒊 𝑂𝑖 𝒋′
𝒊′
𝝎𝑖
Figure 1.7.2-1
~ 117 ~
Requirement of conjugate contact, i.e., expression (1.3.7-3), results in
𝑑𝜎 𝑑𝜎 𝑑(𝑙𝒑)𝑖
[(𝝎0 − 𝑀𝑖 𝝎𝑖 ) × 𝒓 + 𝑑𝜀 0 𝝎0 + 𝑀𝑖 𝝎𝑖 × (𝑙𝒑)𝑖 − 𝑑𝜀 𝑖 𝝎𝑖 − ] ∙ 𝒏𝑡 = 0 (1.7.2-1)
0 0 𝑑𝜀0
Because 𝒓 is any common conjugate contact point 𝑃 on instantaneous contact line between any
conjugate surfaces within a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) and 𝒏𝑡 is common
unit normal to all surfaces within a series of conjugate surfaces 𝐴𝑖 (𝑖 = 1,2,3, ⋯ ) corresponding
to point 𝑃, Existence of expression (1.7.2-1) results in requirement for conjugate motion
(𝜑0 , 𝜑𝑖 ) as follow
𝜗𝑖 (𝝎0 − 𝑀𝑖 𝝎𝑖 ) = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,

𝑑𝜎0 𝑑𝜎 𝑑(𝑙𝒑)𝑖 } (1.7.2-2)
𝜗𝑖 [ 𝑑𝜀 𝝎0 + 𝑀𝑖 𝝎𝑖 × (𝑙𝒑)𝑖 − 𝑑𝜀 𝑖 𝝎𝑖 − ] = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛.
0 0 𝑑𝜀0
Where: 𝜗𝑖 = 𝜗𝑖 (𝜀0 ) is function of 𝜀0 to be determined. Vector of conservation in expression

above is with respect to value of 𝜀0 or just a constant vector.
Let 𝜑𝑟 and 𝜑𝑠 be any two conjugate motions within a series of conjugate motions 𝜑𝑖 ,
substitution of 𝜑𝑟 and 𝜑𝑠 into the first formular of expression (1.7.2-2) gives
𝜗𝑟 (𝝎0 − 𝑀𝑟 𝝎𝑟 ) = 𝜗𝑠 (𝝎0 − 𝑀𝑠 𝝎𝑠 )
Because conjugate motions 𝜑𝑟 and 𝜑𝑠 are different from each other, that is, 𝑀𝑟 𝝎𝑟 ≠ 𝑀𝑠 𝝎𝑠 ,
thus, 𝜗𝑟 ≠ 𝜗𝑠 .
Dot product on both sides of expression above with (𝝎𝑟 × 𝝎𝑠 ) leads
𝜗𝑟 𝝎0 ∙ (𝝎𝑟 × 𝝎𝑠 ) = 𝜗𝑠 𝝎0 ∙ (𝝎𝑟 × 𝝎𝑠 )
That is
(𝜗𝑟 − 𝜗𝑠 )𝝎0 ∙ (𝝎𝑟 × 𝝎𝑠 ) = 0
Due to 𝜗𝑟 ≠ 𝜗𝑠 , thus,
𝝎0 ∙ (𝝎𝑟 × 𝝎𝑠 ) = 0 (1.7.2-3)
Therefore, 𝝎0 , 𝝎𝑟 and 𝝎𝑠 are coplanar. Let 𝝎0 = 𝒌, then, any rotating axis 𝝎𝑖 of conjugate
motion 𝜑𝑖 within a series of conjugate motions 𝜑𝑖 can be expressed as
𝝎𝑖 = − sin 𝛼𝑖 𝒋 − cos 𝛼𝑖 𝒌,
}
(𝑙𝒑)𝑖 = 𝑓𝒊 𝒊 + ℎ𝒊 𝒋.
~ 118 ~
Substitution of expression above into expression (1.7.2-2) results in
𝜗𝑖 [𝒌 + 𝑀𝑖 (sin 𝛼𝑖 𝒋 + cos 𝛼𝑖 𝒌)]

= 𝜗𝑖 [𝑀𝑖 sin 𝛼𝑖 𝒋 + (1 + 𝑀𝑖 cos 𝛼𝑖 )𝒌] = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,
𝑑𝜎0
𝒌 − 𝑀𝑖 (sin 𝛼𝑖 𝒋 + cos 𝛼𝑖 𝒌) × (𝑓𝒊 𝒊 + ℎ𝒊 𝒋)
𝑑𝜀0
𝜗𝑖 [ 𝑑𝜎 𝑑𝑓 𝑑ℎ ]
+ 𝑑𝜀 𝑖 (sin 𝛼𝑖 𝒋 + cos 𝛼𝑖 𝒌) − 𝑑𝜀 𝒊 𝒊 − 𝑑𝜀 𝒊 𝒋
0 0 0
𝑑𝑓𝒊 𝑑ℎ𝒊 𝑑𝜎𝑖
(𝑀𝑖 ℎ𝒊 cos 𝛼𝑖 − 𝑑𝜀 ) 𝒊 − (𝑀𝑖 𝑓𝒊 cos 𝛼𝑖 + 𝑑𝜀 − 𝑑𝜀 sin 𝛼𝑖 ) 𝒋
0 0 0
= 𝜗𝑖 [ 𝑑𝜎0 𝑑𝜎𝑖
] = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛.
+ (𝑀𝑖 𝑓𝒊 sin 𝛼𝑖 + 𝑑𝜀 + 𝑑𝜀 cos 𝛼𝑖 ) 𝒌 }
0 0
Expanding expression above in directions 𝒊, 𝒋 and 𝒌 respectively gives
𝜗𝑖 𝑀𝑖 sin 𝛼𝑖 = 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,

𝜗𝑖 (1 + 𝑀𝑖 cos 𝛼𝑖 ) = 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,
𝑑𝑓
𝜗𝑖 (𝑀𝑖 ℎ𝒊 cos 𝛼𝑖 − 𝑑𝜀 𝒊 ) = 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,
0
𝑑ℎ𝒊 𝑑𝜎𝑖
𝜗𝑖 (𝑀𝑖 𝑓𝒊 cos 𝛼𝑖 + 𝑑𝜀 − 𝑑𝜀 sin 𝛼𝑖 ) = 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,
0 0
𝑑𝜎0 𝑑𝜎𝑖
𝜗𝑖 (𝑀𝑖 𝑓𝒊 sin 𝛼𝑖 + 𝑑𝜀 + 𝑑𝜀 cos 𝛼𝑖 ) = 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛.}
0 0
Where: 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛 in expression above is either a function of 𝜀0 or just a

constant.
Eliminating 𝜗𝑖 from expression above yields

𝑀𝑖 sin 𝛼𝑖
= 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,
1+𝑀𝑖 cos 𝛼𝑖
𝑑𝑓𝒊
𝑀𝑖 ℎ𝒊 cos 𝛼𝑖 −
𝑑𝜀0
𝑀𝑖 𝑓𝒊 cos 𝛼𝑖 +
𝑑ℎ𝒊 𝑑𝜎𝑖
− sin 𝛼𝑖
(1.7.2-4)
𝑑𝜀0 𝑑𝜀0
𝑀𝑖 𝑓𝒊 sin 𝛼𝑖 + + cos 𝛼𝑖
𝑑𝜀0 𝑑𝜀0
= 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,}
Expression (1.7.2-4) is motion requirement for interchangeability of conjugate surfaces which is

only involved with benchmark motion 𝜑0 (𝜀0 𝝎0 , 𝜎0 𝝎0 ) and has nothing with benchmark
surface 𝑇0 . But the geometry of conjugate surface 𝐴𝑖 is directly related with benchmark surface
𝑇0 .
~ 119~
Surfaces in the Case of Intersecting Rotating Axes
In that case, 𝑓𝑖 = ℎ𝑖 = 0, expression (1.7.2-4) is reduced as
𝑑𝜎𝑖
sin 𝛼𝑖
𝑑𝜀0
= 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛, (1.7.3-1)
+ cos 𝛼𝑖
𝑑𝜀0 𝑑𝜀0
= 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛,}
Where: value of conservation in expression (1.7.3-1) is function of 𝜀0 .
1) Constraint of conjugate motion requirement on helical motion

𝑑𝜎
The second formular in expression (1.7.3-1) shows that if any helical motion 𝑑𝜀 𝑟 𝝎𝑟 is equal to
0
𝑑𝜎𝑟 𝑑𝜎𝑖
zero, i.e., 𝑑𝜀 = 0, all the other helical motion 𝑑𝜀 𝝎𝑖 within a series of conjugate motions 𝜑𝑖
0 0
must be also equal to zero. Then, the third formular is updated as
𝑑𝜎0 𝑑𝜎𝑖 𝑑𝜎0
+ cos 𝛼𝑖
= = 𝑐𝑜𝑛𝑠𝑡
1+𝑀𝑖 cos 𝛼𝑖 1+𝑀𝑖 cos 𝛼𝑖
𝑑𝜎
Because 𝑀𝑖 changes with different conjugate motion 𝜑𝑖 , thus, helical motion 𝑑𝜀 0 𝝎0 in
0
𝑑𝜎0
benchmark motion 𝜑0 must be equal to zero, i.e., = 0, in order to keep the third formular
𝑑𝜀0
as constant.
2) Constraint of conjugate motion requirement on transmission ratio
Due to
𝑑𝜀𝑠
𝑑𝜀𝑠 𝑑𝜀0 𝑀
𝑀𝑟𝑠 = 𝑑𝜀 = 𝑑𝜀𝑟 = 𝑀𝑠
𝑟 𝑟
𝑑𝜀0
Then,
𝑀𝑠 = 𝑀𝑟𝑠 𝑀𝑟
Substitution of expression above into the first formular in expression (1.7.3-1) leads to
~ 120 ~
𝑀𝑠 sin 𝛼𝑠 𝑀 𝑀𝑟 sin 𝛼𝑠 𝑀 sin 𝛼𝑟
= 1+𝑀𝑟𝑠 = 1+𝑀𝑟 (1.7.3-2)
1+𝑀𝑠 cos 𝛼𝑠 𝑟𝑠 𝑀𝑟 cos 𝛼𝑠 𝑟 cos 𝛼𝑟
Constraint of conjugate motion requirement on transmission ratio is resulted from expression

(1.7.3-2) as follow:
sin 𝛼𝑟 −𝑀𝑟𝑠 sin 𝛼𝑠
𝑀𝑟 = ,
𝑀𝑟𝑠 sin(𝛼𝑠 −𝛼𝑟 )
sin 𝛼𝑟 −𝑀𝑟𝑠 sin 𝛼𝑠
} (1.7.3-3)
𝑀𝑠 = 𝑀𝑟𝑠 𝑀𝑟 = sin(𝛼 .
𝑠 −𝛼𝑟 )
Expression (1.7.3-3) is used to calculate ratio of roll in manufacturing practice.

Surfaces in the Case of Cross Fixed Rotating Axes
In that case, 𝑓𝑖 = 𝑐𝑜𝑛𝑠𝑡 and ℎ𝑖 = 𝑐𝑜𝑛𝑠𝑡, thus, expression (1.7.2-4) is simplified as
𝑀𝑖 ℎ𝒊 cos 𝛼𝑖
𝑑𝜎𝑖
𝑀𝑖 𝑓𝒊 cos 𝛼𝑖 −
𝑑𝜀0
sin 𝛼𝑖 (1.7.4-1)
𝑀𝑖 𝑓𝒊 sin 𝛼𝑖 + + cos 𝛼𝑖
𝑑𝜀0 𝑑𝜀0
= 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑐𝑜𝑛𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛.}
The first formular in expression (1.7.4-1) shows that if one transmission ratio 𝑀𝑟 is constant
within 𝑀𝑖 (𝑖 = 1,2,3, ⋯ ), the corresponding value of conservation is constant and has nothing
with 𝜀0 , and then, all the other 𝑀𝑖 (𝑖 = 1,2,3, ⋯ ) must be constant. In other word, within a
series of conjugate surface 𝐴𝑖 with interchangeability, if there is one pair of conjugate surfaces
with constant transmission ratio, all other pair of conjugate surfaces must be of constant
transmission ratio.
𝜑𝑟 and 𝜑𝑠 are two conjugate motions selected arbitrarily within a series of conjugate motions
𝜑𝑖 (𝑖 = 1,2,3, ⋯ ). Assume that motion parameters for conjugate motion 𝜑𝑟 are 𝛼𝑟 , 𝑓𝑟 , ℎ𝑟 , 𝑀𝑟
and motion parameters for conjugate motion 𝜑𝑠 are 𝛼𝑠 , 𝑓𝑠 , ℎ𝑠 , 𝑀𝑠 respectively and
𝑑𝜎 𝑑𝜎
corresponding helical motion for both 𝜑𝑟 and 𝜑𝑠 are 𝑑𝜀 𝑟 = 𝑑𝜀 𝑠 = 0. In addition, 𝐴𝑟 and 𝐴𝑠 are
0 0
two conjugate surfaces corresponding to both 𝜑𝑟 and 𝜑𝑠 . In order for 𝐴𝑟 and 𝐴𝑠 to be of
interchangeability with respect to benchmark surface 𝑇0 under benchmark motion 𝜑0 ,
𝑑𝜎 𝑑𝜎
expression (1.7.4-1) must be satisfied by 𝛼𝑟 , 𝑓𝑟 , ℎ𝑟 , 𝑀𝑟 , 𝛼𝑠 , 𝑓𝑠 , ℎ𝑠 , 𝑀𝑠 and 𝑑𝜀 𝑟 = 𝑑𝜀 𝑠 = 0 as
0 0
~121 ~
follow:
𝑀𝑟 sin 𝛼𝑟 𝑀 sin 𝛼𝑠
= 1+𝑀𝑠 ,
1+𝑀𝑟 cos 𝛼𝑟 𝑠 cos 𝛼𝑠
𝑀𝑟 ℎ𝒓 cos 𝛼𝑟 𝑀𝑠 ℎ𝑠 cos 𝛼𝑠
= 1+𝑀 ,
1+𝑀𝑟 cos 𝛼𝑟 𝑠 cos 𝛼𝑠
𝑀𝑟 𝑓𝒓 cos 𝛼𝑟 𝑀 𝑓 cos 𝛼
𝑠 𝑠 𝑠
= 1+𝑀 ,
1+𝑀𝑟 cos 𝛼𝑟 cos 𝛼
𝑠 𝑠
𝑑𝜎 𝑑𝜎0
𝑀𝑟 𝑓𝒓 sin 𝛼𝑟 + 0 𝑀𝑠 𝑓𝑠 sin 𝛼𝑠 +
𝑑𝜀0 𝑑𝜀0
= .}
1+𝑀𝑟 cos 𝛼𝑟 1+𝑀𝑠 cos 𝛼𝑠
Application of expression above results in

𝑀𝑟 sin 𝛼𝑟
𝑀𝑠 = sin 𝛼 ,
𝑠 +𝑀𝑟 sin(𝛼𝑠 −𝛼𝑟 )
𝑓𝑟 sin 𝛼𝑠 cos 𝛼𝑟 tan 𝛼
𝑓𝑠 = = 𝑓𝑟 tan 𝛼𝑠 ,
cos 𝛼𝑠 sin 𝛼𝑟 𝑟
ℎ𝑟 sin 𝛼𝑠 cos 𝛼𝑟 tan 𝛼𝑠 (1.7.4-2)
ℎ𝑠 = = ℎ𝑟 tan 𝛼 ,
cos 𝛼𝑠 sin 𝛼𝑟 𝑟
𝑑𝜎0 (𝑓𝑠 −𝑓𝑟 )𝑀𝑟 𝑀𝑠 sin 𝛼𝑟 sin 𝛼𝑠
= = −𝑓𝑟 tan 𝛼𝑠 = −𝑓𝑠 tan 𝛼𝑟 .}
𝑑𝜀0 𝑀𝑠 sin 𝛼𝑠 −𝑀𝑟 sin 𝛼𝑟
𝑑𝜎
The fourth equation of expression (1.7.4-2) shows that helical motion 𝑑𝜀 0 of benchmark surface
0
𝑇0 is required to generate a pair of line contact conjugate surfaces without helical motion
𝑑𝜎𝑟 𝑑𝜎𝑠
( = = 0).
𝑑𝜀0 𝑑𝜀0
Transmission ratio between conjugate surfaces 𝐴𝑟 and 𝐴𝑠 and their relative position of rotating
axes can be derived by application of expression (1.7.4-2) as follow:
𝑀 sin 𝛼𝑟
𝑀𝑟𝑠 = 𝑀𝑠 = sin 𝛼 ,
𝑟 𝑠 +𝑀𝑟 sin(𝛼𝑠 −𝛼𝑟 )
tan 𝛼 sin(𝛼𝑠 −𝛼𝑟 ) 𝑓 sin 𝛼𝑟𝑠
𝑓𝑟𝑠 = 𝑓𝑠 − 𝑓𝑟 = 𝑓𝑟 (tan 𝛼𝑠 − 1) = 𝑓𝑟 sin 𝛼 = sin𝑟𝛼 , (1.7.4-3)
𝑟 𝑟 cos 𝛼𝑠 𝑟 cos 𝛼𝑠
tan 𝛼 sin(𝛼𝑠 −𝛼𝑟 ) ℎ sin 𝛼𝑟𝑠
ℎ𝑟𝑠 = ℎ𝑠 − ℎ𝑟 = ℎ𝑟 (tan 𝛼𝑠 − 1) = ℎ𝑟 sin 𝛼 = sin𝑟𝛼 .}
𝑟 𝑟 cos 𝛼𝑠 𝑟 cos 𝛼𝑠
Where: 𝛼𝑟𝑠 = 𝛼𝑠 − 𝛼𝑟 .
In manufacturing practice, 𝑀𝑟𝑠 , 𝑓𝑟𝑠 , ℎ𝑟𝑠 , 𝛼𝑠 and 𝛼𝑟 are usually given. Corresponding machine
setting parameters can be determined by application of expressions (1.7.4-2) and (1.7.4-3) as
follow:
~ 122~
sin 𝛼𝑟 −𝑀𝑟𝑠 sin 𝛼𝑠 sin 𝛼𝑟 −𝑀𝑟𝑠 sin 𝛼𝑠
𝑀𝑟 = , 𝑀𝑠 = 𝑀𝑟𝑠 𝑀𝑟 = ,
𝑀𝑟𝑠 sin(𝛼𝑠 −𝛼𝑟 ) sin(𝛼𝑠 −𝛼𝑟 )
𝑓 sin 𝛼 cos 𝛼𝑠 𝑓𝑟𝑠 sin 𝛼𝑠 cos 𝛼𝑟
𝑓𝑟 = 𝑟𝑠 sin 𝛼𝑟 , 𝑓𝑠 = ,
𝑟𝑠 sin 𝛼𝑟𝑠
ℎ𝑟𝑠 sin 𝛼𝑟 cos 𝛼𝑠 ℎ𝑟𝑠 sin 𝛼𝑠 cos 𝛼𝑟
(1.7.4-4)
ℎ𝑟 = , ℎ𝑠 = ,
sin 𝛼𝑟𝑠 sin 𝛼𝑟𝑠
𝑑𝜎0 𝑓𝑟𝑠 𝑀𝑟 𝑀𝑠 sin 𝛼𝑟 sin 𝛼𝑠 𝑓𝑟𝑠 sin 𝛼𝑟 sin 𝛼𝑠 𝑓𝑟𝑠 sin 𝛼𝑠 sin 𝛼𝑟
= =− =− .}
𝑑𝜀0 𝑀𝑠 sin 𝛼𝑠 −𝑀𝑟 sin 𝛼𝑟 sin 𝛼𝑟𝑠 sin 𝛼𝑟𝑠
~ 123 ~
Part II
Non-Circular Gear with Parallel Rotating Axes
Introduction
This part discusses general case of gear set with varied transmission ratio between parallel
rotating axes with varied center distance, including manufacturing methods of shaper, rack and
hob respectively.
~ 124 ~
Chapter 1
Non-Circular Gear Manufactured by Shaper
2.1.1 Motion Requirements and Machine Setting Parameters

1 Motion Condition of Cutters
Assume that 𝐶 and 𝐶̅ are a pair of shapers and can be in conjugate contact to each other.
Tooth profile 𝐴 is generated by 𝐶, and tooth profile 𝐴̅ is generated by 𝐶̅ . If their pitch curves
𝐴0 , ̅̅̅
𝐴0 of tooth profiles 𝐴, 𝐴̅, and pitch curves 𝐶0 , ̅̅̅
𝐶0 of cutters 𝐶 and 𝐶̅ can be in pure rolling
contact with each other at the same instantaneous contact point 𝑃0 during whole
manufacturing process, then, tooth profiles 𝐴 and 𝐴̅ can be in conjugate contact to each other
as shown in figure 2.1.1-1.
Proof:
1) Establishing Coordinate Systems
Coordinate system (𝑂 − 𝒊, 𝒋) is used for tooth profile 𝐴 and rotating axis of tooth profile 𝐴 is
𝝎 = 𝒌 as shown in figure 2.1.1-1.
Coordinate system (𝑂′ − 𝒊′ , 𝒋′ ) is used for tooth profile 𝐴̅ and rotating axis of tooth profile 𝐴̅ is
𝝎′ = −𝒌 as shown in figure 2.1.1-1.
⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂′ = (𝑙𝒑) = 𝑓𝒊 + ℎ𝒋 (2.1.1-1)
Let 𝑃0 (𝑹0𝑝 ) be common instantaneous contact point 𝑃0 , i.e., common pitch point, among
pitch curves 𝐴0 , ̅̅̅
𝐴0 , 𝐶0 and ̅̅̅
𝐶0 at any instant rotating angle 𝜀1 . The coordinates of pitch point
𝑃0 (𝑹0𝑝 ) is calculated by expression (1.4.10-5) and unit normal 𝑵0𝑝 to pitch curve 𝐴0 at pitch
point 𝑃0 (𝑹0𝑝 ) is determined by expression (1.4.10-13).
Coordinate system (𝑂1 − 𝒊1 , 𝒋1 ) is used for cutter 𝐶 and rotating center of cutter 𝐶 is origin 𝑂1
of coordinate system (𝑂1 − 𝒊1 , 𝒋1 ) as shown in figure 2.1.1-1, that is,
⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂1 = (𝑙𝒑)1 = 𝑓1 𝒊1 + ℎ1 𝒋𝟏 ,
𝒊1 = 𝑵0𝑝 = 𝑁𝑜𝑝𝑥 𝒊 + 𝑁𝑜𝑝𝑦 𝒋 , } (2.1.1-2)
𝒋𝟏 = 𝒌 × 𝒊1 = −𝑁𝑜𝑝𝑦 𝒊 + 𝑁𝑜𝑝𝑥 𝒋.
Where: 𝑵0𝑝 is unit normal to pitch curve 𝐴0 of tooth profile 𝐴 at pitch point 𝑃0 and determined
~125 ~
by expression (1.4.10-13).
Pitch circle ̅̅̅

𝐶0 of shaper 𝐶̅
pitch curve 𝐴0 of tooth profile 𝐴
𝒋2
𝑂2 𝑂 𝑹0𝑝 𝒋
𝑟̅0 𝝎2 𝒋1
𝑃0 (𝑙𝒑)1
Cutting edge of 𝐶̅ 𝑃 𝒓𝑝 𝑂1
Tooth profile 𝐴 𝑵1𝑝 𝑂′ 𝝎1 𝒋′
Tooth profile 𝐴̅ 𝑟0
Cutting edge of 𝐶 𝒊1 (𝑵0𝑝 )
𝒊 𝒊′
pitch curve ̅̅̅

𝐴0 of Tooth profile 𝐴̅ pitch circle 𝐶0 of shaper 𝐶
Figure 2.1.1-1 Coordinate System and Motion Condition
Coordinate system (𝑂2 − 𝒊2 , 𝒋2 ) is used for cutter 𝐶̅ and rotating center of cutter 𝐶̅ is origin 𝑂2
of coordinate system (𝑂2 − 𝒊2 , 𝒋2 ) as shown in figure 2.1.1-1, that is,
⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂2 = (𝑙𝒑)2 = 𝑓2 𝒊 + ℎ2 𝒋,
} (2.1.1-3)
𝒊2 = 𝒊1 , 𝒋2 = 𝒋1 .
2) Motion Requirement of Cutter 𝐶 with Respect to Cutter 𝐶̅
Let 𝝎1 and 𝝎𝟐 be rotating axes of 𝐶 and 𝐶̅ respectively, 𝜀𝑐 be rotating angle of cutter 𝐶 about
𝝎1 and 𝜀𝑐̅ be rotating angle of cutter 𝐶̅ about 𝝎2 , that is,
𝝎1 = −𝒌,
} (2.1.1-4)
𝝎2 = 𝒌.
~ 126 ~
Let 𝑹1𝑝 be conjugate contact point 𝑃 among tooth profiles 𝐴, 𝐴̅ and cutting edges of 𝐶 and 𝐶̅
and 𝑵1𝑝 be their corresponding common unit normal to tooth profiles 𝐴, 𝐴̅ , 𝐶 and 𝐶̅ at an
instant rotating angle 𝜀1 ,
𝑹1𝑝 = ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑃0 + ⃗⃗⃗⃗⃗⃗⃗
𝑃0 𝑃 = ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑃0 + 𝒓𝑝 (2.1.1-5)
Let 𝑹𝑐 be conjugate contact point 𝑃 on cutting edge of 𝐶 with respect to origin 𝑂1 of

coordinate system 𝑂1 − 𝒊1 , 𝒋1 as shown in figure 2.1.1-1, that is,
𝑹𝑐 = ⃗⃗⃗⃗⃗⃗⃗
𝑂1 𝑃 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂1 𝑃0 + 𝒓𝑝 = −𝑟0 𝒊1 + 𝒓𝑝 = ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑃0 − ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂1 + 𝒓𝑝
(2.1.1-6)
= 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋 − (𝑙𝒑)1 + 𝒓𝑝 = (𝑥0𝑝 − 𝑓1 )𝒊 + (𝑦0𝑝 − ℎ1 )𝒋 + 𝒓𝑝
Where: (𝑙𝒑)1 = 𝑓1 𝒊 + ℎ1 𝒋 and 𝑟0 is radius of pitch circle of cutter 𝐶. 𝒓𝑝 is a vector from

common pitch point 𝑃0 (𝑹0𝑝 ) to common conjugate contact point 𝑃(𝑹1𝑝 ) among tooth profiles
𝐴, 𝐴̅ , 𝐶 and 𝐶̅ .
With help of expressions (2.1.1-2), (2.1.1-4) and (2.1.1-6), velocity of conjugate contact point 𝑃
on cutting edge of 𝐶 is derived as follow:
𝑑𝜀 𝑑(𝑙𝒑)1 𝑑𝜀 𝑑(𝑙𝒑)1
𝒗𝑐 = 𝑑𝜀𝑐 𝝎1 × 𝑹𝑐 + ⃗⃗⃗⃗⃗⃗⃗⃗⃗
= − 𝑑𝜀𝑐 𝒌 × (𝑂 1 𝑃0 + 𝒓𝑝 ) +
1 𝑑𝜀1 1 𝑑𝜀1
𝑑𝜀𝑐 𝑑𝜀𝑐 𝑑(𝑙𝒑)1
= − 𝑑𝜀 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂1 𝑃0 − 𝑑𝜀 𝒌 × 𝒓𝑝 + (2.1.1-7)
1 1 𝑑𝜀1
𝑑𝜀
= 𝒗0𝑐 − 𝑑𝜀𝑐 𝒌 × 𝒓𝑝
1
Where: 𝜀𝑐 is rotating angle of cutter 𝐶 and 𝒗0𝑐 is velocity of pitch point 𝑃0 on pitch circle 𝐶0 of
cutter 𝐶, that is,
𝒗0𝑐 = − 𝑑𝜀𝑐 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂1 𝑃0 + = − 𝑑𝜀𝑐 𝒌 × [(𝑥0𝑝 − 𝑓1 )𝒊 + (𝑦0𝑝 − ℎ1 )𝒋] +
1 𝑑𝜀1 1 𝑑𝜀1
𝑑𝜀𝑐 𝑑𝑓1 𝑑𝜀𝑐 𝑑ℎ1
(2.1.1-8)
= [𝑑𝜀 (𝑦0𝑝 − ℎ1 ) + 𝑑𝜀 ] 𝒊 + [− 𝑑𝜀 (𝑥0𝑝 − 𝑓1 ) + 𝑑𝜀 ] 𝒋
1 1 1 1
Likewise, let 𝑹𝑐̅ be conjugate contact point 𝑃 on cutting edge of 𝐶̅ with respect to origin 𝑂2 of
coordinate system 𝑂2 − 𝒊2 , 𝒋2 as shown in figure 2.1.1-1, that is,
𝑹𝑐̅ = ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 + 𝒓𝑝 = 𝑟̅0 𝒊1 + 𝒓𝑝 = ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑃0 − ⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂2 + 𝒓𝑝 = 𝑹0𝑝 − (𝑙𝒑)2 + 𝒓𝑝
(2.1.1-9)
= (𝑥0𝑝 − 𝑓2 )𝒊 + (𝑦0𝑝 − ℎ2 )𝒋 + 𝒓𝑝
Where: 𝑟̅0 is radius of pitch circle ̅̅̅

𝐶0 of shaper 𝐶̅ and (𝑙𝒑)2 = 𝑓2 𝒊 + ℎ2 𝒋.
With help of expressions (2.1.1-3), (2.1.1-4) and (2.1.1-9), velocity of conjugate contact point 𝑃
~ 127 ~
on cutting edge 𝐶̅ is yielded as follow:
𝒗𝑐̅ = 𝑑𝜀𝑐̅ 𝝎2 × 𝑹𝑐̅ + = 𝑑𝜀𝑐̅ 𝒌 × ( ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 + 𝒓𝑝 ) +
1 𝑑𝜀1 1 𝑑𝜀1
𝑑𝜀𝑐̅ 𝑑𝜀𝑐̅ 𝑑(𝑙𝒑)2 𝑑𝜀𝑐̅
(2.1.1-10)
= 𝑑𝜀 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 + 𝑑𝜀 𝒌 × 𝒓𝑝 + = 𝒗0𝑐̅ + 𝑑𝜀 𝒌 × 𝒓𝑝
1 1 𝑑𝜀1 1
Where: 𝜀𝑐̅ is rotating angle of cutter 𝐶̅ and 𝒗0𝑐̅ is velocity of pitch point 𝑃0 on pitch circle ̅̅̅
𝐶0 of
cutter 𝐶̅ , that is,
𝒗0𝑐̅ = 𝑑𝜀𝑐̅ 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 + = 𝑑𝜀𝑐̅ 𝒌 × [(𝑥0𝑝 − 𝑓2 )𝒊 + (𝑦0𝑝 − ℎ2 )𝒋] +
1 𝑑𝜀1 1 𝑑𝜀1
𝑑𝜀𝑐̅ 𝑑𝑓2 𝑑𝜀𝑐̅ 𝑑ℎ2
(2.1.1-11)
= [− 𝑑𝜀 (𝑦0𝑝 − ℎ2 ) + 𝑑𝜀 ] 𝒊 + [𝑑𝜀 (𝑥0𝑝 − 𝑓2 ) + 𝑑𝜀 ] 𝒋
1 1 1 1
The relative velocity of cutting edge 𝐶 with respect to cutting edge 𝐶̅ at conjugate contact 𝑃 is
𝑑𝜀 𝑑𝜀
𝒗𝑐 − 𝒗𝑐̅ = 𝒗0𝑐 − 𝒗0𝑐̅ − (𝑑𝜀𝑐 + 𝑑𝜀𝑐̅ ) 𝒌 × 𝒓𝑝 (2.1.1-12)
1 1
Due to 𝑃0 being a pitch point, then,

𝑑𝜀 𝑑(𝑙𝒑) 𝑑𝜀 𝑑(𝑙𝒑)
𝒗0𝑐 − 𝒗0𝑐̅ = − 𝑑𝜀𝑐 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂1 𝑃0 + 𝑑𝜀 1 − 𝑑𝜀𝑐̅ 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 − 𝑑𝜀 2
1 1 1 1
𝑑𝜀𝑐 𝑑𝑓1 𝑑𝜀𝑐̅ 𝑑𝑓2
[𝑑𝜀 (𝑦0𝑝 − ℎ1 ) + 𝑑𝜀 + 𝑑𝜀 (𝑦0𝑝 − ℎ2 ) − 𝑑𝜀 ] 𝒊 (2.1.1-13)
1 1 1 1
={ 𝑑𝜀𝑐 𝑑ℎ1 𝑑𝜀𝑐̅ 𝑑ℎ2
}=0
+ [− (𝑥0𝑝 − 𝑓1 ) + − (𝑥0𝑝 − 𝑓2 ) − ]𝒋
Therefore, the relative velocity of cutting edge 𝐶 with respect to cutting edge 𝐶̅ at conjugate
contact 𝑃, i.e., expression (2.1.1-12), is simplified as follow:
𝑑𝜀 𝑑𝜀
𝒗𝑐 − 𝒗𝑐̅ = − (𝑑𝜀𝑐 + 𝑑𝜀𝑐̅ ) 𝒌 × 𝒓𝑝 (2.1.1-14)
1 1
Because cutting edges of cutters 𝐶 and 𝐶̅ are a pair of given conjugate curves, their relative
velocity at conjugate contact point 𝑃 must be perpendicular to common unit normal 𝑵1𝑝 to
cutting edges, that is,
𝑑𝜀 𝑑𝜀𝑐2
(𝒗𝑐 − 𝒗𝑐̅ ) ∙ 𝑵1𝑝 = − ( 𝑐1 + ) (𝒌 × 𝒓𝑝 ) ∙ 𝑵1𝑝 = 0 (2.1.1-15)
𝑑𝜀 1 𝑑𝜀1
Therefore, 𝒓𝑝 is parallel to 𝑵1𝑝 , and 𝑵1𝑝 must pass through pitch point 𝑃0 .
3) Motion requirement of cutter 𝐶 with respect to tooth profile 𝐴
Velocity 𝒗𝑝 of conjugate contact point 𝑃 on tooth profile 𝐴 at the instant 𝜀1 is
~ 128 ~
⃗⃗⃗⃗⃗⃗⃗0 + 𝒓𝑝 ) = 𝒗0𝑝 + 𝒌 × 𝒓𝑝 = −𝑦0𝑝 𝒊 + 𝑥0𝑝 𝒋 + 𝒌 × 𝒓𝑝
𝒗𝑝 = 𝝎 × 𝑹1𝑝 = 𝝎 × (𝑂𝑃 (2.1.1-16)
Where: 𝝎 = 𝒌, and 𝒗0𝑝 is calculated by expression (1.4.10-19).
With aid of expressions (2.1.1-7) and (2.1.1-16), relative velocity of tooth profile 𝐴 with respect
to cutting edge 𝐶 at conjugate contact point 𝑃 is
𝑑𝜀 𝑑𝜀
𝒗𝑝 − 𝒗𝑐 = 𝒗0𝑝 + 𝒌 × 𝒓𝑝 − 𝒗0𝑐 + 𝑑𝜀𝑐 𝒌 × 𝒓𝑝 = (𝑑𝜀𝑐 + 1) 𝒌 × 𝒓𝑝 (2.1.1-17)
1 1
Where:
𝑑𝜀𝑐 𝑑𝑓1 𝑑𝜀𝑐 𝑑ℎ1
𝒗0𝑝 − 𝒗0𝑐 = [−𝑦0𝑝 − (𝑦0𝑝 − ℎ1 ) − ] 𝒊 + [𝑥0𝑝 + (𝑥0𝑝 − 𝑓1 ) − ]𝒋 = 0 (2.1.1-18)
Inspection of expressions (2.1.1-14) and (2.1.1-17) shows (𝒗𝑝 − 𝒗𝑐 ) ∥ (𝒗𝑐 − 𝒗𝑐̅ ), and thus,
(𝒗𝑝 − 𝒗𝑐 ) ∙ 𝑵1𝑝 = 0 (2.1.1-19)
Therefore, tooth profile 𝐴 can be in conjugate contact with cutting edge 𝐶 at conjugate contact
point 𝑃.
4) Motion requirement of cutting edge of 𝐶̅ with respect to tooth profile 𝐴̅
With help of expression (2.1.1-1), velocity 𝒗′𝑝 of conjugate contact point 𝑃 on tooth profile 𝐴̅ at
the instant 𝜀1 is
𝑑(𝑙𝒑)
⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝒗′𝑝 = 𝑀𝝎′ × (𝑂 ′𝑃 + 𝒓 ) +
0 𝑝 = 𝒗′𝑜𝑝 + 𝑀𝝎′ × 𝒓𝑝 = 𝒗′𝑜𝑝 − 𝑀𝒌 × 𝒓𝑝 (2.1.1-20)
𝑑𝜀1
𝑑𝜀
Where: 𝝎′ = −𝒌, 𝑀 = 𝑑𝜀2 and 𝒗′𝑜𝑝 is velocity of pitch point 𝑃0 on pitch curve ̅̅̅
𝐴0 of tooth
1
profile 𝐴̅, that is,

𝑑(𝑙𝒑) 𝑑(𝑙𝒑)
𝒗′𝑜𝑝 = 𝑀𝝎′ × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂′ 𝑃0 + 𝑑𝜀 = −𝑀𝒌 × [𝑹0𝑝 − (𝑙𝒑)] + 𝑑𝜀
1 1
𝑑𝑓 𝑑ℎ
(2.1.1-21)
= [𝑀(𝑦0𝑝 − ℎ) + 𝑑𝜀 ] 𝒊 + [−𝑀(𝑥0𝑝 − 𝑓) + 𝑑𝜀 ] 𝒋
1 1
With help of expressions (2.1.1-10) and (2.1.1-20), relative velocity of tooth profile 𝐴̅ with
respect to cutting edge of 𝐶̅ at conjugate contact point 𝑃 is
𝑑𝜀 𝑑𝜀
𝒗′𝑝 − 𝒗𝑐̅ = 𝒗′𝑜𝑝 − 𝑀𝒌 × 𝒓𝑝 − 𝒗0𝑐̅ − 𝑑𝜀𝑐̅ 𝒌 × 𝒓𝑝 = − (𝑀 + 𝑑𝜀𝑐̅ ) 𝒌 × 𝒓𝑝 (2.1.1-22)
1 1
Where: 𝒗′𝑜𝑝 − 𝒗0𝑐̅ = 0 is relative velocity of tooth profile 𝐴̅ with respect to cutting edge of 𝐶̅ at
~ 129 ~
pitch point 𝑃0 , application of expressions (2.1.1-11) and (2.1.1-21) gives
𝑑(𝑙𝒑) 𝑑𝜀 𝑑(𝑙𝒑)
𝒗′𝑜𝑝 − 𝒗0𝑐̅ = 𝑀𝝎′ × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂′ 𝑃0 + 𝑑𝜀 − 𝑑𝜀𝑐̅ 𝒌 × ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 − 𝑑𝜀 2
1 1 1
𝑑𝑓 𝑑𝜀𝑐̅ 𝑑𝑓2
[𝑀(𝑦0𝑝 − ℎ) + 𝑑𝜀 + 𝑑𝜀 (𝑦0𝑝 − ℎ2 ) − 𝑑𝜀 ] 𝒊 (2.1.1-23)
1 1 1
={ 𝑑ℎ 𝑑𝜀 𝑑ℎ
}=0
+ [−𝑀(𝑥0𝑝 − 𝑓) + 𝑑𝜀 − 𝑑𝜀𝑐̅ (𝑥0𝑝 − 𝑓2 ) − 𝑑𝜀 2] 𝒋
1 1 1
Inspection of expressions (2.1.1-14) and (2.1.1-22) leads
(𝒗′𝑝 − 𝒗𝑐̅ ) ∥ (𝒗𝑐 − 𝒗𝑐̅ ),
Thus,
(𝒗′𝑝 − 𝒗𝑐̅ ) ∙ 𝑵1𝑝 = 0. (2.1.1-24)
Therefore, tooth profile 𝐴̅ and cutting edge of cutter 𝐶̅ are in conjugate contact to each other
at point 𝑃.
5) Motion requirement of tooth profile 𝐴 with respect to tooth profile 𝐴̅
With help of expressions (2.1.1-16) and (2.1.1-20), the velocity 𝒗1,2

𝑝 of tooth profile 𝐴 with
respect to tooth profile 𝐴̅ at conjugate contact point 𝑃 of the instant rotating angle 𝜀1 is
𝒗1,2 ′ ′
𝑝 = 𝒗𝑝 − 𝒗𝑝 = 𝒗0𝑝 + 𝒌 × 𝒓𝑝 − 𝒗𝑜𝑝 + 𝑀𝒌 × 𝒓𝑝 (2.1.1-25)
Due to 𝒗0𝑝 − 𝒗′𝑜𝑝 being relative velocity of tooth profile 𝐴 with respect to tooth profile 𝐴̅ at
pitch point 𝑃0 of the instant rotating angle 𝜀1 , application of expressions (1.4.10-19) and (2.1.1-
21) results in
𝑑𝑓 𝑑ℎ
𝒗0𝑝 − 𝒗′𝑜𝑝 = [−(1 + 𝑀)𝑦0𝑝 + 𝑀ℎ − 𝑑𝜀 ] 𝒊 + [(1 + 𝑀)𝑥0𝑝 − 𝑀𝑓 − 𝑑𝜀 ] 𝒋 = 0 (2.1.1-26)
1 1
Then, expression (2.1.1-25) becomes
𝒗1,2
𝑝 = (1 + 𝑀)𝒌 × 𝒓𝑝 (2.1.1-27)
Inspection of expressions (2.1.1-14) and (2.1.1-27) gives
𝒗1,2
𝑝 ∥ (𝒗𝑐 − 𝒗𝑐̅ )
Thus
~130 ~
𝒗1,2
𝑝 ∙ 𝑵1𝑝 = 0.
Therefore, tooth profiles 𝐴 and 𝐴̅ are in conjugate contact to each other.
End of Proof.
Combination of expressions (2.1.1-13), (2.1.1-16) and (2.1.1-20) yields requirements for relative
motion among tooth profiles ( 𝐴, 𝐴̅) and cutting edges (𝐶, 𝐶̅ ) as follow:
𝑑𝜀𝑐 𝑑𝑓 𝑑𝜀 𝑑𝑓
(𝑦0𝑝 − ℎ1 ) + 𝑑𝜀1 + 𝑑𝜀𝑐̅ (𝑦0𝑝 − ℎ2 ) − 𝑑𝜀2 = 0,
𝑑𝜀1 1 1 1
𝑑𝜀𝑐 𝑑ℎ1 𝑑𝜀𝑐̅ 𝑑ℎ2
− 𝑑𝜀 (𝑥0𝑝 − 𝑓1 ) + 𝑑𝜀 − 𝑑𝜀 (𝑥0𝑝 − 𝑓2 ) − 𝑑𝜀 = 0,
1 1 1 1
𝑑𝜀𝑐 𝑑ℎ1 𝑑𝜀𝑐 𝑑𝑓
𝑥0𝑝 + 𝑑𝜀 (𝑥0𝑝 − 𝑓1 ) − 𝑑𝜀 = 0, 𝑦0𝑝 + 𝑑𝜀 (𝑦0𝑝 − ℎ1 ) + 𝑑𝜀1 = 0, (2.1.1-28)
1 1 1 1
𝑑𝑓 𝑑𝜀 𝑑𝑓
𝑀(𝑦0𝑝 − ℎ) + 𝑑𝜀 + 𝑑𝜀𝑐̅ (𝑦0𝑝 − ℎ2 ) − 𝑑𝜀2 = 0,
1 1 1
𝑑ℎ 𝑑𝜀𝑐̅ 𝑑ℎ2
−𝑀(𝑥0𝑝 − 𝑓) + 𝑑𝜀 − 𝑑𝜀 (𝑥0𝑝 − 𝑓2 ) − 𝑑𝜀 = 0. }
1 1 1
Where: 𝑥0𝑝 and 𝑦0𝑝 are calculated by expression (1.4.10-6).
2 Motion Parameters of Cutters

1) Rotating Center of Cutter 𝐶
Position vector for center of cutter 𝐶 with respect to coordinate system (𝑂 − 𝒊, 𝒋) is (𝑙𝒑)1 as
shown in figure 2.1.1-1, that is,
(𝑙𝒑)1 = 𝑓1 𝒊 + ℎ1 𝒋 = 𝑹0𝑝 + 𝑟0 𝑵0𝑝

(2.1.1-29)
= (𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 )𝒊 + (𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 )𝒋
Then,
𝑓1 = 𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 ,
} (2.1.1-30)
ℎ1 = 𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 .
Where: 𝑟0 is radius for pitch circle of cutter 𝐶. 𝑥0𝑝 and 𝑦0𝑝 are calculated by expression (1.4.10-
6). 𝑵0𝑝 is determined by expression (1.4.10-13).
2) Rotating Center of Cutter 𝐶̅
Position vector for center of cutter 𝐶̅ with respect to coordinate system (𝑂 − 𝒊, 𝒋) is (𝑙𝒑)2 as
~ 131 ~
(𝑙𝒑)2 = 𝑓2 𝒊 + ℎ2 𝒋 = 𝑹0𝑝 − 𝑟̅0 𝑵0𝑝
(2.1.1-31)
= (𝑥0𝑝 − 𝑟̅0 𝑁𝑜𝑝𝑥 )𝒊 + (𝑦0𝑝 − 𝑟̅0 𝑁𝑜𝑝𝑦 )𝒋
Then,
𝑓2 = 𝑥0𝑝 − 𝑟̅0 𝑁𝑜𝑝𝑥 ,

} (2.1.1-32)
ℎ2 = 𝑦0𝑝 − 𝑟̅0 𝑁𝑜𝑝𝑦 .
Where: 𝑟̅0 is radius for pitch circle of cutter 𝐶̅ .

𝑑𝜀
3) Rate (𝑑𝑠1) of Angular Increment for Tooth Profile 𝐴 with Respect to Arc-Length 𝑠0 of
0 𝜏0
Pitch Curve
𝑑𝜀 𝑑𝜀 (1±𝑀)
( 𝑑𝑠1) is calculated by expression (1.4.10-16), that is, ( 𝑑𝑠1 ) = |𝑱0 |
.
0 𝜏0 0 𝜏0
𝑑𝜀
4) Rate ( 𝑑𝑠2) of Angular Increment for Tooth Profile 𝐴̅ with Respect to Arc-Length 𝑠0 of
0 𝜏0
Pitch Curve
𝑑𝜀 𝑑𝜀 𝑑𝜀
( 𝑑𝑠2) is calculated by expression (1.4.10-18), that is, ( 𝑑𝑠2 ) = 𝑀 ( 𝑑𝑠1 )
0 𝜏0 0 𝜏0 0 𝜏0
𝑑𝜀𝑐
5) Rate ( ) of Angular Increment for Cutter 𝐶 with Respect to Arc-Length 𝑠0 of Pitch
𝑑𝑠0 𝜏
0
Curve
𝑑𝜀 1
(𝑑𝑠 𝑐) is derived by application of expression (1.4.10-24) with consideration of 𝐾1𝜏0 = 𝜌 ,
0 𝜏0 10
1 𝑑𝜀2 𝑑𝜀𝑐
𝐾2𝜏0 = 𝑟 and ( 𝑑𝑠 ) = (𝑑𝑠 ) , that is,
0 0 𝜏0 0 𝜏0
𝑑𝜀 1 1 𝑑𝜀
(𝑑𝑠 𝑐) = 𝜌 + 𝑟 − ( 𝑑𝑠1 ) (2.1.1-33)
0 𝜏0 10 0 0 𝜏0
𝑑𝜀
Where: 𝑟0 is radius for pitch circle of cutter 𝐶. ( 𝑑𝑠1) is calculated by expression (1.4.10-16).
0 𝜏0
𝜌10 is calculated by expression (1.4.10-26).
𝑑𝜀
6) Rate (𝑑𝑠 𝑐̅) of Angular Increment for Cutter 𝐶̅ with Respect to Arc-Length 𝑠0 of Pitch
0 𝜏0
Curve
~ 132 ~
𝑑𝜀
(𝑑𝑠 𝑐̅) can be calculated by application of expression (1.4.10-24) with consideration of 𝐾1𝜏0 =
0 𝜏0
1 1 𝑑𝜀 𝑑𝜀 𝑑𝜀 𝑑𝜀
, 𝐾2𝜏0 = ̅̅̅ , ( 𝑑𝑠1 ) = (𝑑𝑠𝑐) and ( 𝑑𝑠2 ) = (𝑑𝑠𝑐̅) , that is,
𝑟0 𝑟 0 0 𝜏0 0 𝜏0 0 𝜏0 0 𝜏0
𝑑𝜀 1 1 𝑑𝜀
(𝑑𝑠 𝑐̅) = ̅̅̅ + 𝑟 − (𝑑𝑠𝑐) (2.1.1-34)
0 𝜏0 𝑟 0 0 0 𝜏0
𝑑𝜀
Where: 𝑟̅0 is radius for pitch circle of cutter 𝐶̅ . (𝑑𝑠𝑐) is decided in expression (2.1.1-33).
0 𝜏0
𝑑𝜀
Also, (𝑑𝑠𝑐̅) can be calculated through 𝐾1𝑔0 or 𝐾2𝑔0 , that is,
0 𝜏0
𝑑𝜀 1 𝑑𝜀 1 𝑑𝜀 𝑑𝜀 1
(𝑑𝑠 𝑐̅) = 𝐾2𝑔0 + ̅̅̅ − (𝑑𝑠2 ) = 𝐾2𝑔0 + ̅̅̅ − 𝑀 (𝑑𝑠1 ) = ( 𝑑𝑠1 ) − 𝐾1𝑔0 + ̅̅̅ (2.1.1-35)
0 𝜏0 𝑟 0 0 𝜏0 𝑟 0 0 𝜏0 0 𝜏0 𝑟 0
Where: 𝐾1𝑔0 and 𝐾2𝑔0 are related by expression (1.4.10-24) with consideration 𝐾1𝑔0 = 𝐾1𝜏0 and
𝐾2𝑔0 = 𝐾2𝜏0 .
3 Machine Setting Parameters

1) Motion of Machining
Shaping process of tooth profile is composed of five basic motions with respect to machine
coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ) as shown in figure 2.1.1-2 and figure 2.1.1-5, that is,
A. Rotary movement of workpiece about an axis 𝑲𝑚 of work table.

B. Rotary movement of cutter spindle.
C. Radial movement along distance of rotating centers between workpiece and cutter.
D. Axial stroke of cutter.
E. Relief movement of cutter.
Motions A, B and C constitute generating motion for formation of tooth profile, while motions
D and E constitute cutting motion for metal removal action.
Let 𝛿𝑠0 be infeed of arc-length of pitch curve which is determined by geometrical parameters of
workpiece, tool, machine, material specifications and values obtained from trials. Rotary angles
of workpieces and cutters as well as radial movement can be calculated through 𝛿𝑠0 .
2) Machine Setting Parameters for Workpiece 1
Machine setting parameters for workpiece 1 can be obtained by rotating both workpiece 1 and
~ 133 ~
shaper 𝐶 together by an angle −∆𝜀1𝑚 about rotating axis 𝑲𝑚 of work table as shown in figure
2.1.1-3, that is,

ℎ
∆𝜀1𝑚 = tan−1 ( 𝑓1 ) (2.1.1-36)
1
Where: 𝑓1 are ℎ1 are corresponding to 𝜀1 and calculated by expression (2.1.1-30).
Thus, rotary angle 𝜀1𝑚 of workpiece 1 about rotary axis 𝑲𝑚 of work table is
𝜀1𝑚 = 𝜀1 − ∆𝜀1𝑚 (2.1.1-37)
Where: 𝜀1 is calculated by application of expression (1.4.10-16).
workpiece 1 𝑂𝑚 Motions A Motions C
Motions B 𝑂1 𝑰𝑚 Shaper 𝐶 𝑱𝑚
Figure 2.1.1-2 Motion of Shaping Process for Workpiece 1
Due to 𝝎1 = −𝝎, rotary angle 𝜀𝑐𝑚 of shaper 𝐶 about rotary axis 𝑲𝑚 = −𝝎1 of shaper spindle
is
𝜀𝑐𝑚 = −(𝜀𝑐 + ∆𝜀1𝑚 ) (2.1.1-38)
Where: 𝜀𝑐 is decided by application of expression (2.1.1-33).
Center distance ̅̅̅̅̅̅̅

𝑂𝑚 𝑂1 between workpiece 1 and shaper 𝐶 is
~ 134 ~
̅̅̅̅̅̅̅
𝑂𝑚 𝑂1 = √(𝑓1 )2 + (ℎ1 )2 (2.1.1-39)
𝑓1 are ℎ1 are corresponding to 𝜀1 and calculated by expression (2.1.1-30).
𝑲𝑚 = 𝝎 𝑂𝑚 (𝑙𝒑)1 = 𝑓1 𝑰𝑚 + ℎ1 𝑱𝑚 𝝎1 = −𝝎 𝑱𝑚
∆𝜀1𝑚
workpiece 1 𝑂1 𝑰𝑚 Shaper 𝐶
Figure 2.1.1-3 ∆𝜀1𝑚 angle
Likewise, Machine setting parameters for workpiece 2 can be derived by rotating both
workpiece 2 and shaper 𝐶̅ together by an angle −∆𝜀2𝑚 about rotating axis 𝑲𝑚 of work table as
ℎ−ℎ
∆𝜀2𝑚 = tan−1 ( 𝑓−𝑓2) (2.1.1-40)
2
Where:𝑓2 and ℎ2 are calculated by expression (2.1.1-32).
𝜀2 in expression (1.4.10-18) is rotating angle of workpiece 2 about 𝝎′ = −𝑲𝑚 , therefore, rotary
~ 135~
angle 𝜀2𝑚 of workpiece 2 about rotary axis 𝑲𝑚 of work table of shaper is
𝜀2𝑚 = −(𝜀2 + ∆𝜀2𝑚 ) (2.1.1-41)
𝝎2 = 𝑲𝑚 𝑂2 (𝑙𝒑)2 = 𝑓2 𝑰𝑚 + ℎ2 𝑱𝑚
𝑲𝑚 = −𝝎′ 𝑂′ 𝑰𝑚 ∆𝜀2𝑚 (𝑙𝒑) = 𝑓𝑰𝑚 + ℎ𝑱𝑚 𝑱𝑚
Figure 2.1.1-4 ∆𝜀2𝑚 angle
Rotary angle 𝜀𝑐̅𝑚 of shaper 𝐶̅ about rotary axis 𝑲𝑚 = 𝝎1 of shaper spindle is
𝜀𝑐̅𝑚 = 𝜀𝑐̅ − ∆𝜀2𝑚 (2.1.1-42)
Where: 𝜀𝑐̅ is decided by application of expression (2.1.1-34) or (2.1.1-35).
Center distance ̅̅̅̅̅̅

𝑂2 𝑂′ between workpiece 2 and cutter 𝐶̅ is
̅̅̅̅̅̅
𝑂2 𝑂′ = √(𝑓 − 𝑓2 )2 + (ℎ − ℎ2 )2 (2.1.1-43)
~ 136~
Where: 𝑓2 and 𝑓2 are calculated by expression (2.1.1-32).
Motions B 𝑂2 shaper 𝐶̅ Motions C
Motions A workpiece 2 𝑰𝑚 𝑂𝑚 𝑱𝑚
Figure 2.1.1-5 Motion of Shaping Process for Workpiece 2
~ 137 ~
4 Summary of Motion Parameters
Formulas for motion parameters are listed in table 2.1.1
Table 2.1.1
𝑑(𝑙𝒑) 𝑑𝑓 𝑑ℎ
General Case Fixed Rotating Axes (
𝑑𝜀1
= 𝟎,
𝑑𝜀1
=
𝑑𝜀1
= ℎ = 0)
Through proper selection of coordinate system
𝑑ℎ 𝑑𝑓
𝑀𝑓+ 𝑀ℎ− 𝑱
𝑑𝜀1 𝑑𝜀1
𝑥0𝑝 = , 𝑦0𝑝 = . (1.4.10-6). 𝑵0𝑝 = ± |𝑱0 | (1.4.10-13) 𝑀𝑓
1+𝑀 1+𝑀 0 𝑥0𝑝 =
, 𝑦0𝑝 = 0 (1.4.10-7)
1+𝑀
𝑑𝑀
𝑑𝑀 𝑑 2 (𝑙𝒑) 𝑑(𝑙𝒑) 𝑱0 = (1 + 𝑀)𝑹0𝑝 − 𝒌 × (𝑹0𝑝 − 𝑙𝒑) = 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋
𝑱0 = (1 + 𝑀)𝑹0𝑝 − 𝒌 × (𝑹0𝑝 − 𝑙𝒑) + + 𝑀𝒌 × 𝑑𝜀1
𝑑𝜀1 𝑑𝜀12 𝑑𝜀1 Where:
= 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋 𝑓 𝑑𝑀 𝑓 𝑑𝑀 2
(1.4.10-11) 𝐽0𝑥 = 𝑓𝑀, 𝐽0𝑦 = , |𝑱0 | = √(𝑓𝑀)2 + ( )
1+𝑀 𝑑𝜀1 1±𝑀 𝑑𝜀1
Where:
𝑑𝑓 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋 1 𝑓 𝑑𝑀
𝑑ℎ 𝑑ℎ 𝑑𝑀 (ℎ + 𝑑𝜀1 ) 𝑑 2 𝑓 𝑵0𝑝 = = (𝑓𝑀𝒊 + 𝒋)
𝐽0𝑥 = 𝑀 (𝑓 − )+ − + 2, |𝑱0 | |𝑱0 | 1 + 𝑀 𝑑𝜀1
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1 + 𝑀 𝑑𝜀1
𝑑ℎ 𝒆0 = 𝒌, 𝝉0 = 𝒈0 = 𝑵0𝑝 × 𝒆0 = 𝑵0𝑝 × 𝒌
𝑑𝑓 𝑑𝑓 𝑑 2 ℎ 𝑑𝑀 (𝑓 − 𝑑𝜀1 )
𝐽0𝑦 = 𝑀 (ℎ + )− + + , For the case of constant transmission ratio
𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 𝑑𝜀1 1 + 𝑀 𝑀𝑓
𝑥0𝑝 = ,𝑦 = 0
Some Parameters
𝑑𝑓 2
1 ± 𝑀 0𝑝
𝑑ℎ 𝑑ℎ 𝑑𝑀 (ℎ + 𝑑𝜀1 ) 𝑑 2 𝑓 𝑱0 = (1 + 𝑀)𝑹0𝑝 = 𝐽0𝑥 𝒊 + 𝐽0𝑦 𝒋
[𝑀 (𝑓 − )+ − + 2]
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1 + 𝑀 𝑑𝜀1 Where:
𝐽0𝑥 = 𝑓𝑀,
𝐽0𝑦 = 0, |𝑱0 | = 𝑓𝑀.
|𝑱0 | = 2.
𝑑ℎ 𝑵0𝑝 = 𝒊
𝑑𝑓 𝑑𝑓 𝑑 2 ℎ 𝑑𝑀 (𝑓 − 𝑑𝜀1 ) 𝒆0 = 𝒌, 𝝉0 = 𝒈0 = 𝑵0𝑝 × 𝒆0 = 𝒊 × 𝒌 = −𝒋
+ [𝑀 (ℎ + )− + 2+ ]
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 1 + 𝑀 (1 + 𝑀)𝒌 × 𝑹0𝑝
√ } 𝑑𝑀
(1 + 𝑀) 𝒈0 ∙ +2 𝑹
1 𝑑𝜀1 0𝑝
𝒆0 = 𝒌, 𝝉0 = 𝒈0 = 𝑵0𝑝 × 𝒆0 = 𝑵0𝑝 × 𝒌 𝐾1𝑔0 = =
𝜌10 |𝑱0 | 𝑑2 𝑀
(1 + 𝑀)𝒌 × 𝑹0𝑝 − 𝒌 × (𝑹0𝑝 − 𝑙𝒑)
{ 𝑑𝜀12 }
𝑑𝑀 𝑑(𝑙𝒑) +2
+2 [𝑹 + 𝒌 × ] { |𝑱0 | }
𝑑𝜀1 0𝑝 𝑑𝜀1 𝑑𝑀
1 (1 + 𝑀) 𝒈0 −(1 ± 𝑀)𝑥0𝑝 𝑁0𝑝𝑥 ± 2 𝑥 𝑁
𝐾1𝑔0 = = ∙ 𝑑 2 (𝑙𝒑) 𝑑 3 (𝑙𝒑) + 2 (1 ± 𝑀) 𝑑𝜀1 0𝑝 0𝑝𝑦
𝜌10 |𝑱0 | |𝑱0 | +𝑀𝒌 × + =
𝑑𝜀12 𝑑𝜀13 |𝑱0 |𝟐 𝑑2 𝑀
2 ± 2 𝑁0𝑝𝑥 (𝑥0𝑝 − 𝑓) + 2|𝑱0 |
𝑑 𝑀 [ 𝑑𝜀1 ]
− 2 𝒌 × (𝑹0𝑝 − 𝑙𝒑)
{ { 𝑑𝜀1 } } (1.4.10-27)
(1.4.10-26) For the case of constant transmission ratio
(1+𝑀)𝟐 𝑑𝜀1 𝑑𝜀2 1 (1+𝑀)
𝐾2𝑔0 = −𝐾1𝑔0 + = −𝐾1𝑔0 + ( ) +( ) (1.4.10-25) 𝐾1𝑔0 = = (1.4.10-28)
|𝑱0 | 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏 𝜌10 𝑓𝑀
0 0
(𝑙𝒑)1 = 𝑓1 𝒊 + ℎ1 𝒋 = 𝑹0𝑝 + 𝑟0 𝑵0𝑝 (2.1.1-29) For the case of constant transmission ratio
Where: (𝑙𝒑)1 = 𝑓1 𝒊 = 𝑹0𝑝 + 𝑟0 𝑵0𝑝
Machine Setting Parameters
𝑓1 = 𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 , ℎ1 = 𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 . (2.1.1-30) Where:

𝑓1 = 𝑥0𝑝 + 𝑟0
(𝑙𝒑)2 = 𝑓2 𝒊 + ℎ2 𝒋 = 𝑹0𝑝 − 𝑟̅0 𝑵0𝑝 (2.1.1-31) (𝑙𝒑)2 = 𝑓2 𝒊 = 𝑹0𝑝 − 𝑟̅0 𝑵0𝑝
Where: Where:
𝑓2 = 𝑥0𝑝 − 𝑟̅0 𝑁𝑜𝑝𝑥 ℎ2 = 𝑦0𝑝 − 𝑟̅0 𝑁𝑜𝑝𝑦 (2.1.1-32) 𝑓2 = 𝑥0𝑝 − 𝑟̅0 .
𝑑𝜀1 (1+𝑀) 𝑑𝜀2 𝑑𝜀1 For the case of constant transmission ratio
( ) = |𝑱0 |
,(1.4.10-16), ( ) = 𝑀( ) , (1.4.10-18)
𝑑𝑠0 𝜏 𝑑𝑠0 𝜏 𝑑𝑠0 𝜏 𝑑𝜀1 (1+𝑀) 1 𝑑𝜀2 (1+𝑀) 𝑀
0
𝑑𝜀𝑐 1 1
0
𝑑𝜀1
0 ( ) = = , ( ) = = ,
𝑑𝑠0 𝜏 𝑓𝑀 𝜌10 𝑑𝑠0 𝜏 𝑓 𝜌10
( ) = + −( ) (2.1.1-33) 0 0
𝑑𝑠0 𝜏 𝜌10 𝑟0 𝑑𝑠0 𝜏 𝑑𝜀𝑐 1 𝑑𝜀𝑐̅ 1
𝑑𝜀𝑐̅
0
1 1 𝑑𝜀𝑐
0 ( ) = , ( ) = ̅̅̅ .
𝑑𝑠0 𝜏 𝑟0 𝑑𝑠0 𝜏 𝑟0
( ) = ̅̅̅ + −( ) (2.1.1-34) 0 0
𝑑𝑠0 𝜏 𝑟0 𝑟0 𝑑𝑠0 𝜏
0 0
~ 138 ~
2.1.2 Calculation of Tooth Profile
1 Cutting Edges of Cutters
Assume that cutting edges of both cutters 𝐶 and 𝐶̅ contact each other at pitch point 𝑃0 in
initial position as shown in figure 2.1.2-1
pitch curve ̅̅̅

𝐶0 of cutter 𝐶̅
𝑂2 𝒋𝑞
𝑵𝑐 ̅
𝑠𝑛̅ 𝑟̅0 𝒑 𝑹𝑐̅
𝑃̅ ∆𝑠0
𝑵𝑐̅ 𝑃
𝑠𝑛 𝑃0
𝑃0′ ∆𝑠0
𝑟0 𝒑 𝑹𝑐 pitch curve 𝐶0 of cutter 𝐶
𝑂1 𝒋𝑞
𝒊𝑞
Figure 2.1.2-1 Coordinate System for Cutting Edges
~139 ~
Cutting edge of cutter 𝐶 is 𝑹𝑐
𝑹𝑐 = 𝑥𝑐 (𝑢)𝒊𝑞 + 𝑦𝑐 (𝑢)𝒋𝑞 (2.1.2-1)
Where: 𝑥𝑐 (𝑢) and 𝑦𝑐 (𝑢) are given. 𝑞(= 1.2, ⋯ 𝑁) stands for 𝑞𝑡ℎ tooth of workpiece. 𝑁 is total
number of teeth of workpiece.
Cutting edge of cutter 𝐶̅ is 𝑹𝑐̅
𝑹𝑐̅ = 𝑥𝑐̅ (𝑢′ )𝒊𝑞 + 𝑦𝑐̅ (𝑢′ )𝒋𝑞 (2.1.2-2)
Where: 𝑥𝑐̅ (𝑢′ ) and 𝑦𝑐̅ (𝑢′ ) are given. 𝑞(= 1.2, ⋯ 𝑁) stands for 𝑞𝑡ℎ tooth of workpiece. 𝑁 is
total number of teeth of workpiece.
Point 𝑃0′ is any point on pitch curve 𝐶0 of cutter 𝐶 and arc-length between point 𝑃0′ and point 𝑃0
is ∆𝑠0. Point 𝑃 is the point on cutting edge of cutter 𝐶 corresponding to point 𝑃0′ and its unit
normal to cutting edge of cutter 𝐶 at point 𝑃 is passing through point 𝑃0′ as shown in
figure 2.1.2-1.
Let 𝑝 be pitch of cutter, then,
∆𝑠0 = ∆𝑖 𝑠0 = 𝑖𝛿𝑠0 ,
𝑝 } (2.1.2-3)
𝛿𝑠0 = 𝑚 .
Where: 𝑖 = 0, ±1, ±2, ±3, ⋯ until cover whole tooth profile.
1) Point 𝑃 on Cutting Edge of Cutter 𝐶
The point vector of point 𝑃 is 𝑹𝑐 as follow:
𝑹𝑐 = 𝑹𝑐,𝑖 = 𝑥𝑐 (𝑢)𝒊𝑞 + 𝑦𝑐 (𝑢)𝒋𝑞 = 𝑥𝑐 (𝑢𝑖 )𝒊𝑞 + 𝑦𝑐 (𝑢𝑖 )𝒋𝑞 = 𝑟0 𝒑 + 𝑠𝑛 𝑵𝑐

∆𝑖 𝑠0 ∆𝑖 𝑠0 (2.1.2-4)
= 𝑟0 𝒑𝒊 + 𝑠𝑛,𝑖 𝑵𝑐,𝑖 = −𝑟0 cos ( ) 𝒊𝑞 − 𝑟0 sin ( ) 𝒋𝑞 + 𝑠𝑛,𝑖 𝑵𝑐,𝑖
𝑟0 𝑟0
∆𝑖 𝑠0 ∆𝑖 𝑠0
Where: 𝒑 = 𝒑𝑖 = − cos ( ) 𝒊𝑞 − sin ( ) 𝒋𝑞 . 𝑖 refers 𝑖𝑡ℎ interpolating point on cutting
𝑟0 𝑟0
edge and 𝑖 = 0, ±1, ±2, ⋯, until covering entire cutting edge.
Due to,
𝑑𝑹𝑐 𝑑𝑦𝑐 𝑑𝑥𝑐
×𝒌 𝒊 − 𝒋
𝑑𝑢𝑖 𝑑𝑢𝑖 𝑞 𝑑𝑢𝑖 𝑞 1 𝑑𝑦 𝑑𝑥
𝑵𝑐,𝑖 = 𝑑𝑹
= 𝑑𝑥 𝑑𝑦
= 𝑄 (𝑑𝑢𝑐 𝒊𝑞 − 𝑑𝑢𝑐 𝒋𝑞 ) (2.1.2-5)
| 𝑐 ×𝒌| | 𝑐𝒊𝑞 + 𝑐 𝒋𝑞 | 𝑐,𝑖 𝑖 𝑖
𝑑𝑢𝑖 𝑑𝑢𝑖 𝑑𝑢𝑖
~ 140 ~
𝑑𝑥 2 𝑑𝑦 2
Where: 𝑄𝑐,𝑖 = ±√(𝑑𝑢𝑐) + (𝑑𝑢𝑐) .
𝑖 𝑖
Substitution of expression above into expression (2.1.2-4) yields equation as follow

𝑖𝛿𝑠0 1 𝑑𝑦𝑐
𝑥𝑐 (𝑢𝑖 ) = −𝑟0 cos ( )+𝑄 𝑠 ,
𝑟0 𝑐,𝑖 𝑑𝑢𝑖 𝑛,𝑖
𝑖𝛿𝑠0 1 𝑑𝑥𝑐
} (2.1.2-6)
𝑦𝑐 (𝑢𝑖 ) = −𝑟0 sin ( )−𝑄 𝑠𝑛,𝑖 .
𝑟0 𝑐,𝑖 𝑑𝑢𝑖
Given 𝑖 and 𝛿𝑠0 , parameters 𝑢𝑖 and 𝑠𝑛,𝑖 for point 𝑃 on cutting edge of Cutter 𝐶 is resulted from
equation (2.1.2-6).
2) Point 𝑃̅ on Cutting Edge of Cutter 𝐶̅ Corresponding to Point 𝑃 on Cutting Edge of Cutter

𝐶
The point vector of point 𝑃̅ is 𝑹𝑐̅ as follow:
𝑹𝑐̅ = 𝑹𝑐,̅𝑖 = 𝑥𝑐̅ (𝑢′ )𝒊𝑞 + 𝑦𝑐̅ (𝑢′ )𝒋𝑞 = 𝑟̅0 𝒑

̅𝑖 + 𝑠𝑛̅ 𝑵𝑐̅
𝑖𝛿𝑠0 𝑖𝛿𝑠0 (2.1.2-7)
̅𝑖 + 𝑠𝑛̅,𝑖 𝑵𝑐̅,𝑖 = 𝑟̅0 cos (
= 𝑟̅0 𝒑 ) 𝒊𝑞 − 𝑟̅0 sin ( ) 𝒋𝑞 + 𝑠𝑛̅,𝑖 𝑵𝑐̅,𝑖
𝑟0 𝑟0
𝑖𝛿𝑠0 𝑖𝛿𝑠0
̅𝑖 = cos (
Where: 𝒑 ) 𝒊𝑞 − sin ( ) 𝒋𝑞 .
𝑟0 𝑟0
Due to,
𝑑𝑹𝑐̅ 𝑑𝑦𝑐̅ 𝑑𝑥𝑐̅ 𝑑𝑦𝑐̅ 𝑑𝑥𝑐̅
×𝒌 𝒊 − 𝒋 𝒊 − 𝒋 1 𝑑𝑦 𝑑𝑥
𝑑𝑢′ 𝑑𝑢′ 𝑞 𝑑𝑢′ 𝑞 𝑑𝑢′ 𝑞 𝑑𝑢′ 𝑞
𝑵𝑐̅,𝑖 = 𝑑𝑹𝑐̅ = 𝑑𝑦𝑐̅ 𝑑𝑥𝑐̅ = = 𝑄 (𝑑𝑢𝑐̅′ 𝒊𝑞 − 𝑑𝑢𝑐̅′ 𝒋𝑞 ) (2.1.2-8)
| ′ ×𝒌| | ′ 𝒊𝑞 − ′ 𝒋𝑞 | 𝑑𝑥 2 𝑑𝑦 2 𝑐̅,𝑖
𝑑𝑢 𝑑𝑢 𝑑𝑢 ±√( 𝑐̅′ ) +( 𝑐̅′ )
𝑑𝑢 𝑑𝑢
Where: 𝑄𝑐̅,𝑖 = ±√(𝑑𝑢𝑐̅′ ) + (𝑑𝑢𝑐̅′ ) .
Substitution of expression above into expression (2.1.2-7) yields equation as follow

𝑖𝛿𝑠0 1 𝑑𝑦𝑐̅
𝑥𝑐̅ (𝑢𝑖′ ) = 𝑟̅0 cos ( )+𝑄 𝑠 ,
𝑟0 𝑐̅,𝑖 𝑑𝑢𝑖′ 𝑛̅,𝑖
𝑖𝛿𝑠0 1 𝑑𝑥𝑐̅
} (2.1.2-9)
𝑦𝑐̅ (𝑢𝑖′ ) = −𝑟̅0 sin ( )− ′ 𝑠𝑛
̅,𝑖 .
𝑟0 𝑄𝑐̅,𝑖 𝑑𝑢𝑖
Given 𝑖 and 𝛿𝑠0 , parameters 𝑢𝑖′ and 𝑠𝑛̅,𝑖 for point 𝑃̅ on cutting edge of Cutter 𝐶̅ is resulted from
equation (2.1.2-9).
2 Coordinate System
~ 141 ~
Let coordinate systems (𝑂1 − 𝒊𝑞 , 𝒋𝑞 ) and (𝑂2 − 𝒊𝑞 , 𝒋𝑞 ) be integrated with coordinate system
(𝑂 − 𝒊, 𝒋) at pitch point 𝑃0 of intersection between pitch curve 𝐴0 of tooth profile 𝐴 and tooth
profile 𝐴 of 𝑞𝑡ℎ tooth as shown in figure 2.1.2-2, that is,
𝒊𝑞 = 𝑵0𝑝 |𝜀 = 𝑁0𝑝𝑥 |𝜀 𝒊 + 𝑁0𝑝𝑦 |𝜀 𝒋,

1 =𝜀1𝑞 1 =𝜀1𝑞 1 =𝜀1𝑞
𝒋𝑞 = 𝒌 × 𝒊𝑞 = −𝑁0𝑝𝑦 |𝜀 𝒊 + 𝑁0𝑝𝑥 |𝜀 𝒋, (2.1.2-10)

1 =𝜀1𝑞 1 =𝜀1𝑞
⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂1 𝑃0 = −𝑟0 𝒊𝑞 , ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂2 𝑃0 = 𝑟̅0 𝒊𝑞 , }
Where: 𝜀1𝑞 is parameter of pitch point 𝑃0 defined in expression (1.4.10-6) corresponding to
intersecting point between pitch curve and tooth profile of 𝑞𝑡ℎ tooth. 𝑁0𝑝𝑥 |𝜀 and
1 =𝜀1𝑞
𝑁0𝑝𝑦 |𝜀 are calculated by expression (1.4.10-13).

1 =𝜀1𝑞
3 Cutting Position
𝒋𝑞
Cutting Edge of 𝐶 pitch curve 𝐴0 of tooth profile 𝐴
𝑂 𝑃0 𝒋
𝑂2 𝒋𝑞
(𝑙𝒑)1
𝑵𝑐 𝑹𝑐
𝑟0 𝒑 𝑂1
pitch circle 𝐶0 of shaper 𝐶
𝒊 𝒊𝑞 (𝑵0𝑝 )
Figure 2.1.2-2 Coordinate System for Cutter 𝐶
1) Cutting Position of Cutter 𝐶
~ 142~
Corresponding to 𝑞𝑡ℎ tooth of workpiece, the initial position of cutting edge 𝑹𝑐 of cutter 𝐶
with respect to coordinate system (𝑂 − 𝒊, 𝒋) is derived by substitution of expression (2.1.2-10)
into expression (2.1.2-4), that is,
𝑹𝑐 = 𝑹𝑐,𝑖 = 𝑥𝑐 (𝑢𝑖 )𝒊𝑞 + 𝑦𝑐 (𝑢𝑖 )𝒋𝑞 = 𝑥𝑐,𝑞 (𝑢𝑖 )𝒊 + 𝑦𝑐,𝑞 (𝑢𝑖 )𝒋
[𝑥𝑐 (𝑢𝑖 )𝑁0𝑝𝑥 |𝜀 − 𝑦𝑐 (𝑢𝑖 )𝑁0𝑝𝑦 |𝜀 ]𝒊 (2.1.2-11)

1 =𝜀1,𝑞 1 =𝜀1,𝑞
={ }
+ [𝑥𝑐 (𝑢𝑖 )𝑁0𝑝𝑦 |𝜀 + 𝑦𝑐 (𝑢𝑖 )𝑁0𝑝𝑥 |𝜀 ]𝒋
1 =𝜀1,𝑞 1 =𝜀1,𝑞
Where: 𝑥𝑐 (𝑢𝑖 ) and 𝑦𝑐 (𝑢𝑖 ) are decided by expression (2.1.2-6), then,
𝑥𝑐,𝑞 (𝑢𝑖 ) = 𝑥𝑐 (𝑢𝑖 )𝑁0𝑝𝑥 | − 𝑦𝑐 (𝑢𝑖 )𝑁0𝑝𝑦 | ,

𝜀1 =𝜀1,𝑞 𝜀1 =𝜀1,𝑞
}
𝑦𝑐,𝑞 (𝑢𝑖 ) = 𝑥𝑐 (𝑢𝑖 )𝑁0𝑝𝑦 |𝜀 + 𝑦𝑐 (𝑢𝑖 )𝑁0𝑝𝑥 |𝜀 .
1 =𝜀1,𝑞 1 =𝜀1,𝑞
Likewise, unit normal 𝑵𝑐,𝑖 is transformed as follow:

1 𝑑𝑦 𝑑𝑥
𝑵𝑐 = 𝑵𝑐,𝑖 = 𝑄 (𝑑𝑢𝑐 𝒊𝑞 − 𝑑𝑢𝑐 𝒋𝑞 ) = 𝐴𝑐,𝑖 𝒊 + 𝐵𝑐,𝑖 𝒋
𝑐,𝑖 𝑖 𝑖
1 𝑑𝑦𝑐 𝑑𝑥𝑐 𝑑𝑦𝑐 𝑑𝑥𝑐
(2.1.2-12)
= 𝑄 [(𝑑𝑢 𝑁0𝑝𝑥 |𝜀 + 𝑑𝑢 𝑁0𝑝𝑦 |𝜀 )𝒊 + ( 𝑁0𝑝𝑦 |𝜀 − 𝑑𝑢 𝑁0𝑝𝑥 |𝜀 ) 𝒋]
𝑐,𝑖 𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞 𝑑𝑢𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞
Where:
1 𝑑𝑦 𝑑𝑥
𝐴𝑐,𝑖 = 𝑄 (𝑑𝑢𝑐 𝑁0𝑝𝑥 |𝜀 + 𝑑𝑢𝑐 𝑁0𝑝𝑦 |𝜀 ),
𝑐,𝑖 𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞
1 𝑑𝑦 𝑑𝑥
𝐵𝑐,𝑖 = 𝑄 (𝑑𝑢𝑐 𝑁0𝑝𝑦 |𝜀 − 𝑑𝑢𝑐 𝑁0𝑝𝑥 |𝜀 ),
𝑐,𝑖 𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞
𝑄𝑐,𝑖 = ±√( 𝑑𝑢𝑐 ) + (𝑑𝑢𝑐) .
𝑖 𝑖 }
Point 𝑃(𝑹𝑐 ) on cutting edge of cutter 𝐶 reaches to cutting position from initial position after
rotating by an angle ∆𝑖 𝜀𝑐,𝑞 about 𝝎1 (= −𝒌) as an axis together with translation of
(𝑙𝒑)1 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 , that is,
𝑹1𝑝 |𝜀 = (∆𝑖 𝜀𝑐,𝑞 𝝎1 ) ⊗ 𝑹𝑐,𝑖 + (𝑙𝒑)1 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= 𝑥𝑝 |𝜀 𝒊 + 𝑦𝑝 |𝜀 𝒋
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 (2.1.2-13)
[𝑥𝑐,𝑞 (𝑢𝑖 ) cos(∆𝑖 𝜀𝑐,𝑞 ) + 𝑦𝑐,𝑞 (𝑢𝑖 ) sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝑓1 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ]𝒊
={ }
+[−𝑥𝑐,𝑞 (𝑢𝑖 ) sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝑦𝑐,𝑞 (𝑢𝑖 ) cos(∆𝑖 𝜀𝑐,𝑞 ) + ℎ1 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ]𝒋
~ 143 ~
Where: 𝑓1 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 and ℎ1 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 are decided in expression (2.1.1-30) and
𝑥𝑝 |𝜀 = 𝑥𝑐,𝑞 (𝑢𝑖 ) cos(∆𝑖 𝜀𝑐,𝑞 ) + 𝑦𝑐,𝑞 (𝑢𝑖 ) sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝑓1 |𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ,
1 =𝜀1𝑞 +∆𝑖 𝜀1,𝑞
}
𝑦𝑝 |𝜀 = −𝑥𝑐,𝑞 (𝑢𝑖 ) sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝑦𝑐,𝑞 (𝑢𝑖 ) cos(∆𝑖 𝜀𝑐,𝑞 ) + ℎ1 |𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 .
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Unit normal 𝑵1𝑝 |𝜀 to tooth profile 𝐴 for 𝑞𝑡ℎ tooth of driving gear at cutting position
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
is as follow;
𝑵1𝑝 |𝜀 = −(∆𝑖 𝜀𝑐,𝑞 𝝎1 ) ⊗ 𝑵𝑐,𝑖 = 𝐴𝑝 |𝜀 𝒊 + 𝐵𝑝 |𝜀 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= −(∆𝑖 𝜀𝑐,𝑞 𝝎1 ) ⊗ (𝐴𝑐,𝑖 𝒊 + 𝐵𝑐,𝑖 𝒋) (2.1.2-14)

= −[𝐴𝑐,𝑖 cos(∆𝑖 𝜀𝑐,𝑞 ) + 𝐵𝑐,𝑖 sin(∆𝑖 𝜀𝑐,𝑞 )]𝒊 − [−𝐴𝑐,𝑖 sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝐵𝑐,𝑖 cos(∆𝑖 𝜀𝑐,𝑞 )]𝒋
Where: 𝐴𝑐,𝑖 and 𝐵𝑐,𝑖 are decided by expression (2.1.2-12) and
𝐴𝑝 |𝜀 = −𝐴𝑐,𝑖 cos(∆𝑖 𝜀𝑐,𝑞 ) − 𝐵𝑐,𝑖 sin(∆𝑖 𝜀𝑐,𝑞 ) ,

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
}
𝐵𝑝 |𝜀 = 𝐴𝑐,𝑖 sin(∆𝑖 𝜀𝑐,𝑞 ) − 𝐵𝑐,𝑖 cos(∆𝑖 𝜀𝑐,𝑞 ) .
1 =𝜀1.𝑞 +∆𝑖 𝜀1,𝑞
∆𝑖 𝜀1,𝑞 is calculated by application of expression (1.4.10-16), that is,
𝑑𝜀 1+𝑀|𝜀1=𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞

∆𝑖 𝜀1,𝑞 = ∆𝑖−1 𝜀1,𝑞 + 𝛿𝑠0 (𝑑𝑠1 ) | = ∆𝑖−1 𝜀1,𝑞 + 𝛿𝑠0 ,
0 𝜏0 |𝑱0 |𝜀1 =𝜀1,𝑞+∆𝑖−1 𝜀1,𝑞 | } (2.1.2-15)
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
𝜀1,𝑞 = 𝜀1,𝑞−1 + ∆𝑚 𝜀1,𝑞−1 .
Where: 𝜀1,1 = 0. ∆0 𝜀1,𝑞 = 0. 𝑞 = 1,2,3, ⋯ 𝑁. 𝑖 = 1,2,3, ⋯, until covering entire tooth profile.
Corresponding to 𝑖𝑡ℎ point on cutting edge of 𝑞𝑡ℎ tooth, total rotating angle of cutter 𝐶 from
initial position to cutting position is 𝜀𝑐,𝑞 + ∆𝑖 𝜀𝑐,𝑞 which is calculated by application of expression
(2.1.1-33), that is,
𝑑𝜀
∆𝑖 𝜀𝑐,𝑞 = ∆𝑖−1 𝜀𝑐,𝑞 + 𝛿𝑠0 (𝑑𝑠𝑐) |
0 𝜏0 𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖−1 1,𝑞
1 𝑑𝜀 (2.1.2-16)
= ∆𝑖−1 𝜀𝑐,𝑞 + 𝛿𝑠0 [𝐾1𝑔0 | + 𝑟 − (𝑑𝑠1 ) | ],
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 0 0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
𝜀𝑐,𝑞 = 𝜀𝑐,𝑞−1 + ∆𝑚 𝜀𝑐,𝑞−1 . }
Where: 𝜀𝑐,1 = 0. ∆0 𝜀𝑐,𝑞 = 0. 𝑞 = 1,2,3, ⋯ 𝑁. 𝑖 = 1,2,3, ⋯, until covering entire tooth profile.
~ 144 ~
𝐾1𝑔0 | is calculated by expression (1.4.10-26).
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
2) Cutting Position of Cutter 𝐶̅
Corresponding to 𝑞𝑡ℎ tooth of workpiece 2 as shown in figure 2.1.2-3, the initial position of
cutting edge 𝑹𝑐̅ of cutter 𝐶̅ with respect to coordinate system (𝑂 − 𝒊, 𝒋) is derived by
substitution of expression (2.1.2-10) into expression (2.1.2-7), that is,
𝑹𝑐̅ = 𝑹𝑐,̅𝑖 = 𝑥𝑐̅ (𝑢𝑖′ )𝒊𝑞 + 𝑦𝑐̅ (𝑢𝑖′ )𝒋𝑞 = 𝑥𝑐̅,𝑞 (𝑢𝑖′ )𝒊 + 𝑦𝑐̅,𝑞 (𝑢𝑖′ )𝒋
[𝑥𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑥 |𝜀 − 𝑦𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑦 |𝜀 ]𝒊
1 =𝜀1,𝑞 1 =𝜀1,𝑞 (2.1.2-17)
={ }
+ [𝑥𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑦 |𝜀 + 𝑦𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑥 |𝜀 ]𝒋
1 =𝜀1,𝑞 1 =𝜀1,𝑞
Where: 𝑥𝑐̅ (𝑢𝑖′ ) and 𝑦𝑐̅ (𝑢𝑖′ ) are decided by expression (2.1.2-9), then,
𝑥𝑐̅,𝑞 (𝑢𝑖′ ) = 𝑥𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑥 |𝜀 − 𝑦𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑦 |𝜀 ,

1 =𝜀1,𝑞 1 =𝜀1,𝑞
}
𝑦𝑐̅,𝑞 (𝑢𝑖′ ) = 𝑥𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑦 |𝜀 + 𝑦𝑐̅ (𝑢𝑖′ )𝑁0𝑝𝑥 |𝜀 .
1 =𝜀1,𝑞 1 =𝜀1,𝑞
Likewise, unit normal 𝑵𝑐̅,𝑖 is changed as follow:
1 𝑑𝑦 𝑑𝑥
𝑵𝑐̅ = 𝑵𝑐̅,𝑖 = 𝑄 (𝑑𝑢𝑐̅′ 𝒊𝑞 − 𝑑𝑢𝑐̅′ 𝒋𝑞 ) = 𝐴𝑐̅,𝑖 𝒊 + 𝐵𝑐̅,𝑖 𝒋
𝑐̅,𝑖 𝑖 𝑖
(2.1.2-18)
1 𝑑𝑦𝑐̅ 𝑑𝑥𝑐̅ 𝑑𝑦𝑐̅ 𝑑𝑥
= 𝑄 [(𝑑𝑢′ 𝑁0𝑝𝑥 |𝜀 + 𝑑𝑢′ 𝑁0𝑝𝑦 |𝜀 )𝒊 + ( 𝑁 | − 𝑑𝑢𝑐̅′ 𝑁0𝑝𝑥 |𝜀 ) 𝒋]
𝑐̅,𝑖 𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞 𝑑𝑢′ 0𝑝𝑦 𝜀
𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞
Where:
1 𝑑𝑦 𝑑𝑥
𝐴𝑐̅,𝑖 = 𝑄 (𝑑𝑢𝑐̅′ 𝑁0𝑝𝑥 |𝜀 + 𝑑𝑢𝑐̅′ 𝑁0𝑝𝑦 |𝜀 ),
𝑐̅,𝑖 𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞
1 𝑑𝑦 𝑑𝑥
𝐵𝑐̅,𝑖 = 𝑄 (𝑑𝑢𝑐̅′ 𝑁0𝑝𝑦 |𝜀 − 𝑑𝑢𝑐̅′ 𝑁0𝑝𝑥 |𝜀 ),
𝑐̅,𝑖 𝑖 1 =𝜀1,𝑞 𝑖 1 =𝜀1,𝑞
𝑄𝑐̅,𝑖 = ±√(𝑑𝑢𝑐̅′ ) + (𝑑𝑢𝑐̅′ ) . }
Point 𝑃̅ (𝑹𝑐̅ ) on cutting edge of cutter 𝐶̅ reaches to cutting position from initial position after
rotating by an angle ∆𝑖 𝜀𝑐̅,𝑞 about 𝝎2 (= 𝒌) as an axis together with translation of
(𝑙𝒑)2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 , that is,
~145 ~
𝑹1𝑝 |𝜀 = (∆𝑖 𝜀𝑐,̅𝑞 𝝎2 ) ⊗ 𝑹𝑐̅,𝑖 + (𝑙𝒑)2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 (2.1.2-19)
[𝑥𝑐̅,𝑞 (𝑢𝑖′ ) cos(∆𝑖 𝜀𝑐̅,𝑞 ) − 𝑦𝑐̅,𝑞 (𝑢𝑖′ ) sin(∆𝑖 𝜀𝑐̅,𝑞 ) + 𝑓2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ]𝒊
={ }
+[𝑥𝑐̅,𝑞 (𝑢𝑖′ ) sin(∆𝑖 𝜀𝑐̅,𝑞 ) + 𝑦𝑐̅,𝑞 (𝑢𝑖′ ) cos(∆𝑖 𝜀𝑐,̅𝑞 ) + ℎ2 |𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ]𝒋
Where: 𝑓2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 and ℎ2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 are determined by expression (2.1.1-32) and
𝑥𝑝 |𝜀 = 𝑥𝑐̅,𝑞 (𝑢𝑖′ ) cos(∆𝑖 𝜀𝑐̅,𝑞 ) − 𝑦𝑐̅,𝑞 (𝑢𝑖′ ) sin(∆𝑖 𝜀𝑐,̅𝑞 ) + 𝑓2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ,
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
}
𝑦𝑝 |𝜀 = 𝑥𝑐̅,𝑞 (𝑢𝑖′ ) sin(∆𝑖 𝜀𝑐̅,𝑞 ) + 𝑦𝑐̅,𝑞 (𝑢𝑖′ ) cos(∆𝑖 𝜀𝑐,̅𝑞 ) + ℎ2 |𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 .
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Pitch circle ̅̅̅

𝐶0 of shaper 𝐶̅ 𝒋𝑞
Cutting edge of 𝐶̅
𝑟̅0 (𝑙𝒑)2 𝑂 𝒋
𝑂2
𝑹𝑐̅ 𝒋𝑞
𝑃0
𝑵𝑐̅ 𝒋′
𝑂′ 𝑂1
𝒊𝑞 (𝑵0𝑝 )
pitch curve ̅̅̅
𝐴0 of Tooth profile 𝐴̅
𝒊 𝒊′
Figure 2.1.2-3 Coordinate System for Cutter 𝐶̅
~146 ~
Unit normal 𝑵2𝑝 |𝜀 to tooth profile 𝐴̅ for 𝑞𝑡ℎ tooth of driven gear at cutting position
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
is as follow:
𝑵2𝑝 |𝜀 = −(∆𝑖 𝜀𝑐̅,𝑞 𝝎2 ) ⊗ 𝑵𝑐̅,𝑖 = 𝐴′𝑝 |𝜀 𝒊 + 𝐵𝑝′ |𝜀 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= −(∆𝑖 𝜀𝑐̅,𝑞 𝝎2 ) ⊗ (𝐴𝑐̅,𝑖 𝒊 + 𝐵𝑐̅,𝑖 𝒋) (2.1.2-20)

= −[𝐴𝑐̅,𝑖 cos(∆𝑖 𝜀𝑐,̅𝑞 ) − 𝐵𝑐̅,𝑖 sin(∆𝑖 𝜀𝑐̅,𝑞 )]𝒊 − [𝐴𝑐̅,𝑖 sin(∆𝑖 𝜀𝑐̅,𝑞 ) + 𝐵𝑐̅,𝑖 cos(∆𝑖 𝜀𝑐̅,𝑞 )]𝒋
Where: 𝐴𝑐̅,𝑖 and 𝐵𝑐̅,𝑖 are decided by expression (2.1.2-18).
Corresponding to 𝑖𝑡ℎ point on cutting edge of 𝑞𝑡ℎ tooth, total rotating angle of cutter 𝐶̅ from
initial position to cutting position is 𝜀𝑐̅,𝑞 + ∆𝑖 𝜀𝑐̅,𝑞 which is calculated by application of
expressions (2.1.1-29) and (2.1.1-30), that is,
𝑑𝜀
∆𝑖 𝜀𝑐̅,𝑞 = ∆𝑖−1 𝜀𝑐̅,𝑞 + 𝛿𝑠0 (𝑑𝑠𝑐̅ ) |
0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
1 1 𝑑𝜀
= ∆𝑖−1 𝜀𝑐̅,𝑞 + 𝛿𝑠0 [𝑟̅ + 𝑟 − (𝑑𝑠𝑐 ) | ]
0 0 0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 (2.1.2-21)
1 𝑑𝜀
= ∆𝑖−1 𝜀𝑐,̅𝑞 + 𝛿𝑠0 [𝑟̅ − 𝐾1𝑔0 | + (𝑑𝑠1 ) | ],
0 𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
𝜀𝑐̅,𝑞 = 𝜀𝑐̅,𝑞−1 + ∆𝑚 𝜀𝑐̅,𝑞−1 . }
Where: 𝜀𝑐̅,1 = 0. ∆0 𝜀𝑐̅,𝑞 = 0, 𝑞 = 1,2,3, ⋯ , 𝑁. 𝑖 = ±1, ±2, ±3, ⋯, until covering entire tooth
profile. 𝐾1𝑔0 | is calculated by expression (1.4.10-26).
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
4 Tooth Profile of Driving Gear

Tooth profile 𝐴 for 𝑞𝑡ℎ tooth of driving gear is as follow:
𝑹1,𝑞 = [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝝎] ⊗ 𝑹1𝑝 |𝜀 = 𝑥𝑞,𝑖 𝒊 + 𝑦𝑞,𝑖 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝒌] ⊗ [𝑥𝑝 |𝜀 𝒊 + 𝑦𝑝 |𝜀 𝒋]

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(2.1.2-22)
[𝑥𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒊
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
={ }
+ [−𝑥𝑝 | sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 | cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒋
𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
~ 147 ~
Where: 𝑞 = 1,2,3, ⋯ , 𝑁, and 𝑖 = 0, ±1, ±2, ±3, ⋯. 𝑥𝑝 |𝜀 and 𝑦𝑝 |𝜀 are
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
calculated by expression (2.1.2-13), then,
𝑥𝑞 = 𝑥𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) ,

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
}
𝑦𝑞 = −𝑥𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ).
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Likewise, unit normal to tooth profile 𝐴 for 𝑞𝑡ℎ tooth of driving gear is
𝑵𝑞 = [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝝎] ⊗ 𝑵1𝑝 |𝜀 = 𝐴𝑞 𝒊 + 𝐵𝑞 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝒌] ⊗ [𝐴𝑝 | 𝒊 + 𝐵𝑝 | 𝒋]

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(2.1.2-23)
[𝐴𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒊
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
={ }
+ [−𝐴𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒋
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Where: 𝐴𝑝 |𝜀 and 𝐵𝑝 |𝜀 are calculated by expression (2.1.2-14), then,

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
𝐴𝑞 = 𝐴𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) ,

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
}
𝐵𝑞 = −𝐴𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) .
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
5 Tooth Profile of Driven Gear

Tooth profile 𝐴̅ for 𝑞𝑡ℎ tooth of driven gear is derived by application of expression (1.3.8-8) as
follow:
𝑹2,𝑞 = [−(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝝎′ ] ⊗ [𝑹1𝑝 |𝜀 − (𝑙𝒑)|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ] = 𝑥𝑞′ 𝒊 + 𝑦𝑞′ 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) 𝒊

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= [(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝒌] ⊗ [ ]
+ (𝑦𝑝 |𝜀 =𝜀 +∆ 𝜀 − ℎ|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) 𝒋
1 1,𝑞 𝑖 1,𝑞
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) (2.1.2-24)

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
[ ]𝒊
− (𝑦𝑝 |𝜀 − ℎ|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
=
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )
𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
+[ ]𝒋
+ (𝑦𝑝 |𝜀 =𝜀 +∆ 𝜀 − ℎ|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )
{ 1 1,𝑞 𝑖 1,𝑞 }
~ 148 ~
Where: 𝑥𝑝 |𝜀 and 𝑦𝑝 |𝜀 are calculated by either expression (2.1.2-13) or
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
expression (2.1.2-19), and
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
𝑥𝑞′ =[ ],
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(2.1.2-25)
𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
𝑦𝑞′ = [ ].
+ (𝑦𝑝 |𝜀 =𝜀 +∆ 𝜀 − ℎ|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )
1 1,𝑞 𝑖 1,𝑞 }
𝜀2,𝑞 and ∆𝑖 𝜀2,𝑞 are calculated by application of expression (1.4.10-18), that is,
𝑑𝜀
∆𝑖 𝜀2,𝑞 = ∆𝑖−1 𝜀2,𝑞 + 𝛿𝑠0 𝑀|𝜀1=𝜀1,𝑞+∆𝑖−1𝜀1,𝑞 (𝑑𝑠1 ) |
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 ,} (2.1.2-26)
0 𝜏0
𝜀2,𝑞 = 𝜀2,𝑞−1 + ∆𝑚 𝜀2,𝑞−1 , ∆0 𝜀2,𝑞 = 0.
Where: 𝑞 = 1,2,3, ⋯ , 𝑁. 𝑖 = ±1, ±2, ±3, ⋯, until covering entire tooth profile. 𝜀2,1 = 0 and
∆0 𝜀2,𝑞 = 0.
Likewise, unit normal to tooth profile 𝐴̅ for 𝑞𝑡ℎ tooth of driven gear is as follow:
𝑵′𝑞 = −[−(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝝎′ ] ⊗ 𝑵1𝑝 |𝜀 = 𝐴′𝑞 𝒊 + 𝐵𝑞′ 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= −[(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝒌] ⊗ [𝐴𝑝 |𝜀 𝒊 + 𝐵𝑝 |𝜀 𝒋]

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(2.1.2-27)
− [𝐴𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) − 𝐵𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )] 𝒊
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
={ }
− [𝐴𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) + 𝐵𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )] 𝒋
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Where: 𝐴𝑝 |𝜀 and 𝐵𝑝 |𝜀 are calculated by either expression (2.1.2-14) and

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
𝐴′𝑞 = −𝐴𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) + 𝐵𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ),

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
}
𝐵𝑞′ = −𝐴𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) − 𝐵𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ).
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
2.1.3 Curvature of Tooth Profile

1 Curvature of Tooth Profile 𝐴 of Driving Gear
~ 149 ~
With tooth profile 𝐴 of workpiece 1 being considered as the first conjugate surface and cutting
edge of cutter 𝐶 being assumed as the second conjugate surface, application of expression
(1.4.10-31) yields curvature of tooth profile of 𝐴, that is,
1 1
𝜌1 = 𝐾 = 𝐾1𝜏0 +𝐾2𝜏 𝐾2𝜏
+ 𝑠𝑛 ,
1𝜏 0−
(𝝉0 ∙𝝉) 1+𝑠𝑛 𝐾2𝜏
(2.1.3-1)
𝝉0 = 𝑵0𝑝 × 𝒌,
𝝉 = 𝑵1𝑝 × 𝒌. }
Where: 𝑵0𝑝 = 𝑵0𝑝 |𝜀 is calculated by expression of (1.4.10-13). 𝑵1𝑝 =

1 =𝜀1,𝑞+∆𝑖 𝜀1,𝑞
𝑵1𝑝 | is decided in expression (2.1.2-14). 𝐾1𝜏0 = 𝐾1𝜏0 | is calculated by

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 𝜀1 =𝜀1,𝑞+∆𝑖 𝜀1,𝑞
1
expression (1.4.10-27) and 𝐾2𝜏0 = . 𝑠𝑛 = −𝑠𝑛,𝑖 is distance from pitch point 𝑃0 to conjugate
𝑟0
contact point 𝑃 along unit normal 𝑵1𝑝 to tooth profile of 𝐴 and 𝑠𝑛,𝑖 is decided in expression
(2.1.2-6). 𝐾2𝜏 is curvature of cutting edge 𝐶 which is given.
In order to eliminate undercut of tooth profile of 𝐴, 𝜌1 must be greater than zero, that is,
1
𝜌1 = 𝐾1𝜏0 +𝐾2𝜏 𝐾2𝜏
+ 𝑠𝑛 > 0 (2.1.3-2)
0−
(𝝉0 ∙𝝉) 1+𝑠𝑛 𝐾2𝜏
For involute shaper, the cutting edge of shaper is involute as shown in figure 2.1.3-1, that is,
(𝝉0 ∙ 𝝉) = sin 𝛼 ,
1
𝐾2𝜏0 = 𝑟 ,
0
1 𝑑𝑠0 (2.1.3-3)
𝜌2 = 𝐾 = 𝑟𝑏 (𝛼 + 𝜎0 + ) = 𝑟𝑏 (𝛼 + 𝜎0 ) + 𝑑𝑠0 cos 𝛼 ,
2𝜏 𝑟0
𝑑𝑠0
𝑠𝑛 = −𝑠𝑛,𝑖 = −𝑟𝑏 = −𝑑𝑠0 cos 𝛼 . }
𝑟0
Substitution expressions (2.1.3-3) into (2.1.3-1) yields the curvature of tooth profile 𝐴
generated by involute shaper 𝐶 as follow
1 sin 𝛼 sin 𝛼
𝜌1 = 𝐾1𝜏0 +𝐾2𝜏 + 𝑠𝑛 = + 𝑠𝑛 = − 𝑑𝑠0 cos 𝛼
0
−
𝐾2𝜏 𝐾1𝜏0 + 1 − sin 𝛼 𝐾1𝜏0 + 1 − sin 𝛼
𝑟0 𝜌2+𝑠𝑛 𝑟0 𝑟𝑏(𝛼+𝜎0 )
(𝝉0 ∙𝝉) 1+𝑠𝑛 𝐾2𝜏 (2.1.3-4)
sin 𝛼
= 𝐾1𝜏0
− 𝑑𝑠0 cos 𝛼
Inspection of expressions (2.1.3-2) and (2.1.3-4) shows that undercut appears most likely in the
place with maximum curvature of pitch curve.
~ 150 ~
𝑑𝑠0
𝑟0
𝜌1 𝑠𝑛,𝑖 𝑑𝑠0
Cutting Edge of Shaper 𝐶
𝛼 𝜎0
𝑟0
𝑟𝑏
𝒋𝑞
Base Circle
Tip Circle
Pitch Circle
𝒊𝑞
Figure 2.1.3-1 Geometry of Involute Shaper
2 Curvature of Tooth Profile 𝐴̅

1) Method 1 (Through curvature parameters of both pitch curves and tooth profile 𝐴)
With tooth profile 𝐴̅ of workpiece 2 being considered as the second conjugate surface and
either cutting edge of cutter 𝐶̅ or tooth profile 𝐴 of workpiece 1 being thought as the first
conjugate surface, application of expression (1.4.10-31) gives curvature of tooth profile of 𝐴̅,
that is,
~ 151 ~
1 1
𝜌2 = 𝐾 = 𝐾1𝜏0 +𝐾2𝜏 𝐾1𝜏
− 𝑠𝑛 (2.1.3-5)
2𝜏 0
(𝝉0 ∙𝝉)
−
1−𝑠𝑛 𝐾1𝜏
Where: 𝐾2𝜏0 is curvature of pitch curve of tooth profile 𝐴̅ and calculated by expression (1.4.10-
28). 𝐾1𝜏 is curvature of either pitch curve 𝐴0 of tooth profile 𝐴 or pitch curve 𝐶0̅ of cutter 𝐶̅ .
0
1
Therefore, 𝐾1𝜏0 is either equal to 𝑟̅ of pitch curve of cutter 𝐶0̅ or calculated by expression
0
(1.4.10-28). 𝑠𝑛 = 𝑠𝑛,𝑖 , 𝝉0 and 𝝉 are decided in expression (2.1.3-3). 𝐾1𝜏 is curvature of either
tooth profile 𝐴 or cutting edge 𝐶̅ .
In order to eliminate undercut of tooth profile of 𝐴̅, 𝜌2 must be greater than zero, that is,
1 1
𝜌2 = 𝐾 = 𝐾1𝜏0 +𝐾2𝜏 𝐾1𝜏
− 𝑠𝑛 > 0 (2.1.3-6)
2𝜏 0−
(𝝉0 ∙𝝉) 1−𝑠𝑛 𝐾1𝜏
2) Method 2 (Based on both motion parameters and curvature parameter of tooth profile
𝐴)
Application of expression (1.5.6-19) gives curvature of tooth profile of 𝐴̅, that is,
1
𝜌2 = (1±𝑀)2 1
− 𝑠𝑛 (2.1.3-7)
−
(𝑱𝑝 ∙𝑵1𝑝 ) (𝜌1−𝑠𝑛 )
Where: 𝑱𝑝 is calculated by expression (1.5.2-7). 𝜌1 is curvature radius of tooth profile 𝐴. 𝑠𝑛 is

calculated by expression (2.1.3-3).
In order to eliminate undercut of tooth profile of 𝐴̅, 𝜌2 must be greater than zero, that is,
1 1
𝜌2 = 𝐾 = (1±𝑀)2 1
− 𝑠𝑛 > 0 (2.1.3-8)
2𝜏 −
(𝑱𝑝 ∙𝑵1𝑝 ) (𝜌1 −𝑠𝑛 )
Example 2. 1-1 continue Example 1.4-1.
Given Condition:
1) Parameters of Cutter 𝐶----- Involute Shaper
Tooth number of cutter 𝐶: 𝑧0 = 30.
Diametral pitch:𝑃𝑑 = 0.4.
Pressure angle: 𝛼 = 20° = 0.349.
2) Parameters of Cutter 𝐶̅
~ 152 ~
Cutter 𝐶̅ is identical to cutter 𝐶.
Then, let pitch of workpiece is equally divided by 𝑚 = 40 segments.

𝜋 𝑧
Pitch: 𝑝 = 𝑃 = 7.85398(𝑚𝑚) ; Radius of pitch circle: 𝑟0 = 𝑟̅0 = 2𝑃0 = 37.5(𝑚𝑚).
𝑑 𝑑
Radius of base circle: 𝑟𝑏 = 𝑟0 cos 𝛼 = 35.2385.
Radius of tip circle: 𝑟𝑎 = 𝑟0 + ℎ𝑎 = 40.0(𝑚𝑚).
Radius of root circle: 𝑟𝑑 = 𝑟0 − ℎ𝑑 = 35(𝑚𝑚).
Involute function: 𝜎0 = tan 𝛼 − 𝛼 = 0.0149(𝑟𝑎𝑑 ).

𝑝
Interpolating arc-length of pitch curve: 𝛿𝑠0 = = 0.1963(𝑚𝑚).
𝑚
𝑆0
Tooth number of workpiece: 𝑁 = = 15.
𝑝
Calculation of Cutting Edge of Cutter:
1) Cutting Edge of Cutter 𝐶 corresponding to Right-Flank of Tooth Space of Workpiece 1.
Point on cutting edge 𝐶 is 𝑹𝑐 as shown in figure example 2.1-1a, that is,
𝑹𝑐 = 𝑹𝑐,𝑖 = 𝑟0 𝒑𝒊 + 𝑠𝑛,𝑖 𝑵𝑐,𝑖 = 𝑥𝑐,𝑖 𝒊𝑞 + 𝑦𝑐,𝑖 𝒋𝑞
Where:
𝒑𝒊 = − cos ( ) 𝒊𝑞 − sin (± ) 𝒋𝑞 ,
𝑟0 𝑟0
𝑵𝑐,𝑖 = − sin (𝛼 ± ) 𝒊𝑞 + cos (𝛼 ± ) 𝒋𝑞
𝑟0 𝑟0
[− sin (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 − cos (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 ]𝒊
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
={ },
+ [− sin (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 + cos (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 ]𝒋
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
𝑥𝑐,𝑖 = −𝑟0 cos ( ) − 𝑠𝑛,𝑖 sin (𝛼 ± ),
𝑟0 𝑟0
𝑦𝑐,𝑖 = −𝑟0 sin (± ) + 𝑠𝑛,𝑖 cos (𝛼 ± ),
𝑟0 𝑟0
𝑠𝑛,𝑖 = ± 𝑟𝑏 , 𝜌𝑐,𝑖 = 𝑟𝑏 (𝜎0 + 𝛼 ± ). }
𝑟0 𝑟0
Here: positive sign of " ± " is for addendum section of cutting edge and negative sign of " ± "
~ 153 ~
is for dedendum section of cutting edge. 𝑁0𝑝𝑥 |𝜀 and 𝑁0𝑝𝑦 |𝜀 are components of unit
1 =𝜀1,𝑞 1 =𝜀1,𝑞
normal to pitch curve of workpiece 1 at pitch point corresponding to intersecting point

between pitch curve of workpiece 1 and right-flank of tooth space of 𝑞th tooth of workpiece 1.
𝑖𝛿𝑠0
𝜌𝑐,𝑖 𝑠𝑛,𝑖
𝑵𝑐,𝑖 Cutting Edge of Shaper 𝐶
𝒑𝒊
𝑹𝑐
𝛼 𝜎0
𝑟𝑏 𝑟0
𝑟𝑎
𝒋𝑞
Base Circle
Tip Circle
Pitch Circle
𝒊𝑞
Figure example 2.1-1a. Cutting Edge of Shaper 𝐶 Corresponding to Right-Flank of Tooth Space
of Workpiece 1.
2) Cutting Edge of Cutter 𝐶̅ corresponding to Right-Flank of Tooth Thickness of Workpiece

2
Point on cutting edge 𝐶̅ is 𝑹𝑐̅ as shown in figure example 2.1-1b, that is,
̅𝑖 + 𝑠𝑛̅,𝑖 𝑵𝑐̅,𝑖
𝑹𝑐̅ = 𝑹𝑐,̅𝑖 = 𝑥𝑐̅,𝑖 𝒊𝑞 + 𝑦𝑐̅,𝑖 𝒋𝑞 = 𝑟0 𝒑
~ 154~
Where:
𝑖𝛿𝑠0 𝑖𝛿𝑠0 𝑖𝛿𝑠0 𝑖𝛿𝑠0

̅𝑖 = cos (
𝒑 ) 𝒊𝑞 + sin (± ) 𝒋𝑞 , 𝑠𝑛̅,𝑖 = ±𝑟𝑏 𝑟0
, 𝜌𝑐̅,𝑖 = 𝑟𝑏 (𝜎0 + 𝛼 ± 𝑟0
),
𝑟0 𝑟0
𝑵𝑐̅,𝑖 = sin (𝛼 ± ) 𝒊𝑞 − cos (𝛼 ± ) 𝒋𝑞
𝑟0 𝑟0
[sin (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 + cos (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 ]𝒊
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
={ }
+ [sin (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 − cos (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 ]𝒋
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
𝑥𝑐̅,𝑖 = 𝑟0 cos ( ) + 𝑠𝑛̅,𝑖 sin (𝛼 ± ),
𝑟0 𝑟0
𝑦𝑐̅,𝑖 = 𝑟0 sin (± ) − 𝑠𝑛̅,𝑖 cos (𝛼 ± ). }
𝑟0 𝑟0
𝒋𝑞
𝑟𝑏
Base Circle 𝑟0 𝛼
𝜎0 Tip Circle
𝑹𝑐̅ Pitch Circle
̅𝑖
𝒑
𝑵𝑐̅,𝑖
𝒊𝑞 𝑖𝛿𝑠0 𝑠𝑛̅,𝑖
Figure example 2.1-1b. Cutting Edge of Shaper 𝐶̅ Corresponding to Right-Flank of Tooth

Thickness of Workpiece 2.
~ 155 ~
is for dedendum section of cutting edge. 𝑁0𝑝𝑥 |𝜀 =𝜀 and 𝑁0𝑝𝑦 |𝜀 =𝜀 are components of unit
1 1,𝑞 1 1,𝑞

between pitch curve of workpiece 1 and right-flank of tooth space of 𝑞th tooth of workpiece 1.
3) Cutting Edge of Cutter 𝐶 corresponding to Left-Flank of Tooth Space of Workpiece 1.
Point on cutting edge 𝐶 is 𝑹𝑐 as shown in figure example 2.1-1c, that is,
𝑹𝑐 = 𝑹𝑐,𝑖 = 𝑟0 𝒑𝒊 + 𝑠𝑛,𝑖 𝑵𝑐,𝑖 = 𝑥𝑐,𝑖 𝒊𝑞 + 𝑦𝑐,𝑖 𝒋𝑞
𝑖𝛿𝑠0 𝑠𝑛,𝑖
Cutting Edge of Shaper 𝐶
𝑹𝑐 𝑵𝑐,𝑖
𝜎0 𝛼 𝒑𝒊
𝑟𝑏
𝑟0
𝒋𝑞
Base Circle
Tip Circle
Pitch Circle
𝒊𝑞
Figure example 2.1-1c. Cutting Edge of Shaper 𝐶 Corresponding to Left-Flank of Tooth Space of
Workpiece 1.
Where:
~ 156 ~
𝒑𝒊 = − cos ( ) 𝒊𝑞 + sin (± ) 𝒋𝑞 , 𝑠𝑛,𝑖 = ± 𝑟𝑏 𝑟0
, 𝜌𝑐,𝑖 = 𝑟𝑏 (𝜎0 + 𝛼 ± 𝑟0
),
𝑟0 𝑟0
𝑵𝑐,𝑖 = − sin (𝛼 ± ) 𝒊𝑞 − cos (𝛼 ± ) 𝒋𝑞
𝑟0 𝑟0
[− sin (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 + cos (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 ]𝒊
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
={ }
𝑖𝛿𝑠 𝑖𝛿𝑠0
+ [− sin (𝛼 ± 𝑟 0 ) 𝑁0𝑝𝑦 |𝜀 − cos (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 ]𝒋
0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
𝑥𝑐,𝑖 = −𝑟0 cos ( ) − 𝑠𝑛,𝑖 sin (𝛼 ± ),
𝑟0 𝑟0
𝑦𝑐,𝑖 = 𝑟0 sin (± ) − 𝑠𝑛,𝑖 cos (𝛼 ± ). }
𝑟0 𝑟0
1 1,𝑞 1 1,𝑞

between pitch curve of workpiece 1 and left-flank of tooth space of 𝑞th tooth of workpiece 1.
4) Cutting Edge of Cutter 𝐶̅ corresponding to Left-Flank of Tooth Thickness of Workpiece 2
Point on cutting edge 𝐶̅ is 𝑹𝑐̅ as shown in figure example 2.1-1d, that is,
̅𝑖 + 𝑠𝑛̅,𝑖 𝑵𝑐̅,𝑖
𝑹𝑐̅ = 𝑹𝑐,̅𝑖 = 𝑥𝑐̅,𝑖 𝒊𝑞 + 𝑦𝑐̅,𝑖 𝒋𝑞 = 𝑟0 𝒑
Where:

̅𝑖 = cos (
𝒑 ) 𝒊𝑞 − sin (± ) 𝒋𝑞 , 𝑠𝑛̅,𝑖 = ±𝑟𝑏 𝑟0
, 𝜌𝑐̅,𝑖 = 𝑟𝑏 (𝜎0 + 𝛼 ± 𝑟0
),
𝑟0 𝑟0
𝑵𝑐̅,𝑖 = sin (𝛼 ± ) 𝒊𝑞 + cos (𝛼 ± ) 𝒋𝑞
𝑟0 𝑟0
[sin (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 − cos (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 ]𝒊
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
={ }
+ [sin (𝛼 ± ) 𝑁0𝑝𝑦 |𝜀 + cos (𝛼 ± ) 𝑁0𝑝𝑥 |𝜀 ]𝒋
𝑟0 1 =𝜀1,𝑞 𝑟0 1 =𝜀1,𝑞
𝑥𝑐̅,𝑖 = 𝑟0 cos ( ) + 𝑠𝑛̅,𝑖 sin (𝛼 ± ),
𝑟0 𝑟0
𝑦𝑐̅,𝑖 = −𝑟0 sin (± ) + 𝑠𝑛̅,𝑖 cos (𝛼 ± ). }
𝑟0 𝑟0
ere: positive sign of " ± " is for addendum section of cutting edge and negative sign of " ± "
1 1,𝑞 1 1,𝑞
between pitch curve of workpiece 1 and left-flank of tooth space of 𝑞th tooth of workpiece 1.
~ 157 ~
𝒋𝑞
𝑟0
Base Circle 𝑟𝑏 𝛼
𝜎0 Tip Circle
̅𝑖
𝒑 Pitch Circle
𝑵𝑐̅,𝑖
𝑠𝑛̅,𝑖 𝑖𝛿𝑠0 𝑹𝑐̅
𝒊𝑞
Figure example 2.1-1d. Cutting Edge of Shaper 𝐶̅ Corresponding to Left-Flank of Tooth

Thickness of Workpiece 2.
Procedure for Calculation of Tooth Profile:
Step 1. Calculation of Rotating Angles of Workpieces 1 & 2, i.e., expressions (2.1.2-15) and
𝑑𝜀 𝜀
(2.1.2-26), and transmission ratio, i.e., 𝑀 = 𝑑𝜀2 = 2𝐸 (𝐾1 + 𝐷𝑚𝑖𝑛 ),
1 1
Let 𝜀1,1 = 0 and 𝜀2,1 = 0.
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
𝑞 𝜀1,𝑞 +∆0 𝜀1,𝑞

∆0 𝜀1,𝑞 = 0, ∆0 𝜀2,𝑞 = 0 , 𝑀0 = 2𝐸 ( + 𝐷𝑚𝑖𝑛 ) ,
𝐾1
~ 158 ~
𝑞 𝑓 𝑑𝑀
= 𝑓𝑀0𝑞 , 𝑞
𝐽0𝑥,0 𝐽0𝑦,0 = 1+𝑀𝑞 𝑑𝜀 . Expression (1.4.10-11)
0 1
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑖 = 1; 𝑖 ≤ 𝑢𝑛𝑡𝑖𝑙 𝑐𝑜𝑣𝑒𝑟𝑖𝑛𝑔 𝑒𝑛𝑡𝑖𝑟𝑒 𝑡𝑜𝑜𝑡ℎ 𝑝𝑟𝑜𝑓𝑖𝑙𝑒; 𝑖 + +)
𝑑𝜀
∆𝑖 𝜀1,𝑞 = ∆𝑖−1 𝜀1,𝑞 + 𝛿𝑠0 (𝑑𝑠1 ) |
0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
𝑞 , Expression (2.1.2-15)
1+𝑀𝑖−1
= ∆𝑖−1 𝜀1,𝑞 + 𝟐 𝟐
𝛿𝑠0
√(𝐽𝑞 𝑞
) +(𝐽0𝑦,𝑖−1 )
0𝑥,𝑖−1
𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 𝑓 𝑑𝑀

𝑀𝑖𝑞 = 2𝐸 ( 𝑞
= 𝑓𝑀𝑖𝑞 , 𝐽0𝑦,𝑖
𝑞
+ 𝐷𝑚𝑖𝑛 ), 𝐽0𝑥,𝑖 = 1+𝑀𝑞 𝑑𝜀 ,
𝐾1 𝑖 1
𝑑𝜀
∆𝑖 𝜀2,𝑞 = ∆𝑖−1 𝜀2,𝑞 + 𝛿𝑠0 𝑀|𝜀1=𝜀1,𝑞+∆𝑖−1 𝜀1,𝑞 (𝑑𝑠1 ) |
0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
𝑞 , Expression (2.1.2-26)
𝑞 1+𝑀𝑖−1
= ∆𝑖−1 𝜀2,𝑞 + 𝛿𝑠0 𝑀𝑖−1 2 2
√(𝐽𝑞 𝑞
) +(𝐽0𝑦,𝑖−1 )
0𝑥,𝑖−1
𝜀1,𝑞+1 = 𝜀1,𝑞 + ∆𝑚 𝜀1,𝑞 , 𝜀2,𝑞+1 = 𝜀2,𝑞 + ∆𝑚 𝜀2,𝑞
Step 2. Calculation of Curvature and Unit Normal to Pitch Curve
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
{
𝑞 𝑞
𝑞 𝐽0𝑥,𝑖 𝑞 𝐽0𝑦,𝑖
𝑁0𝑝𝑥,𝑖 = 2 2
, 𝑁0𝑝𝑦,𝑖 = 2 2 . Expression (1.4.10-13)
√(𝐽𝑞 ) +(𝐽𝑞 ) √(𝐽𝑞 ) +(𝐽𝑞 )
0𝑥,𝑖 0𝑦,𝑖 0𝑥,𝑖 0𝑦,𝑖
𝑞
𝑞 𝑓𝑀
𝑥0𝑝,𝑖 = 1+𝑀𝑖 𝑞. Expression (1.4.10-6)
𝑖
~ 159 ~
𝑞 𝑞 𝑞 𝑞 𝑑𝑀 𝑞 𝑞
(1+𝑀𝑖 ) −(1+𝑀𝑖 )𝑥0𝑝,𝑖 𝑁0𝑝𝑥,𝑖 +2 𝑥 𝑁
𝑞 𝑑𝜀1 0𝑝,𝑖 0𝑝𝑦,𝑖
𝐾1𝑔0,𝑖 = 2 2
[ 2 2
+ 2] . Expression (1.4.10-27)
√(𝐽𝑞 ) +(𝐽𝑞 ) √(𝐽𝑞 ) +(𝐽𝑞 )
0𝑥,𝑖 0𝑦,𝑖 0𝑥,𝑖 0𝑦,𝑖
𝑞 2
𝑞 𝑞 (1+𝑀𝑖 )
𝐾2𝑔0,𝑖 = −𝐾1𝑔0,𝑖 + 2 2
. Expression (1.4.10-25)
√(𝐽𝑞 ) +(𝐽𝑞 )
0𝑥,𝑖 0𝑦,𝑖
Step 3. Calculation for Cutting Position of Cutter
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
{
𝑞 𝑞 𝑞 𝑞 𝑞
𝑓1,𝑖 = 𝑥0𝑝,𝑖 + 𝑟0 𝑁0𝑝𝑥,𝑖 , ℎ1,𝑖 = 𝑟0 𝑁0𝑝𝑦,𝑖 . Expression (2.1.1-30)
𝑓2,𝑖 = 𝑥0𝑝,𝑖 − 𝑟0 𝑁0𝑝𝑥,𝑖 , ℎ2,𝑖 = −𝑟0 𝑁0𝑝𝑦,𝑖 . Expression (2.1.1-32)
Step 4. Calculation for Rotary Angle of Cutter 1 & 2, that is, expressions (2.1.2-16) and (2.1.2-21)
Let 𝜀𝑐,1 = 0 and 𝜀𝑐̅,0 = 0.
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
∆0 𝜀𝑐,𝑞 = 0, ∆0 𝜀𝑐̅,𝑞 = 0 ,
~ 160~
𝑑𝜀
∆𝑖 𝜀𝑐,𝑞 = ∆𝑖−1 𝜀𝑐,𝑞 + 𝛿𝑠0 (𝑑𝑠𝑐) |
0 𝜏0 𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖−1 1,𝑞
Expression (2.1.2-16)
𝑞
𝑞 1 1+𝑀𝑖−1
= ∆𝑖−1 𝜀𝑐,𝑞 + 𝛿𝑠0 [𝐾1𝑔0,𝑖−1 +𝑟 − 𝟐 𝟐
],
0 √(𝐽𝑞 𝑞
) +(𝐽0𝑦,𝑖−1 )
0𝑥,𝑖−1
𝑑𝜀
∆𝑖 𝜀𝑐̅,𝑞 = ∆𝑖−1 𝜀𝑐̅,𝑞 + 𝛿𝑠0 (𝑑𝑠𝑐̅ ) |
0 𝜏0
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
𝑞
1 𝑞 1+𝑀𝑖−1
= ∆𝑖−1 𝜀𝑐,̅𝑞 + 𝛿𝑠0 [𝑟̅ − 𝐾1𝑔0,𝑖−1 + 𝟐 𝟐
],
0 √(𝐽𝑞 𝑞
) +(𝐽0𝑦,𝑖−1 )
0𝑥,𝑖−1
𝜀𝑐,𝑞+1 = 𝜀𝑐,𝑞 + ∆𝑚 𝜀𝑐,𝑞 , 𝜀𝑐̅,𝑞+1 = 𝜀𝑐̅,𝑞 + ∆𝑚 𝜀𝑐̅,𝑞 .
Step 5. Calculation for Cutting Edge of Cutter, that is, expressions (2.1.2-11) and (2.1.2-17)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
{
𝑖 𝑞 𝑞 𝑖 𝑞 𝑞
𝑥𝑐,𝑞 = 𝑥𝑐,𝑖 𝑁0𝑝𝑥,0 − 𝑦𝑐,𝑖 𝑁0𝑝𝑦,0 , 𝑦𝑐,𝑞 = 𝑥𝑐,𝑖 𝑁0𝑝𝑦,0 + 𝑦𝑐,𝑖 𝑁0𝑝𝑥,0 . Expression (2.1.2-11)
𝑞 𝑞 𝑞 𝑞
𝑥𝑐̅𝑖 ,𝑞 = 𝑥𝑐̅,𝑖 𝑁0𝑝𝑥,0 − 𝑦𝑐̅,𝑖 𝑁0𝑝𝑦,0 , 𝑦𝑐̅𝑖 ,𝑞 = 𝑥𝑐̅,𝑖 𝑁0𝑝𝑦,0 + 𝑦𝑐̅,𝑖 𝑁0𝑝𝑥,0 . Expression (2.1.2-17)
Step 6. Calculation for Conjugate Cutting Point, that is, expression (2.1.2-13) or (2.1.2-19)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
~ 161 ~
{
𝑖 𝑖 𝑖 𝑞
𝑥𝑝,𝑞 = 𝑥𝑐,𝑞 cos(∆𝑖 𝜀𝑐,𝑞 ) + 𝑦𝑐,𝑞 sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝑓1,𝑖 ,
𝑖 𝑖 𝑖 𝑞 } Expression (2.1.2-13)
𝑦𝑝,𝑞 = −𝑥𝑐,𝑞 sin(∆𝑖 𝜀𝑐,𝑞 ) + 𝑦𝑐,𝑞 cos(∆𝑖 𝜀𝑐,𝑞 ) + ℎ1,𝑖 .
OR
𝑞
𝑖
𝑥𝑝,𝑞 = 𝑥𝑐̅𝑖 ,𝑞 cos(∆𝑖 𝜀𝑐̅,𝑞 ) − 𝑦𝑐̅𝑖 ,𝑞 sin(∆𝑖 𝜀𝑐̅,𝑞 ) + 𝑓2,𝑖 ,
𝑞 } Expression (2.1.2-19)
𝑖
𝑦𝑝,𝑞 = 𝑥𝑐̅𝑖 ,𝑞 sin(∆𝑖 𝜀𝑐̅,𝑞 ) + 𝑦𝑐̅𝑖 ,𝑞 cos(∆𝑖 𝜀𝑐̅,𝑞 ) + ℎ2,𝑖 .
Step 7. Calculation for Tooth Profile of Workpiece 1 & 2, that is, expressions (2.1.2-22) and
(2.1.2-24)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
{
𝑖 𝑖 𝑖
𝑥1,𝑞 = 𝑥𝑝,𝑞 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝,𝑞 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) ,
𝑖 𝑖 𝑖
} Expression (2.1.2-22)
𝑦1,𝑞 = −𝑥𝑝,𝑞 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝,𝑞 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) .
𝑖 𝑖 𝑖
𝑥2,𝑞 = (𝑥𝑝,𝑞 − 𝑓) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) − 𝑦1,𝑞 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) ,
𝑖 𝑖 𝑖
} Expression (2.1.2-24)
𝑦2,𝑞 = (𝑥𝑝,𝑞 − 𝑓) sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) + 𝑦1,𝑞 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) .
Finally, tooth profiles for workpieces 1 & 2 are generated by computer program with algorithms
above and presented graphically as follow:
~161 ~
workpiece 1 workpiece 2
Figure example 2.1-1e. A Pair of Workpieces 1 & 2
Cutter 𝐶̅ workpiece 1
workpiece 2 Cutter 𝐶
Figure example 2.1-1f. A Pair of Workpieces 1 & 2 and Cutters
~ 162~
workpiece 1 Shaper 𝐶
Figure example 2.1-1g. Manufacturing Process of Workpieces 1
Shaper 𝐶̅
workpiece 2
Figure example 2.1-1h. Manufacturing Process of Workpieces 2
~ 163~
Chapter 2
Non-Circular Gear Manufactured by Rack
2.2.1 Motion Requirements and Machine Setting Parameters

1 Expression for Cutting Edge of Rack
With aid of figure 2.2.1-1, expression 𝑹𝑐 for cutting edge of rack corresponding to tooth space
of workpiece 1 is derived as follow:
𝑑𝑠𝑛 ∅0 𝑑𝑠 𝑵𝑟
𝑑𝑠0 ≤ 0
𝑂𝑞 𝑑𝑠 𝒋𝑞
𝑑𝑠0 ≥ 0
𝒊𝑞 𝑑𝑠𝑛
Cutting edge of rack
Figure 2.2.1-1 cutting edge of rack for workpiece 1
𝑹𝑐 = 𝑑𝑠𝝉 = −𝑑𝑠(cos ∅0 𝒊𝑞 + sin ∅0 𝒋𝑞 ) (2.2.1-1)

𝜋
Where: 𝝉 = − cos ∅0 𝒊𝑞 − sin ∅0 𝒋𝑞 . 0 < ∅0 < is corresponding to right-flank of tooth space
2
𝜋
of workpiece 1, and < ∅0 < 𝜋 is corresponding left-flank of tooth space of workpiece 1. Unit
2
normal 𝑵𝑟 to cutting edge of rack is
𝑵𝑟 = 𝝉 × 𝒌 = − sin ∅0 𝒊𝑞 + cos ∅0 𝒋𝑞 (2.2.1-2)
2 Coordinate System
Let coordinate systems (𝑂𝑞 − 𝒊𝑞 , 𝒋𝑞 ) be integrated with coordinate system (𝑂 − 𝒊, 𝒋) at pitch

point 𝑃0 of intersection between pitch curve 𝐴0 of tooth profile 𝐴 and tooth profile 𝐴 of 𝑞𝑡ℎ
tooth as shown in figure 2.2.1-2, that is,
~ 164~
𝒊𝑞 = 𝑵0𝑝 |𝜀 = 𝑁0𝑝𝑥 |𝜀 𝒊 + 𝑁0𝑝𝑦 |𝜀 𝒋,
1 =𝜀1,𝑞 1 =𝜀1,𝑞 1 =𝜀1,𝑞
𝒋𝑞 = 𝒌 × 𝒊𝑞 = −𝑁0𝑝𝑦 |𝜀 𝒊 + 𝑁0𝑝𝑥 |𝜀 𝒋, (2.2.1-3)

1 =𝜀1,𝑞 1 =𝜀1,𝑞
̅̅̅̅̅̅
𝑂𝑂𝑞 = 𝑹0𝑝 = 𝑥0𝑝 |𝜀 𝒊 + 𝑦0𝑝 |𝜀 𝒋.
1 =𝜀1,𝑞 1 =𝜀1,𝑞 }
Where: 𝜀1,𝑞 is parameter of pitch point 𝑃0 defined in expression (1.4.10-6) corresponding to

intersecting point between pitch curve and tooth profile of 𝑞𝑡ℎ tooth. 𝑁0𝑝𝑥 |𝜀 and
1 =𝜀1,𝑞
𝑁0𝑝𝑦 |𝜀 are calculated by expression (1.4.10-13).

1 =𝜀1,𝑞
𝑵𝑐 𝑂 𝒋
𝑑𝑠 𝑹0𝑝 𝒋𝑞
∅0 𝑑𝑠0
𝝉 𝑂𝑞 (𝑃0 )
𝑑𝑠𝑛 𝑑𝑠0 cutting edge of rack
𝑃0" 𝑃0′ 𝑃 𝒊𝑞
𝒊
Figure 2.2.1-2 Coordinate System for Rack
3 Rotary Angle and Position of Rack
Point 𝑃0" on pitch curve 𝐴0 of tooth profile 𝐴 will reach to position of conjugate contact with
point 𝑃0′ on pitch line of rack after workpiece 1 rotates by an angle 𝑑𝜀1 about 𝝎 = 𝒌 as an axis,
and corresponding to 𝑑𝜀1 , point 𝑃 on cutting edge will reach to conjugate cutting position after
rotating by an angle 𝑑𝜀𝑟 about 𝝎1 = −𝒌 as an axis, that is,
𝑹1𝑝 = (𝑑𝜀𝑟 𝝎1 ) ⊗ (𝑑𝑠𝝉) + 𝑹0𝑝 |𝜀 + 𝑑𝑠0 (𝒌 × 𝑵0𝑝 |𝜀 )

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
= (𝑑𝜀𝑟 𝝎1 ) ⊗ (𝑑𝑠𝝉) + (𝑙𝒑)𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 ,

(2.2.1-4)
(− cos ∅0 𝑁0𝑝𝑥 | + sin ∅0 𝑁0𝑝𝑦 |𝜀 )𝒊
𝜀1 =𝜀1,𝑞 1 =𝜀1,𝑞
𝝉=[ ].
− (cos ∅0 𝑁0𝑝𝑦 | + sin ∅0 𝑁0𝑝𝑥 | )𝒋
𝜀1 =𝜀1,𝑞 𝜀1 =𝜀𝜀1,𝑞 }
~ 165 ~
Where: 𝑹0𝑝 |𝜀 is calculated by expression (1.4.10-5) and 𝑵0𝑝 |𝜀 is calculated
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
by expression (1.4.10-13). (𝑙𝒑)𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 = 𝑹0𝑝 |𝜀 + 𝑑𝑠0 (𝒌 × 𝑵0𝑝 |𝜀 ).

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
Because unit normal 𝑵𝑐 to cutting edge at point 𝑃 must pass through point 𝑃0′ , thus,
𝑑𝑠 = 𝑑𝑠0 sin ∅0 = ∆𝑖 𝑠,
} (2.2.1-5)
𝑑𝑠𝑛 = 𝑑𝑠0 cos ∅0 .
Where: 𝛿𝑠0 is defined in expression (2.1.2-3). 𝑑𝑠0 = −𝑖𝛿𝑠0 in positive side of coordinate axis 𝒋𝑞
and 𝑑𝑠0 = 𝑖𝛿𝑠0 in negative side of coordinate axis 𝒋𝑞 .
𝑑𝜀𝑟 can be calculated by application of expression (1.4.10-24) with consideration of 𝐾2𝜏0 = 0

𝑑𝜀2 𝑑𝜀𝑟
and ( ) =( ) as follow:
0 0
𝑑𝜀
𝑑𝜀𝑟 = ∆𝑖 𝜀𝑟,𝑞 = ∆𝑖−1 𝜀𝑟,𝑞 + 𝛿𝑠0 (𝑑𝑠𝑟 ) |
0 𝜏0 𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖−1 1,𝑞
𝑑𝜀
= ∆𝑖−1 𝜀𝑟,𝑞 + 𝛿𝑠0 [𝐾1𝑔0 | − (𝑑𝑠1 ) | ]
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 0 𝜏0 (2.2.1-6)
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
1+𝑀|𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
= ∆𝑖−1 𝜀𝑟,𝑞 + 𝛿𝑠0 [𝐾1𝑔0 | − ],
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 |𝑱0 |𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 |
𝜀𝑟,𝑞 = 𝜀𝑟,𝑞−1 + ∆𝑚 𝜀𝑟,𝑞−1 . }
Where: 𝜀1,𝑞 and ∆𝑖 𝜀1,𝑞 are calculated by expression (2.1.2-15). 𝜀𝑟,1 = 0. ∆0 𝜀𝑟,𝑞 = 0. 𝑞 =
1,2,3, ⋯ 𝑁. 𝑖 = 1,2,3, ⋯, until covering entire tooth profile. 𝐾1𝑔0 | is calculated by
𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
Origin 𝑂𝑞 of coordinate system 𝑂𝑞 − 𝒊𝑞 , 𝒋𝑞 is translated to (𝑙𝒑)𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 at instant rotating

angle 𝜀1 = 𝜀1,𝑞 + 𝑑𝜀1 , that is,
(𝑙𝒑)𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 = 𝑹0𝑝 | + 𝑑𝑠0 (𝒌 × 𝑵0𝑝 |𝜀 )
𝜀 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 (2.2.1-7)
= 𝑓𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 𝒊 + ℎ𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 𝒋
Where: 𝑑𝜀1 = ∆𝑖 𝜀1,𝑞 is calculated by expression (2.1.2-15) and
𝑓𝑟 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 = 𝑥0𝑝 |𝜀 − 𝑑𝑠0 𝑁0𝑝𝑦 |𝜀 ,

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
}
ℎ𝑟 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 = 𝑦0𝑝 |𝜀 + 𝑑𝑠0 𝑁0𝑝𝑥 |𝜀 .
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
~ 166 ~
Substitution of expressions (2.2.1-3) and (2.2.1-7) into expression (2.2.1-4) results in conjugate
cutting position of point 𝑃 on cutting edge as follow:
𝑹1𝑝 |𝜀 = (𝑑𝜀𝑟 𝝎1 ) ⊗ (𝑑𝑠𝝉) + (𝑙𝒑)𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1

1 =𝜀1,𝑞 +𝑑𝜀1
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
(− cos ∅0 𝑁0𝑝𝑥 | + sin ∅0 𝑁0𝑝𝑦 |𝜀 )𝒊 (2.2.1-8)

𝜀1 =𝜀1,𝑞 1 =𝜀1,𝑞
(−𝑑𝜀𝑟 𝒌) ⊗ {𝑑𝑠 [ ]}
= − (cos ∅0 𝑁0𝑝𝑦 |𝜀 + sin ∅0 𝑁0𝑝𝑥 |𝜀 )𝒋
1 =𝜀1,𝑞 1 =𝜀1,𝑞
{ +(𝑙𝒑)𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 }
Where: 𝜀1,𝑞 and 𝑑𝜀1 = ∆𝑖 𝜀1,𝑞 are calculated by expression (2.1.2-15). 𝑑𝜀𝑟 = ∆𝑖 𝜀𝑟,𝑞 is decided by
expression (2.2.1-6). 𝑑𝑠 is expressed in formular (2.2.1-5). Then,
(− cos ∅0 𝑁0𝑝𝑥 | + sin ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 ) cos 𝑑𝜀𝑟

𝜀1 =𝜀1,𝑞 1 1𝑞
𝑑𝑠 [ ]
𝑥𝑝 |𝜀 = − (cos ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 + sin ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 ) sin 𝑑𝜀𝑟 ,
1 =𝜀1,𝑞 +𝑑𝜀1
1 1,𝑞 1 1𝑞
{ +𝑓𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 }
(2.2.1-9)
− (− cos ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 + sin ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 ) sin 𝑑𝜀𝑟
1 1,𝑞 1 1𝑞
𝑑𝑠 [ ]
𝑦𝑝 |𝜀 = − (cos ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 + sin ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 ) cos 𝑑𝜀𝑟 .
1 =𝜀1,𝑞 +𝑑𝜀1
1 1,𝑞 1 1,𝑞
{ +ℎ𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 }}
Unit normal 𝑵1𝑝 |𝜀 to tooth profile 𝐴 of workpiece 1 at conjugate cutting position is as

1 =𝜀1,𝑞 +𝑑𝜀1
follow:
𝑵1𝑝 |𝜀 = −(𝑑𝜀𝑟 𝝎1 ) ⊗ (𝑵𝑟 ) = 𝐴𝑝 |𝜀 𝒊 + 𝐵𝑝 |𝜀 𝒋

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
= −(−𝑑𝜀𝑟 𝒌) ⊗ (− sin ∅0 𝒊𝑞 + cos ∅0 𝒋𝑞 )

(2.2.1-10)
(− sin ∅0 𝑁0𝑝𝑥 | − cos ∅0 𝑁0𝑝𝑦 |𝜀 )𝒊
𝜀1 =𝜀1,𝑞 1 =𝜀1,𝑞
= −(−𝑑𝜀𝑟 𝒌) ⊗ [ ]
+ (− sin ∅0 𝑁0𝑝𝑦 | + cos ∅0 𝑁0𝑝𝑥 | )𝒋
𝜀1 =𝜀1,𝑞 𝜀1 =𝜀1,𝑞
Where:
~167 ~
− (− sin ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 − cos ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 ) cos 𝑑𝜀𝑟
1 1,𝑞 1 1,𝑞
𝐴𝑝 |𝜀 =⌈ ⌉,
1 =𝜀1,𝑞 +𝑑𝜀1
− (− sin ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 + cos ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 ) sin 𝑑𝜀𝑟
1 1,𝑞 1 1,𝑞
(− sin ∅0 𝑁0𝑝𝑥 | − cos ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 ) sin 𝑑𝜀𝑟

𝜀1 =𝜀1,𝑞 1 1,𝑞
𝐵𝑝 |𝜀 =[ ].
1 =𝜀1,𝑞 +𝑑𝜀1
− (− sin ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 + cos ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 ) cos 𝑑𝜀𝑟
1 1,𝑞 1 1,𝑞 }

1) Manufacturing Compensate Angle ∆𝑖 𝜀𝑚,𝑞
With respect to machine coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ), rotary angle of workpiece 1

should be adjusted by a compensate angle ∆𝑖 𝜀𝑚,𝑞 as shown in figure 2.2.1-3, that is,
𝑁0𝑝𝑦 |
𝜀1 =𝜀1,𝑞 +𝑑𝜀1
∆𝑖 𝜀𝑚,𝑞 = tan−1 (𝑁 ) (2.2.1-11)
0𝑝𝑥 |𝜀 =𝜀 +𝑑𝜀
1 1,𝑞 1
With respect to machine coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ), rotating angle 𝜀1𝑚 of

workpiece 1 about 𝑲𝑚 as an axis is
𝜀1𝑚 = 𝜀1,𝑞 + 𝑑𝜀1 − ∆𝑖 𝜀𝑚,𝑞 = 𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 − ∆𝑖 𝜀𝑚,𝑞 (2.2.1-12)
Where: 𝜀1,𝑞 and 𝑑𝜀1 = ∆𝑖 𝜀1,𝑞 are calculated by expression (2.1.2-15).
In manufacturing process of workpiece 1, position of reference point 𝑂𝑟 on pitch line of rack is

as shown in figure 2.2.1-4, that is,
̅̅̅̅̅̅
𝑂 𝑂𝑟 = 𝑓1𝑚 𝑰𝑚 + ℎ1𝑚 𝑱𝑚 (2.2.1-13)
Due to
𝑓1𝑚 𝑵0𝑝 |𝜀 = 𝑹0𝑝 |𝜀 + 𝑑𝑠1 (𝒌 × 𝑵0𝑝 |𝜀 ),

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
𝑓1𝑚 𝑁0𝑝𝑥 |𝜀 = 𝑥0𝑝 |𝜀 − 𝑑𝑠1 𝑁0𝑝𝑦 |𝜀 ,

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
𝑓1𝑚 𝑁0𝑝𝑦 |𝜀 = 𝑦0𝑝 |𝜀 + 𝑑𝑠1 𝑁0𝑝𝑥 |𝜀

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 }
thus, 𝑓1𝑚 and 𝑑𝑠1 are obtained from solution to equation above as follow:
~ 168 ~
𝑓1𝑚 = 𝑥0𝑝 |𝜀 𝑁0𝑝𝑥 |𝜀 + 𝑦0𝑝 |𝜀 𝑁0𝑝𝑦 |𝜀 ,
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
} (2.2.1-14)
𝑑𝑠1 = 𝑥0𝑝 |𝜀 𝑁0𝑝𝑦 |𝜀 − 𝑦0𝑝 |𝜀 𝑁0𝑝𝑥 |𝜀 .
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
Where: 𝜀1,𝑞 and 𝑑𝜀1 = ∆𝑖 𝜀1,𝑞 are calculated by expression (2.1.2-15).
Pitch line of rack 𝒌 × 𝑵0𝑝 |𝜀

1 =𝜀1,𝑞 +𝑑𝜀1
ℎ2𝑚
𝑂𝑟 ∆𝑖 𝜀𝑚,𝑞
𝑂 𝑓1𝑚 𝒋
ℎ1𝑚
𝑃0 𝑑𝑠1 𝑠0
𝑑𝑠2 𝑵0𝑝 |𝜀
1 =𝜀1,𝑞 +𝑑𝜀1
𝑓2𝑚 𝑂′ 𝒋′
𝑹0𝑝 |𝜀
1 =𝜀1,𝑞 +𝑑𝜀1
Pitch line of workpiece 1 𝒊 𝒊′ Pitch line of workpiece 2
Figure 2.2.1-3 Manufacturing compensate angle ∆𝑖 𝜀𝑚,𝑞
Then, ℎ1𝑚 in expression (2.2.1-13) is as follow:
ℎ1𝑚 = 𝑠0 − 𝑑𝑠1 = [𝑚(𝑞 − 1) + 𝑖]𝛿𝑠0 − 𝑑𝑠1 (2.2.1-15)
Where: 𝑚 and 𝛿𝑠0 are defined in expression (2.1.2-3). 𝑑𝑠1 is decided by expression (2.2.1-14).
𝑖 = 0, ±1, ±2, ±3, ⋯, until covering entire tooth profile. 𝑞 = 1,2,3, ⋯ 𝑁.
about 𝝎′ = −𝑲𝑚 is 𝜀2𝑚 , that is,
~ 169 ~
𝜀2𝑚 = 𝜀2,𝑞 + 𝑑𝜀2 + ∆𝑖 𝜀𝑚,𝑞 = 𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 + ∆𝑖 𝜀𝑚,𝑞 (2.2.1-16)
Where: 𝜀2,𝑞 and ∆𝑖 𝜀2,𝑞 are calculated by expression (2.1.2-25). ∆𝑖 𝜀𝑚,𝑞 is decided by expression
(2.2.1-11).
Pitch line of workpiece 1
𝑂𝑚 𝑱𝑚
𝑓1𝑚
𝑑𝑠1 ℎ1𝑚
𝑃0 𝑂𝑟
𝑠0
Pitch line of rack
𝑰𝑚
Figure 2.2.1-4 Machine Setting Parameters for Workpiece 1 with respect to machine coordinate
system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 )
In manufacturing process of workpiece 2, position of reference point 𝑂𝑟 on pitch line of rack is

as shown in figure 2.2.1-5, that is,
̅̅̅̅̅̅̅
𝑂′ 𝑂𝑟 = −𝑓2𝑚 𝑰𝑚 + ℎ2𝑚 𝑱𝑚 (2.2.1-17)
Due to
𝑓2𝑚 𝑵0𝑝 |𝜀 = 𝑑𝑠2 (𝒌 × 𝑵0𝑝 |𝜀 ) + (𝑙𝒑)|𝜀1=𝜀1,𝑞+𝑑𝜀1 − 𝑹0𝑝 | ,

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 𝜀1 =𝜀1,𝑞 +𝑑𝜀1
𝑓2𝑚 𝑁0𝑝𝑥 |𝜀 = −𝑑𝑠2 𝑁0𝑝𝑦 |𝜀 + 𝑓|𝜀1=𝜀1,𝑞+𝑑𝜀1 − 𝑥0𝑝 |𝜀 ,

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
𝑓2𝑚 𝑁0𝑝𝑦 |𝜀 = 𝑑𝑠2 𝑁0𝑝𝑥 |𝜀 + ℎ|𝜀1=𝜀1,𝑞+𝑑𝜀1 − 𝑦0𝑝 |𝜀 .

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1 }
thus, 𝑓2𝑚 and 𝑑𝑠2 are obtained from solution to equation above as follow:
~ 170 ~
ℎ2𝑚
𝑑𝑠2 𝑠0 𝑂𝑟
−𝑓2𝑚 𝑃0
𝑂𝑚 = 𝑂′ 𝑱𝑚
𝑰𝑚
Figure 2.2.1-5 Machine Setting Parameters for Workpiece 2 with respect to machine
coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 )
(𝑓|𝜀1=𝜀1,𝑞+𝑑𝜀1 − 𝑥0𝑝 | ) 𝑁0𝑝𝑥 |

𝜀1 =𝜀1,𝑞 +𝑑𝜀1 𝜀1 =𝜀1,𝑞 +𝑑𝜀1
𝑓2𝑚 = [ ],
+ (ℎ|𝜀1=𝜀1,𝑞 +𝑑𝜀1 − 𝑦0𝑝 |𝜀 =𝜀 +𝑑𝜀 ) 𝑁0𝑝𝑦 |𝜀 =𝜀 +𝑑𝜀
1 1,𝑞 1 1 1,𝑞 1
(2.2.1-18)
(𝑓|𝜀1=𝜀1,𝑞+𝑑𝜀1 − 𝑥0𝑝 | ) 𝑁0𝑝𝑦 |
𝜀1 =𝜀1,𝑞 +𝑑𝜀1 𝜀1 =𝜀1,𝑞 +𝑑𝜀1
𝑑𝑠2 = [ ].
− (ℎ|𝜀1=𝜀1,𝑞+𝑑𝜀1 − 𝑦0𝑝 |𝜀 =𝜀 +𝑑𝜀 ) 𝑁0𝑝𝑥 |𝜀 =𝜀 +𝑑𝜀
1 1,𝑞 1 1 1,𝑞 1 }
Then, ℎ2𝑚 in expression (2.2.1-17) is as follow:
ℎ2𝑚 = 𝑠0 + 𝑑𝑠2 = [𝑚(𝑞 − 1) + 𝑖]𝛿𝑠0 + 𝑑𝑠2 (2.2.1-19)
Where: 𝑚 and 𝛿𝑠0 are defined in expression (2.1.2-3). 𝑑𝑠2 is decided by expression (2.2.1-18).
𝑖 = 0, ±1, ±2, ±3, ⋯, until covering entire tooth profile. 𝑞 = 1,2,3, ⋯ 𝑁.
2.2.2 Tooth Profile of Workpieces

1 Tooth Profile of Workpiece 1
~ 171 ~
Tooth profile 𝐴 for 𝑞𝑡ℎ tooth of driving gear in initial position is as follow:
Tooth profile 𝐴 for 𝑞𝑡ℎ tooth of driving gear in initial position is derived by application of
𝑹1,𝑞 = [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝝎] ⊗ 𝑹1𝑝 |𝜀 = 𝑥𝑞,𝑖 𝒊 + 𝑦𝑞,𝑖 𝒋

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝒌] ⊗ [𝑥𝑝 |𝜀 𝒊 + 𝑦𝑝 |𝜀 𝒋]

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(2.2.2-1)
[𝑥𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒊
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
={ }
+ [−𝑥𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒋
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Where: 𝑞 = 1,2,3, ⋯ , 𝑁, and 𝑖 = 0,1,2,3, ⋯. 𝑥𝑝 |𝜀 and 𝑦𝑝 |𝜀 are calculated

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
by expression (2.2.1-9) and thus
𝑥𝑞,𝑖 = 𝑥𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) ,

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
} (2.2.2-2)
𝑦𝑞,𝑖 = −𝑥𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝑦𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Correspondingly, unit normal 𝑵𝑞 to tooth profile 𝐴 for 𝑞𝑡ℎ tooth of driving gear in initial
position is as follow:
𝑵𝑞 = [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝝎] ⊗ 𝑵1𝑝 |𝜀 = 𝐴|𝜀1=𝜀1,𝑞+𝑑𝜀1 𝒊 + 𝐵|𝜀1=𝜀1,𝑞+𝑑𝜀1 𝒋

1 =𝜀1,𝑞 +𝑑𝜀1
= [−(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )𝒌] ⊗ (𝐴𝑝 |𝜀 𝒊 + 𝐵𝑝 |𝜀 𝒋)

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
(2.2.2-3)
[𝐴𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒊
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
={ }
+ [−𝐴𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 )] 𝒋
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
Where: 𝐴𝑝 |𝜀 and 𝐵𝑝 |𝜀 are calculated by expression (2.2.1-10) and

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
𝐴|𝜀1 =𝜀1,𝑞+𝑑𝜀1 = 𝐴𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) ,

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
}
𝐵|𝜀1=𝜀1,𝑞+𝑑𝜀1 = −𝐴𝑝 |𝜀 sin(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) + 𝐵𝑝 |𝜀 cos(𝜀1,𝑞 + ∆𝑖 𝜀1,𝑞 ) .
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
Tooth profile 𝐴̅ for 𝑞𝑡ℎ tooth of driven gear in initial position is derived by application of
~ 172~
𝑹2,𝑞 = [−(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝝎′ ] ⊗ [𝑹1𝑝 |𝜀 − (𝑙𝒑)|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ] = 𝑥𝑞′ 𝒊 + 𝑦𝑞′ 𝒋
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) 𝒊

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
= [(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝒌] ⊗ [ ]
+ (𝑦𝑝 |𝜀 =𝜀 +∆ 𝜀 − ℎ|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) 𝒋
1 1,𝑞 𝑖 1,𝑞
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) (2.2.2-4)

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
[ ]𝒊
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
=
𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
+[ ]𝒋
+ (𝑦𝑝 |𝜀 =𝜀 +∆ 𝜀 − ℎ|𝜀1=𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )
{ 1 1,𝑞 𝑖 1,𝑞 }
Where: 𝑥𝑝 |𝜀 and 𝑦𝑝 |𝜀 are calculated by either expression (2.2.1-9). 𝜀2,𝑞

1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
and ∆𝑖 𝜀2,𝑞 are calculated by application of expression (2.1.2-26) and
(𝑥𝑝 | − 𝑓|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
𝑥𝑞′ = [ ],
1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
𝑦𝑞′ = [ ].
+ (𝑦𝑝 |𝜀 =𝜀 +∆ 𝜀 − ℎ|𝜀1=𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )
1 1,𝑞 𝑖 1,𝑞 }
Correspondingly, unit normal 𝑵′𝑞 to tooth profile 𝐴̅ for 𝑞𝑡ℎ tooth of driven gear in initial
position is as follow:
𝑵′𝑞 = [−(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝝎′ ] ⊗ (−𝑵1𝑝 |𝜀 ) = 𝐴′ |𝜀1=𝜀1,𝑞+𝑑𝜀1 𝒊 + 𝐵 ′ |𝜀1=𝜀1,𝑞+𝑑𝜀1 𝒋

1 =𝜀1,𝑞 +𝑑𝜀1
= −[(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )𝒌] ⊗ (𝐴𝑝 |𝜀 𝒊 + 𝐵𝑝 |𝜀 𝒋)

1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
(2.2.2-5)
[𝐴𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) − 𝐵𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )] 𝒊
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
= −{ }
+ [𝐴𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) + 𝐵𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 )] 𝒋
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
Where:
~ 173 ~
𝐴′ |𝜀1=𝜀1,𝑞+𝑑𝜀1 = −𝐴𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) + 𝐵𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) ,
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
}
𝐵 ′ |𝜀1=𝜀1,𝑞+𝑑𝜀1 = −𝐴𝑝 |𝜀 sin(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) − 𝐵𝑝 |𝜀 cos(𝜀2,𝑞 + ∆𝑖 𝜀2,𝑞 ) .
1 =𝜀1,𝑞 +𝑑𝜀1 1 =𝜀1,𝑞 +𝑑𝜀1
2.2.3 Curvature of Tooth Profile of Workpiece

1 Curvature of Tooth Profile of Workpiece 1
With consideration of 𝜌20 = ∞, and 𝜌2 = ∞ in expression (1.4.10-31), curvature radius 𝜌1 for
tooth profile 𝐴 of workpiece 1 is derived as follow:
(𝝉0 ∙𝝉)
𝜌1 = 𝜌1 |𝜀1=𝜀1,𝑞+𝑑𝜀1 = 𝐾 + 𝑠𝑛,𝑖 (2.2.3-1)
1𝑔0 |𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖 1,𝑞
Where: 𝐾1𝑔0 | is calculated by expression (1.4.10-26).

𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞
Due to 𝝉0 = −𝒋𝑞 and 𝝉 = − cos ∅0 𝒊𝑞 − sin ∅0 𝒋𝑞 , then,
𝝉0 ∙ 𝝉 = sin ∅0 (2.2.3-2)
And
𝑠𝑛,𝑖 = −𝑑𝑠𝑛 (2.2.3-3)
Where: 𝑑𝑠𝑛 is decided by expression (2.2.1-5).

Substitution of expressions (2.2.3-2) and (2.2.3-3) into expression (2.2.3-1) results in
sin ∅0 sin ∅0
𝜌1 |𝜀1=𝜀1,𝑞+𝑑𝜀1 = 𝐾 − 𝑑𝑠𝑛 = 𝐾 − 𝑑𝑠0 cos ∅0 (2.2.3-4)
1𝑔0 |𝜀 =𝜀 +∆ 𝜀 1𝑔0 |𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖 1,𝑞 1 1,𝑞 𝑖 1,𝑞
Expression (2.2.3-4) is the same as expression (2.1.3-4).

Method 1.
Application of expression (1.5.6-19) results in curvature radius 𝜌2 for tooth profile 𝐴̅ of

workpiece 2 as follow:
(𝑱𝑝 | ∙𝑵1𝑝 | )(𝜌1 |𝜀1 =𝜀1,𝑞+𝑑𝜀1 −𝑠𝑛,𝑖 )

𝜀1 =𝜀1,𝑞 +𝑑𝜀1 𝜀1=𝜀1,𝑞 +𝑑𝜀1
𝜌2 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 = 𝟐 − 𝑠𝑛,𝑖 (2.2.3-5)
(𝜌1 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 −𝑠𝑛,𝑖 )(1+𝑀|𝜀1 =𝜀1,𝑞+∆𝑖 𝜀1,𝑞 ) −𝑱𝑝 | ∙𝑵 |
𝜀1 =𝜀1,𝑞 +𝑑𝜀1 1𝑝 𝜀1 =𝜀1,𝑞 +𝑑𝜀1
~ 174 ~
Where: 𝑠𝑛,𝑖 is calculated by expression (2.2.3-3). 𝑵1𝑝 |𝜀 is determined by formular
1 =𝜀1,𝑞 +𝑑𝜀1
(2.2.1-10). 𝜌1 |𝜀1=𝜀1,𝑞+𝑑𝜀1 is decided by expression (2.2.3-4). 𝑱𝑝 |𝜀 is calculated by

1 =𝜀1,𝑞 +𝑑𝜀1
Method 2
Application of expression (1.4.10-31) yields curvature radius 𝜌2 for tooth profile 𝐴̅ of workpiece
2 as follow:
(𝝉0 ∙𝝉)(𝜌1 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 −𝑠𝑛,𝑖 )

𝜌2 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 = − 𝑠𝑛,𝑖 (2.2.3-6)
(𝐾1𝑔0 | +𝐾2𝑔0 | )(𝜌1 |𝜀1 =𝜀1,𝑞 +𝑑𝜀1 −𝑠𝑛,𝑖 )−(𝝉0 ∙𝝉)
𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞 𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
Where: 𝐾1𝑔0 | is calculated by expression (1.4.10-26). 𝐾2𝑔0 | is decided

𝜀1 =𝜀1,𝑞 +∆𝑖−1 𝜀1,𝑞 𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
by expression (1.4.10-25). 𝜌1 |𝜀1=𝜀1,𝑞+𝑑𝜀1 is determined by expression (2.2.3-4). 𝑠𝑛,𝑖 is calculated
by expression (2.2.3-3). (𝝉0 ∙ 𝝉) = sin ∅0 is calculated by expression (2.2.3-2).
Method 3
Let cutting edge of rack be the first conjugate surface, thus, 𝜌10 = ∞, and 𝜌1 = ∞ in expression
(1.4.10-31), therefore, curvature radius 𝜌2 for tooth profile 𝐴̅ of workpiece 2 is derived by
𝝉0 ∙𝝉
𝜌2 = 𝜌2 |𝜀1=𝜀1,𝑞+𝑑𝜀1 = 𝐾 − 𝑠𝑛,𝑖
2𝑔0 |𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖 1,𝑞
sin ∅0 (2.2.3-7)
=𝐾 + 𝑑𝑠𝑛
2𝑔0 |𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖 1,𝑞
Where: 𝐾2𝑔0 | is calculated by expression (1.4.10-25). 𝑑𝑠𝑛 is decided by expression

𝜀1 =𝜀1,𝑞 +∆𝑖 𝜀1,𝑞
(2.2.1-5).
Example 2. 2-1 continue Example 1.4-1.
Given Condition:
Parameters of Rack
Pressure angle: 𝛼 = 20° = 0.349.
~ 175 ~
𝜋 1
Pitch: 𝑝 = 𝑃 = 7.85398 (𝑚𝑚).
𝑑
𝑆0
Tooth number of workpiece: 𝑁 = = 15.
𝑝
𝑑𝜀 𝜀
1 1
Same as Step 1 in Example 2. 1.1
Step 3. Calculation for Cutting Position of Rack, i.e., expression (2.2.1-7)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
𝑑𝑠0,𝑖 = ±𝑖𝛿𝑠0
𝑞 𝑞 𝑞
𝑓𝑟,𝑖 = 𝑥0𝑝,𝑖 − 𝑑𝑠0,𝑖 𝑁0𝑝𝑦,𝑖 ,
𝑞 𝑞 } Expression (2.2.1-7)
ℎ𝑟,𝑖 = 𝑑𝑠0,𝑖 𝑁0𝑝𝑥,𝑖 .
Step 4. Calculation for Rotary Angle of Rack, that is, expression (2.2.1-6)
Let 𝜀𝑟,0 = 0, then,
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
~ 176 ~
∆0 𝜀𝑟,𝑞 = 0,
𝑑𝜀
∆𝑖 𝜀𝑟,𝑞 = ∆𝑖−1 𝜀𝑟,𝑞 + 𝛿𝑠0 ( 𝑑𝑠𝑟 ) |
0 𝜏0 𝜀 =𝜀 +∆ 𝜀
1 1,𝑞 𝑖−1 1,𝑞
𝑞
𝑞 1+𝑀𝑖−1
= ∆𝑖−1 𝜀𝑟,𝑞 + 𝛿𝑠0 [𝐾1𝑔0,𝑖−1 − 𝟐 𝟐
],
√(𝐽𝑞 𝑞
) +(𝐽0𝑦,𝑖−1 )
0𝑥,𝑖−1
𝜀𝑟,𝑞+1 = 𝜀𝑟,𝑞 + ∆𝑚 𝜀𝑟,𝑞 ,
Step 5. Calculation for Conjugate Cutting Point, that is, expression (2.2.1-9)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 1; 𝑞 ≤ 𝑁; 𝑞 + +)
𝑑𝑠𝑖 = 𝑑𝑠0,𝑖 sin ∅0
(− cos ∅0 𝑁0𝑝𝑥 | + sin ∅0 𝑁0𝑝𝑦 |𝜀 ) cos ∆𝑖 𝜀𝑟,𝑞

𝜀1 =𝜀1,𝑞 1 =𝜀1𝑞
𝑖
𝑑𝑠𝑖 [ ]
𝑥𝑝,𝑞 = − (cos ∅0 𝑁0𝑝𝑦 | + sin ∅0 𝑁0𝑝𝑥 | ) sin ∆𝑖 𝜀𝑟,𝑞 ,
𝜀1 =𝜀1,𝑞 𝜀1 =𝜀1𝑞
{ +𝑓𝑟 |𝜀1=𝜀1,𝑞 +𝑑𝜀1 }

Exp. (2.2.1-9)
− (− cos ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 + sin ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 ) sin ∆𝑖 𝜀𝑟,𝑞
1 1,𝑞 1 1𝑞
𝑖
𝑑𝑠𝑖 [ ]
𝑦𝑝,𝑞 = − (cos ∅0 𝑁0𝑝𝑦 |𝜀 =𝜀 + sin ∅0 𝑁0𝑝𝑥 |𝜀 =𝜀 ) cos ∆𝑖 𝜀𝑟,𝑞 .
1 1,𝑞 1 1,𝑞
{ +ℎ𝑟 |𝜀1=𝜀1,𝑞+𝑑𝜀1 }}
~ 177 ~
Step 7. Calculation for Tooth Profiles of Workpiece 1 & 2
Same as Step 6 in Example 2. 1-1.
As shown in figure example 2.2-1a, 2.2-1b, 2.2-1c and 2.2-1d
Workpiece 1 Workpiece 2
Figure example 2.2-1a. A Pair of Gear Set
~ 178 ~
Rack Workpiece 1 Workpiece 2
Figure example 2.2-1b. A Pair of Workpieces 1 & 2 and Rack
Workpiece 1 Rack
Figure example 2.2-1c. Manufacturing Process of Workpieces 1
~ 179 ~
Rack Workpiece 2
Figure example 2.2-1d. Manufacturing Process of Workpieces 2
~180 ~
Chapter 3
Non-Circular Gear Manufactured by Hob
2.3.1 Geometry Property of Cylindrical Helicoid with Constant Lead

Profile of hob is a cylindrical helicoid with constant lead. Equation of cylindrical helicoid with
constant lead is derived in Chapter 1 of Part one. Geometry properties of cylindrical helicoid are
further discussed here. There are two types of hobs which are most usually used in practice,
that is, involute helicoid hob and Archimedean helicoid hob. Involute helicoid hob is able to
generate a pair of accurate conjugate surfaces, and Archimedean helicoid hob can only
generate a pair of approximate conjugate surfaces when rate of lead for Archimedean helicoid
is very small.
1. Unit Normal to Cylindrical Helicoid
Any point 𝑃 in cylindrical helicoid is expressed in expression (1.6.2-3) as follow:
𝑹ℎ = 𝜂𝒓0 + 𝑧ℎ 𝒌ℎ = 𝜂 cos 𝜇 𝒊ℎ + 𝜂 sin 𝜇 𝒋ℎ + 𝑧ℎ 𝒌ℎ = 𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ
Where: 𝑥ℎ = 𝜂 cos 𝜇 and 𝑦ℎ = 𝜂 sin 𝜇.
Let 𝑏𝑟 = 0 in formular (1.6.2-9), unit normal𝑵ℎ𝑝 to cylindrical helicoid with

constant lead at point 𝑃 is generated as follow:
𝑵ℎ = 𝐴ℎ 𝒊ℎ + 𝐵ℎ 𝒋ℎ + 𝐶ℎ 𝒌ℎ
1 −[𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + 𝜂 cos 𝛽 cos 𝜇]𝒊ℎ (2.3.1-1)
= 𝑄{ }
−[𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + 𝜂 cos 𝛽 sin 𝜇]𝒋ℎ + 𝜂 sin 𝛽 sin 𝜎 𝒌ℎ
Where:
1
𝐴ℎ = − 𝑄 [𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + 𝜂 cos 𝛽 cos 𝜇],
1
𝐵ℎ = − 𝑄 [𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + 𝜂 cos 𝛽 sin 𝜇],
1
𝐶ℎ = 𝑄 𝜂 sin 𝛽 sin 𝜎 ,
𝑄 = ±|𝜻 × 𝒗12 2 2 2 2 2 2
𝑝 | = ±√𝑏𝑎 sin 𝛽 + 𝜂 (cos 𝛽 + sin 𝛽 sin 𝜎) + 𝜂𝑏𝑎 sin(2𝛽) cos 𝜎 .}
Combination of expressions (1.6.2-3) and (2.3.1-1) gives following relationship as
𝐴ℎ 𝑦ℎ − 𝐵ℎ 𝑥ℎ = 𝑏𝑎 𝐶ℎ (2.3.1-2)
~ 181 ~
Expression (2.3.1-2) is a very important property of cylindrical helicoid.
2. Curvature of Cylindrical Helicoid
Let 𝑏𝑟 = 0 in formular (1.6.2-10), it gives normal curvature 𝐾1𝜁 of cylindrical helicoid at
point 𝑃 in direction 𝜻 tangent to generatrix of helicoid as follow:

𝜅𝑐
𝐾1𝜁 = −𝜅𝑐 (𝑵1𝑝 ∙ 𝝃) = [𝑏𝑎 sin 𝛽 cos 𝜈 − 𝜂(sin 𝜈 sin 𝜎 − cos 𝜈 cos 𝜎 cos 𝛽)] (2.3.1-3)
𝑄
Likewise, torsional curvature 𝐺1𝜁 of cylindrical helicoid at point 𝑃 in direction 𝜻 is resulted from
𝐾1𝜁 sin 𝛽
𝐺1𝜁 = − (𝑏𝑎 cos 𝛽 − 𝜂 cos 𝜎 sin 𝛽) + (𝑏𝑎 sin 𝛽 + 𝜂 cos 𝜎 cos 𝛽) (2.3.1-4)
𝑄 𝑄2
Normal curvature 𝐾1𝑞 of cylindrical helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is derived by

cos 𝛽+𝐺1𝜁 {𝑏𝑎 cos 𝛽−𝜂 cos 𝜎 sin 𝛽}
𝐾1𝑞 = − (2.3.1-5)
𝑄
Torsional curvature 𝐺1𝑞 of cylindrical helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is as follow:
𝐺1𝑞 = −𝐺1𝜁 (2.3.1-6)
2.3.2 Geometry Property of Involute Helicoid with Constant Lead

1. Intersection of Involute Helicoid with Plane Tangent to Base Cylinder
A. Right-Flank of Involute Helicoid
Surface equation of right-flank of involute helicoid is derived in similar way to expression (1.1.1-
19) as follow:
𝑯 = 𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ
−[𝑟𝑏 cos Γ + 𝑟𝑏 (Γ + 𝜎0 ) sin Γ]𝒊ℎ
= (𝜃𝐤 ℎ ) ⊗ { } + 𝑏𝑎 𝜃𝒌ℎ
+[−𝑟𝑏 sin Γ + 𝑟𝑏 (Γ + 𝜎0 ) cos Γ] 𝒋ℎ (2.3.2-1)
−𝑟𝑏 [cos(Γ + 𝜃) + (Γ + 𝜎0 ) sin(Γ + 𝜃)]𝒊ℎ
={ }
+𝑟𝑏 [− sin(Γ + 𝜃) + (Γ + 𝜎0 ) cos(Γ + 𝜃)]𝒋ℎ + 𝑏𝑎 𝜃𝒌ℎ
Where: any point 𝑃 on involute helicoid is defined by two surface parameters Γ and 𝜃
~ 182 ~
𝑥ℎ = −𝑟𝑏 [cos(Γ + 𝜃) + (Γ + 𝜎0 ) sin(Γ + 𝜃)],
𝑦ℎ = 𝑟𝑏 [− sin(Γ + 𝜃) + (Γ + 𝜎0 ) cos(Γ + 𝜃)],}
𝑧ℎ = 𝑧𝑝 = 𝑏𝑎 𝜃.
Let 𝐓 be tangent plane to base cylinder and 𝒘0 be unit normal to tangent plane 𝐓 as shown in
figure 2.3.2-1, that is,
𝒘0 = − cos ∅ 𝒊ℎ − sin ∅ 𝒋ℎ (2.3.2-2)
𝑮0 involute curve
𝜎0
𝐓 ∅ 𝛼0
𝜃 Γ
𝑟𝑏 𝒘0
𝒋ℎ
𝒊ℎ
Figure 2.3.2-1 Tangent Plane to Base Cylinder of Involute Helicoid (Right-Flank)
Point on intersection curve between 𝑯 and 𝐓 satisfies the following condition:
𝒘0 ∙ 𝑯 = 𝑟𝑏
Substitution of expressions (2.3.2-1) and (2.3.2-2) into expression above leads
cos(Γ + 𝜃 − ∅) + (Γ + 𝜎0 ) sin(Γ + 𝜃 − ∅) = 1 (2.3.2-3)
Due to Γ + 𝜎0 ≠ 0 , then, expression (2.3.2-3) generates relationship of parameters for
~ 183 ~
intersection curve between 𝑯 and 𝐓 as follow:
Γ+𝜃−∅=0 (2.3.2-4)
Substitution of expression (2.3.2-4) into expression (2.3.2-1) gives equation for intersection
curve, that is,
−𝑟𝑏 [cos ∅ + (∅ − 𝜃 + 𝜎0 ) sin ∅]𝒊ℎ

𝑯={ } (2.3.2-5)
+𝑟𝑏 [− sin ∅ + (∅ − 𝜃 + 𝜎0 ) cos ∅]𝒋ℎ + 𝑏𝑎 𝜃𝒌ℎ
Where: ∅ is given parameter of tangent plane to base cylinder.
Expression (2.3.2-5) stands for a straight line with 𝜃 as variable. 𝑯 is also a tangent line to
involute helicoid at point 𝑃 with parameters Γ and 𝜃 satisfying expression (2.3.2-4). Therefore,
unit tangent 𝜻 to involute helicoid at point 𝑃 with parameters Γ and 𝜃 is as follow:
𝑑𝑯
𝑑𝜃 𝑟𝑏 sin ∅𝒊ℎ −𝑟𝑏 cos ∅𝒋ℎ +𝑏𝑎 𝒌ℎ
𝜻= 𝑑𝑯 = (2.3.2-6)
| | √𝑟𝑏2 +𝑏𝑎2
𝑑𝜃
Any point 𝑃 on involute helicoid can be alternatively expressed in expression (1.6.2-3) as shown
in figure 1.6.2-1, that is,
𝑯 = 𝜂𝒓0 + 𝑧𝑝 𝒌 = 𝜂 cos 𝜇 𝒊 + 𝜂 sin 𝜇 𝒋 + 𝑧𝑝 𝒌
With help of expression (2.3.2-4), combination of expression (2.3.2-1) and expression above
results in
cos(Γ+𝜃)+(Γ+𝜎0 ) sin(Γ+𝜃) cos ∅+(Γ+𝜎0 ) sin ∅
cos 𝜇 = − =− ,
√1+(Γ+𝜎0 )2 √1+(Γ+𝜎0 )2
− sin(Γ+𝜃)+(Γ+𝜎0 ) cos(Γ+𝜃) − sin ∅+(Γ+𝜎0 ) cos ∅
sin 𝜇 = = (2.3.2-7)
√1+(Γ+𝜎0 )2 √1+(Γ+𝜎0 )2
𝜂 = 𝑟𝑏 √1 + (Γ + 𝜎0 )2 . }
Similarly, 𝒘0 is alternatively expressed in expression (1.6.2-6) as shown in figure 1.6.2-1, that is,
𝒘0 = (𝜎𝒌) ⊗ 𝒓0 = (𝜎𝒌) ⊗ (cos 𝜇 𝒊 + sin 𝜇 𝒋) = cos(𝜇 + 𝜎) 𝒊 + sin(𝜇 + 𝜎) 𝒋
Combination of expression (2.3.2-2) and expression above yields
𝜇+𝜎 = 𝜋+∅ (2.3.2-8)
Likewise, unit tangent 𝜻 is also expressed by formula (1.6.2-7), that is,
~ 184 ~
𝜻 = (𝛽𝒘0 ) ⊗ 𝒌
= cos 𝛽 𝒌 + sin 𝛽 𝒘0 × 𝒌
= − sin 𝛽 sin ∅ 𝒊 + sin 𝛽 cos ∅ 𝒋 + cos 𝛽 𝒌
Combination of expression (2.3.2-6) and expression above generates

𝑏𝑎
cos 𝛽 = ,
√𝑟𝑏2 +𝑏𝑎2
𝑟𝑏
sin 𝛽 = − , (2.3.2-9)
𝑟
tan 𝛽 = − 𝑏𝑏 = − tan 𝛽𝑏 .}
𝑎
Where: 𝛽𝑏 is helical angle of helical curve on base cylinder, for right-hand helicoid: 𝛽𝑏 > 0 and
for left-hand helicoid: 𝛽𝑏 < 0.
Combination of expressions (2.3.2-4), (2.3.2-7), (2.3.2-8) and (2.3.2-9) gives
Γ + 𝜃 = ∅,
cos ∅+(Γ+𝜎0 ) sin ∅
cos 𝜇 = − ,
√1+(Γ+𝜎0 )2
− sin ∅+(Γ+𝜎0 ) cos ∅
sin 𝜇 = ,
√1+(Γ+𝜎0 )2 (2.3.2-10)
𝜂 = 𝑟𝑏 √1 + (Γ + 𝜎0 )2 ,
𝜎 = 𝜋 + ∅ − 𝜇,
𝑟
tan 𝛽 = − 𝑏𝑏 = − tan 𝛽𝑏 . }
𝑎
B. Left-Flank of Involute Helicoid
Likewise, involute helicoid of left flank is as shown in figure 2.3.2-2, that is,
−[𝑟𝑏 cos Γ + 𝑟𝑏 (Γ + 𝜎0 ) sin Γ]𝒊ℎ

𝑯 = 𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ = (𝜃𝐤 ℎ ) ⊗ { } + 𝑏𝑎 𝜃𝒌ℎ
+[𝑟𝑏 sin Γ − 𝑟𝑏 (Γ + 𝜎0 ) cos Γ] 𝒋ℎ
(2.3.2-11)
−𝑟𝑏 [cos(Γ − 𝜃) + (Γ + 𝜎0 ) sin(Γ − 𝜃)]𝒊ℎ
={ }
+𝑟𝑏 [sin(Γ − 𝜃) − (Γ + 𝜎0 ) cos(Γ − 𝜃)]𝒋ℎ + 𝑏𝑎 𝜃𝒌ℎ
𝑥ℎ = −𝑟𝑏 [cos(Γ − 𝜃) + (Γ + 𝜎0 ) sin(Γ − 𝜃)],

𝑦ℎ = 𝑟𝑏 [sin(Γ − 𝜃) − (Γ + 𝜎0 ) cos(Γ − 𝜃)], }
𝑧ℎ = 𝑏𝑎 𝜃.
Let 𝐓 be tangent plane to base cylinder and 𝒘0 be unit normal to tangent plane 𝐓 as shown in
~ 185 ~
𝒘0 = − cos ∅ 𝒊ℎ + sin ∅ 𝒋ℎ (2.3.2-12)
Point on intersection curve between 𝑯 and 𝐓 satisfies the following condition:
𝒘0 ∙ 𝑯 = 𝑟𝑏
Substitution of expressions (2.3.2-11) and (2.3.2-12) into expression above leads
cos(Γ − 𝜃 − ∅) + (Γ + 𝜎0 ) sin(Γ − 𝜃 − ∅) = 1
Due to Γ + 𝜎0 ≠ 0 , then, expression above generates relationship of parameters for
intersection curve between 𝑯 and 𝐓 as follow:
Γ−𝜃−∅=0 (2.3.2-13)
𝑮0 involute curve
𝜎0
Γ ∅ 𝐓
𝛼0 𝜃
𝑟𝑏 𝒘0
𝒋ℎ
𝒊ℎ
Figure 2.3.2-2 Involute Helicoid (Left-Flank)
Substitution of expression (2.3.2-13) into expression (2.3.2-11) gives equation for intersection
~186 ~
curve, that is,
−𝑟𝑏 [cos ∅ + (𝜃 + ∅ + 𝜎0 ) sin ∅]𝒊ℎ

𝑯={ } (2.3.2-14)
+𝑟𝑏 [sin ∅ − (𝜃 + ∅ + 𝜎0 ) cos ∅]𝒋ℎ + 𝑏𝑎 𝜃𝒌ℎ
Where: ∅ is given parameter of tangent plane to base cylinder.
Expression (2.3.2-14) represents a straight line with 𝜃 as variable. 𝑯 is also a tangent line to
involute helicoid at point 𝑃 with parameters Γ and 𝜃 satisfying expression (2.3.2-13). Therefore,
unit tangent 𝜻 to involute helicoid at point 𝑃 with parameters Γ and 𝜃 is as follow:

𝑑𝑯
𝑑𝜃 −𝑟𝑏 sin ∅𝒊ℎ −𝑟𝑏 cos ∅𝒋ℎ +𝑏𝑎 𝒌ℎ
𝜻= 𝑑𝑯 = (2.3.2-15)
| | √𝑟𝑏2 +𝑏𝑎2
𝑑𝜃
Any point 𝑃 on involute helicoid can be alternatively expressed in expression (1.6.2-3) as shown
in figure 1.6.2-1, that is,
𝑯 = 𝜂𝒓0 + 𝑧𝑝 𝒌 = 𝜂 cos 𝜇 𝒊 + 𝜂 sin 𝜇 𝒋 + 𝑧𝑝 𝒌
With help of expression (2.3.2-13), comparison between expression (2.3.2-14) and expression
above results in
cos(Γ−𝜃)+(Γ+𝜎0 ) sin(Γ−𝜃) cos ∅+(Γ+𝜎0 ) sin ∅
cos 𝜇 = − =− ,
√1+(Γ+𝜎0 )2 √1+(Γ+𝜎0 )2
sin(Γ−𝜃)−(Γ+𝜎0 ) cos(Γ−𝜃) sin ∅−(Γ+𝜎0 ) cos ∅
sin 𝜇 = = , (2.3.2-16)
√1+(Γ+𝜎0 )2 √1+(Γ+𝜎0 )2
𝜂 = 𝑟𝑏 √1 + (𝜃 + ∅ + 𝜎0 )2 = 𝑟𝑏 √1 + (Γ + 𝜎0 )2 . }
Similarly, 𝒘0 is alternatively expressed in expression (1.6.2-6) as shown in figure 1.6.2-1, that is,
𝒘0 = (𝜎𝒌) ⊗ 𝒓0 = (𝜎𝒌) ⊗ (cos 𝜇 𝒊 + sin 𝜇 𝒋) = cos(𝜇 + 𝜎) 𝒊 + sin(𝜇 + 𝜎) 𝒋
Comparison between expression (2.3.2-12) and expression above gives
𝜇+𝜎 = 𝜋−∅ (2.3.2-17)
Likewise, with help of expression (2.3.2-12), unit tangent 𝜻 is also expressed by formula (1.6.2-
7), that is,
𝜻 = (𝛽𝒘0 ) ⊗ 𝒌 = cos 𝛽 𝒌 + sin 𝛽 𝒘0 × 𝒌 = sin 𝛽 sin ∅ 𝒊 + sin 𝛽 cos ∅ 𝒋 + cos 𝛽 𝒌
~ 187 ~
𝑟𝑏
sin 𝛽 = − ,
𝑏𝑎
cos 𝛽 = , (2.3.2-18)
𝑟
tan 𝛽 = − 𝑏𝑏 = − tan 𝛽𝑏 .}
𝑎
Where: 𝛽𝑏 is helical angle of helical curve on base cylinder, for right-hand helicoid: 𝛽𝑏 > 0 and
for left-hand helicoid: 𝛽𝑏 < 0.
Combination of expressions (2.3.2-13), (2.3.2-16), (2.3.2-17) and (2.3.2-18) gives
Γ − 𝜃 = ∅,
cos ∅+(Γ+𝜎0 ) sin ∅
cos 𝜇 = − ,
√1+(Γ+𝜎0 )2
sin ∅−(Γ+𝜎0 ) cos ∅
sin 𝜇 = ,
√1+(Γ+𝜎0 )2 (2.3.2-19)
𝜂 = 𝑟𝑏 √1 + (Γ + 𝜎0 )2 ,
𝜎 = 𝜋 − ∅ − 𝜇,
𝑟
tan 𝛽 = − 𝑏𝑏 = − tan 𝛽𝑏 . }
𝑎
2 Unit Normal to Involute Helicoid

With help of expression (2.3.2-10), application of expression (2.3.1-1) yields unit normal 𝑵ℎ to
involute helicoid of right-flank as follow:
1 −[𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + 𝜂 cos 𝛽 cos 𝜇]𝒊ℎ
= 𝑄{ }
−[𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + 𝜂 cos 𝛽 sin 𝜇]𝒋ℎ + 𝜂 sin 𝛽 sin 𝜎 𝒌ℎ (2.3.2-20)
𝑏𝑎 sin ∅ 𝑏𝑎 cos ∅ 𝑟𝑏
=− 𝒊ℎ + 𝒋ℎ + 𝒌ℎ
√𝑟𝑏2 +𝑏𝑎2 √𝑟𝑏2 +𝑏𝑎2 √𝑟𝑏2 +𝑏𝑎2
Where:
𝐴ℎ = − , 𝐵ℎ = , 𝐶ℎ = ,
}
𝑄 = −√𝑏𝑎2 sin2 𝛽 + 𝜂2 (cos 2 𝛽 + sin2 𝛽 sin2 𝜎) + 𝜂𝑏𝑎 sin(2𝛽) cos 𝜎 = −𝑟𝑏 (Γ + 𝜎0 ).
~ 188 ~
Similarly, with help of expression (2.3.2-19), application of expression (2.3.1-1) yields unit
normal 𝑵ℎ to involute helicoid of left-flank as follow:
1 −[𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + 𝜂 cos 𝛽 cos 𝜇]𝒊ℎ
= 𝑄{ }
−[𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + 𝜂 cos 𝛽 sin 𝜇]𝒋ℎ + 𝜂 sin 𝛽 sin 𝜎 𝒌ℎ (2.3.2-21)
=− 𝒊ℎ − 𝒋ℎ − 𝒌ℎ
Where:
1 𝑏𝑎 sin ∅
𝐴ℎ = − 𝑄 [𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + 𝜂 cos 𝛽 cos 𝜇] = − ,
1 𝑏𝑎 cos ∅
𝐵ℎ = − 𝑄 [𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + 𝜂 cos 𝛽 sin 𝜇] = −
𝑟𝑏
𝐶ℎ = −
𝑄 = −√𝑏𝑎2 sin2 𝛽 + 𝜂2 (cos 2 𝛽 + sin2 𝛽 sin2 𝜎) + 𝜂𝑏𝑎 sin(2𝛽) cos 𝜎 = −𝑟𝑏 (Γ + 𝜎0 )}
3 Curvature of Involute Helicoid

Due to intersection curve between 𝑯 and 𝐓 being a straight line, then, 𝜅𝑐 = 0 in expression
(2.3.1-3), normal curvature 𝐾1𝜁 of involute helicoid of right-flank at point 𝑃 in direction 𝜻 is as
follow:
𝐾1𝜁 = 0 (2.3.2-22)
Likewise, with help of expressions (2.3.2-10) and (2.3.2-22), torsional curvature 𝐺1𝜁 of involute
helicoid at point 𝑃 in direction 𝜻 is resulted from expression (2.3.1-4)
𝐾1𝜁 sin 𝛽
𝐺1𝜁 = − (𝑏𝑎 cos 𝛽 − 𝜂 cos 𝜎 sin 𝛽) + (𝑏𝑎 sin 𝛽 + 𝜂 cos 𝜎 cos 𝛽) = 0 (2.3.2-23)
𝑄 𝑄2
Normal curvature 𝐾1𝑞 of involute helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is derived by

cos 𝛽+𝐺1𝜁 {𝑏𝑎 cos 𝛽−𝜂 cos 𝜎 sin 𝛽} cos 𝛽 cos 𝛽 𝑏𝑎
𝐾1𝑞 = − =− =𝑟 = (2.3.2-24)
𝑄 𝑄 𝑏 (Γ+𝜎0 ) 𝑟𝑏 (Γ+𝜎0 )√𝑟𝑏2 +𝑏𝑎2
~ 189 ~
Torsional curvature 𝐺1𝑞 of involute helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is derived by
𝐺1𝑞 = −𝐺1𝜁 = 0 (2.3.2-25)
Likewise, due to 𝜅𝑐 = 0, normal curvature 𝐾1𝜁 of involute helicoid of left-flank at point 𝑃 in

direction 𝜻 is derived by application of expression (2.3.1-3), that is,
𝐾1𝜁 = 0 (2.3.2-26)
Torsional curvature 𝐺1𝜁 of involute helicoid of left-flank at point 𝑃 in direction 𝜻 is resulted

from expression (2.3.1-4)
𝐺1𝜁 = 0 (2.3.2-27)
Normal curvature 𝐾1𝑞 of involute helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is derived by

cos 𝛽 𝑏𝑎
𝐾1𝑞 = 𝑟 = (2.3.2-28)
𝑏 (Γ+𝜎0 )
𝑟𝑏 (Γ+𝜎0 )√𝑟𝑏2 +𝑏𝑎2
Torsional curvature 𝐺1𝑞 of involute helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is derived by

𝐺1𝑞 = −𝐺1𝜁 = 0 (2.3.2-29)
4 Conjugate Surface of Involute Helicoid in Line Contact between Parallel Rotary

Axes
Given condition:
1 The first conjugate surface is an involute helicoid, that is, expression (2.3.2-1)
−𝑟𝑏 [cos(Γ + 𝜃) + (Γ + 𝜎0 ) sin(Γ + 𝜃)]𝒊ℎ
𝑯 = 𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ = { } (2.3.2-1)
+𝑟𝑏 [− sin(Γ + 𝜃) + (Γ + 𝜎0 ) cos(Γ + 𝜃)]𝒋ℎ + 𝑏𝑎 𝜃𝒌ℎ
~ 190 ~
𝑥ℎ = −𝑟𝑏 [cos(Γ + 𝜃) + (Γ + 𝜎0 ) sin(Γ + 𝜃)],
𝑦ℎ = 𝑟𝑏 [− sin(Γ + 𝜃) + (Γ + 𝜎0 ) cos(Γ + 𝜃)],}
𝑧ℎ = 𝑧𝑝 = 𝑏𝑎 𝜃.
2 Conjugate motion as shown in figure 2.3.2-3, that is,

𝑑𝜀2
𝑀= = 𝑐𝑜𝑛𝑠𝑡, 𝜎1 = 0, 𝜎2 = 0, 𝛼 = 0 ,
𝑑𝜀1 }
𝑓 = 𝑐𝑜𝑛𝑠𝑡, ℎ = 0.
Calculation Objects:
1 Instantaneous contact line
After rotating by an angle 𝜀1 about 𝝎 = 𝒌ℎ as an axis, the first conjugate surface 𝑯 arrives
conjugate contact position as follow:
𝑯𝑝 = (𝜀1 𝝎) ⊗ 𝑯 = (𝜀1 𝒌ℎ ) ⊗ (𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ ) = 𝑥ℎ𝑝 𝒊ℎ + 𝑦ℎ𝑝 𝒋ℎ + 𝑧ℎ𝑝 𝒌ℎ

(2.3.2-30)
= (𝑥ℎ cos 𝜀1 − 𝑦ℎ sin 𝜀1 )𝒊ℎ + (𝑥ℎ sin 𝜀1 + 𝑦ℎ cos 𝜀1 )𝒋ℎ + 𝑧ℎ 𝒌ℎ
Where: 𝑥ℎ , 𝑦ℎ and 𝑧ℎ are calculated by expression (2.3.2-1) and ∅ = Γ + 𝜃, then,
𝑥ℎ𝑝 = 𝑥ℎ cos 𝜀1 − 𝑦ℎ sin 𝜀1 = −𝑟𝑏 [cos(∅ + 𝜀1 ) + (Γ + 𝜎0 ) sin(∅ + 𝜀1 )],

𝑦ℎ𝑝 = 𝑥ℎ sin 𝜀1 + 𝑦ℎ cos 𝜀1 = 𝑟𝑏 [− sin(∅ + 𝜀1 ) + (Γ + 𝜎0 ) cos(∅ + 𝜀1 )],}
𝑧ℎ𝑝 = 𝑧ℎ = 𝑏𝑎 𝜃,
With help of expression (2.3.2-20), unit normal to the first conjugate surface at conjugate
contact point of instant rotating angle 𝜀1 is derived by rotating 𝑵ℎ by an angle about 𝝎 = 𝒌ℎ
as an axis, that is,
𝑵ℎ𝑝 = (𝜀1 𝝎) ⊗ 𝑵ℎ = (𝜀1 𝝎) ⊗ (𝐴ℎ 𝒊ℎ + 𝐵ℎ 𝒋ℎ + 𝐶ℎ 𝒌ℎ ) = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ

(2.3.2-31)
= (𝐴ℎ cos 𝜀1 − 𝐵ℎ sin 𝜀1 )𝒊ℎ + (𝐴ℎ sin 𝜀1 + 𝐵ℎ cos 𝜀1 )𝒋ℎ + 𝐶ℎ 𝒌ℎ
Where: ∅ = Γ + 𝜃 and
𝑏𝑎 sin(∅+𝜀1 )
𝐴ℎ𝑝 = 𝐴ℎ cos 𝜀1 − 𝐵ℎ sin 𝜀1 = − ,
𝑏𝑎 cos(∅+𝜀1 )
𝐵ℎ𝑝 = 𝐴ℎ sin 𝜀1 + 𝐵ℎ cos 𝜀1 = ,
𝑟𝑏
𝐶ℎ𝑝 = .
√𝑟𝑏2 +𝑏𝑎2 }
Relative velocity of the first conjugate surface 𝑯𝑝 with respect to the second conjugate surface
~ 191 ~
is obtained by application of expression (1.3.5-3), that is,
𝒗12 1 2
1 1 𝑑𝜀1
= (1 + 𝑀)𝒌ℎ × 𝑯𝑝 − 𝑀𝒌ℎ × (𝑓𝒊ℎ ) (2.3.2-32)
12 12 12
= −(1 + 𝑀)𝑦ℎ𝑝 𝒊ℎ + [(1 + 𝑀)𝑥ℎ𝑝 − 𝑓𝑀]𝒋ℎ = 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑧 𝒌
Where: 𝑥ℎ𝑝 and 𝑦ℎ𝑝 are decided by expression (2.3.2-30) and ∅ = Γ + 𝜃, then,
12
𝑣𝑝𝑥 = −(1 + 𝑀)𝑟𝑏 [− sin(∅ + 𝜀1 ) + (Γ + 𝜎0 ) cos(∅ + 𝜀1 )],
12
𝑣𝑝𝑦 = −(1 + 𝑀)𝑟𝑏 [cos(∅ + 𝜀1 ) + (Γ + 𝜎0 ) sin(∅ + 𝜀1 )] − 𝑓𝑀,}
12
𝑣𝑝𝑧 = 0.
The second conjugate surface
𝑂ℎ′ 𝒋ℎ
𝜎0 𝛼0 𝑟𝑏′
The first conjugate surface 𝑃0 𝑓<0
Path of contact 𝑃𝑏
𝑟𝑏 𝒘0 𝑂ℎ 𝒋ℎ
𝒊ℎ
Figure 2.3.2-3 Engagement between A Pair of Involute Helicoid
Requirement of conjugate contact, i.e., 𝒗12

𝑝 ∙ 𝑵ℎ𝑝 = 0, results in
𝑟𝑏 (1 + 𝑀) − 𝑓𝑀 cos(∅ + 𝜀1 ) = 0
Due to property of involute curve, i.e., 𝑟𝑏 = −𝑥0𝑝 cos 𝛼0, and expression (1.4.10-7), expression
above is updated as follow:
𝛼0 = ∅ + 𝜀1 = Γ + 𝜃 + 𝜀1 (2.3.2-33)
~ 192~
Where: ∅ is defined in expression (2.3.2-4), that is, ∅ = Γ + 𝜃.
Therefore, instantaneous contact line at instant rotating angle 𝜀1 is generated by substituting

expression (2.3.2-33) into expression (2.3.2-30), that is,
𝑯𝑝 = 𝑥ℎ𝑝 𝒊ℎ + 𝑦ℎ𝑝 𝒋ℎ + 𝑧ℎ𝑝 𝒌ℎ (2.3.2-34)
Where: 𝑥ℎ , 𝑦ℎ and 𝑧ℎ are calculated by expression (2.3.2-1) and ∅ = Γ + 𝜃, then,
𝑥ℎ𝑝 = −𝑟𝑏 [cos 𝛼0 + (Γ + 𝜎0 ) sin 𝛼0 ],

𝑦ℎ𝑝 = 𝑟𝑏 [− sin 𝛼0 + (Γ + 𝜎0 ) cos 𝛼0 ],}
𝑧ℎ𝑝 = 𝑧ℎ = 𝑏𝑎 𝜃 = 𝑏𝑎 (𝛼0 − Γ − 𝜀1 ),
Likewise, unit normal to the first conjugate surface is yielded by substituting expression (2.3.2-
33) into expression (2.3.2-31), that is,
𝑵ℎ𝑝 = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ (2.3.2-35)
Where:
𝑏𝑎 sin 𝛼0
𝑏𝑎 cos 𝛼0 𝑟𝑏
𝐵ℎ𝑝 = 𝐴ℎ sin 𝜀1 + 𝐵ℎ cos 𝜀1 = , 𝐶ℎ𝑝 = .
√𝑟𝑏2 +𝑏𝑎2 √𝑟𝑏2 +𝑏𝑎2
}
Expressions (2.3.2-34) and (2.3.2-35) show that instantaneous contact line is a straight line and
unit normal to the first conjugate surface at any point along instantaneous contact line
corresponding to any instant rotating angle 𝜀1 is constant.
Then, unit tangent to instantaneous contact line corresponding to any instant rotating angle 𝜀1
is as follow:
𝑑𝑯𝑝
𝑑Γ
𝜻= 𝑑𝑯𝑝 = 𝜁𝑝𝑥 𝒊ℎ + 𝜁𝑝𝑦 𝒋ℎ + 𝜁𝑝𝑧 𝒌ℎ (2.3.2-36)
| |
𝑑Γ
1 1 𝑏𝑎
Where: 𝜁𝑝𝑥 = 𝑟𝑏 sin 𝛼0 , 𝜁𝑝𝑦 = − 𝑟𝑏 cos 𝛼0 and 𝜁𝑝𝑧 = .
2 Path of contact
Let Γ and 𝜀1 be two variables, then, expression (2.3.2-34) represents a path of contact between
the first and second conjugate surfaces, that is,
~ 193 ~
Where: Γ and 𝜀1 are two parameters of path of contact, and

𝑦ℎ𝑝 = 𝑟𝑏 [− sin 𝛼0 + (Γ + 𝜎0 ) cos 𝛼0 ],}
𝑧ℎ𝑝 = 𝑧ℎ = 𝑏𝑎 𝜃 = 𝑏𝑎 (𝛼0 − Γ − 𝜀1 ).
Let 𝑦ℎ𝑝 = 𝑟𝑏 [− sin 𝛼0 + (Γ + 𝜎0 ) cos 𝛼0 ] = 0, then,

sin 𝛼0
(Γ + 𝜎0 ) =
cos 𝛼0
Then, intersection between path of contact and coordinate plane 𝒊ℎ − 𝑂 − 𝒌ℎ is as follow:

𝑟
𝑥ℎ𝑝 = − cos𝑏𝛼 (2.3.2-38)
0
Thus, path of contact passes through pitch point 𝑃0 . Unit normal 𝑵𝑝 to path of contact is
derived as follow:
𝜕𝑯𝑝 𝜕𝑯𝑝
× (−𝑟𝑏 sin 𝛼0 𝒊ℎ +𝑟𝑏 cos 𝛼0 𝒋ℎ −𝑏𝑎 𝒌ℎ )×(−𝑏𝑎 𝒌ℎ )
𝜕Γ 𝜕𝜀1
𝑵𝑝 = 𝜕𝑯𝑝 𝜕𝑯𝑝 = 𝜕𝑯𝑝 𝜕𝑯𝑝 = cos 𝛼0 𝒊ℎ + sin 𝛼0 𝒋ℎ
| × | | × |
𝜕Γ 𝜕𝜀1 𝜕Γ 𝜕𝜀1
Due to 𝑵𝑝 being constant, then, path of contact is a plane.
3 The second conjugate surface 𝑯′
The second conjugate surface 𝑯′ is generated through rotating instantaneous contact line 𝑯𝑝
by (−𝜀2 = −𝑀𝜀1 ) about 𝝎′ = −𝒌ℎ , that is,
𝑯′ = (−𝑀𝜀1 𝝎′ ) ⊗ (𝑯𝑝 − 𝑓𝒊ℎ ) = 𝑥ℎ′ 𝒊ℎ + 𝑦ℎ′ 𝒋ℎ + 𝑧ℎ′ 𝒌ℎ (2.3.2-39)
Where: 𝜀1 is decided by expression (2.3.2-33), that is, 𝜀1 = 𝛼0 − ∅ = 𝛼0 − Γ − 𝜃 and
𝑥ℎ′ = (𝑥ℎ𝑝 − 𝑓) cos(𝑀𝜀1 ) − 𝑦ℎ𝑝 sin(𝑀𝜀1 )

= −𝑟𝑏 [cos(𝛼0 + 𝑀𝜀1 ) + (Γ + 𝜎0 ) sin(𝛼0 + 𝑀𝜀1 )] − 𝑓 cos(𝑀𝜀1 ) ,
𝑦 ′ = (𝑥ℎ𝑝 − 𝑓) sin(𝑀𝜀1 ) + 𝑦ℎ𝑝 cos(𝑀𝜀1 )
= −𝑟𝑏 [sin(𝛼0 + 𝑀𝜀1 ) − (Γ + 𝜎0 ) cos(𝛼0 + 𝑀𝜀1 )] − 𝑓 sin(𝑀𝜀1 ) ,
𝑧ℎ′ = 𝑧ℎ𝑝 = 𝑏𝑎 𝜃. }
̅̅̅̅̅0 | + ⌈𝑂
As shown in figure 2.3.2-3, 𝑓 = −(|𝑂𝑃 ̅̅̅̅̅̅
′ 𝑃 ⌉), due to 𝑃 being a pitch point and property
0 0
~194 ~
of involute curve, then,
𝑑𝜀 ̅̅̅̅̅̅|
|𝑂𝑃 𝑟 |𝑂𝑃 | 𝑟 ̅̅̅̅̅̅
𝑀 = 𝑑𝜀2 = |𝑂̅̅̅̅̅̅̅
0
, ̅̅̅̅̅
𝑂𝑃0 = cos𝑏𝛼 , ̅̅̅̅̅̅
𝑂′ 𝑃0 = 𝑀0 = 𝑀 cos𝑏 𝛼 ,
′𝑃 |
1 0 0 0
𝑟𝑏 𝑟𝑏 𝑟𝑏 (1+𝑀)
} (2.3.2-40)
𝑓 = − cos 𝛼 − 𝑀 cos 𝛼 = − 𝑀 cos 𝛼 .
0 0 0
In addition,
cos(𝑀𝜀1 ) = cos(𝛼0 + 𝑀𝜀1 − 𝛼0 ) = cos(𝛼0 + 𝑀𝜀1 ) cos 𝛼0 + sin(𝛼0 + 𝑀𝜀1 ) sin 𝛼0 ,

}
sin(𝑀𝜀1 ) = sin(𝛼0 + 𝑀𝜀1 − 𝛼0 ) = sin(𝛼0 + 𝑀𝜀1 ) cos 𝛼0 − cos(𝛼0 + 𝑀𝜀1 ) sin 𝛼0 .
Then, with help of condition of instantaneous contact line, i.e., expression (2.3.2-33),
employment of expression (2.3.2-40) gives
𝑟𝑏 (1+𝑀)
𝑓 cos(𝑀𝜀1 ) = − [cos(𝛼0 + 𝑀𝜀1 ) + sin(𝛼0 + 𝑀𝜀1 ) tan 𝛼0 ]
𝑀
𝑟𝑏 (1+𝑀)
=− {cos[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃] + sin[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃] tan 𝛼0 },
𝑀
𝑟𝑏 (1+𝑀)
(2.3.2-41)
𝑓 sin(𝑀𝜀1 ) = − [sin(𝛼0 + 𝑀𝜀1 ) − cos(𝛼0 + 𝑀𝜀1 ) tan 𝛼0 ]
𝑀
𝑟𝑏 (1+𝑀)
=− {sin[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃] − cos[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃] tan 𝛼0 }.}
𝑀
Due to tan 𝛼0 = 𝛼0 + 𝜎0 , let 𝜃 ′ = −𝑀𝜃 and Γ ′ = (1 + 𝑀)𝛼0 − 𝑀Γ ,

𝑏𝑎
𝑏𝑎′ = − ,
𝑀
𝑟𝑏 } (2.3.2-42)
𝑟𝑏′ = .
𝑀
Substitution of expressions (2.3.2-41) and (2.3.2-42) into expression (2.3.2-39) generates the
second conjugate surface 𝑯′ as follow:
𝑯′ = 𝑥ℎ′ 𝒊ℎ + 𝑦ℎ′ 𝒋ℎ + 𝑧ℎ′ 𝒌ℎ (2.3.2-43)
Where:
𝑟𝑏
𝑥ℎ′ = {cos(𝛼0 + 𝑀𝜀1 ) + [−𝑀(Γ + 𝜎0 ) + (1 + 𝑀) tan 𝛼0 ] sin(𝛼0 + 𝑀𝜀1 )}
𝑀
𝑟𝑏
= {cos[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃] + [−𝑀Γ + (1 + 𝑀)𝛼0 + 𝜎0 ] sin[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃]}
𝑀
= 𝑟𝑏′ [cos(Γ ′ + 𝜃 ′ ) + (Γ ′ + 𝜎0 ) sin(Γ ′ + 𝜃 ′ )],
𝑟
𝑦ℎ′ = 𝑀𝑏 {sin(𝛼0 + 𝑀𝜀1 ) + [𝑀(Γ + 𝜎0 ) − (1 + 𝑀) tan 𝛼0 ] cos(𝛼0 + 𝑀𝜀1 )}
𝑟𝑏
= {sin[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃] + [𝑀Γ − (1 + 𝑀)𝛼0 − 𝜎0 ] cos[(1 + 𝑀)𝛼0 − 𝑀Γ − 𝑀𝜃]}
𝑀
= 𝑟𝑏′ [sin(Γ ′ + 𝜃 ′ ) − (Γ ′ + 𝜎0 ) cos(Γ ′ + 𝜃 ′ )],
𝑧ℎ′ = 𝑧ℎ𝑝 = 𝑏𝑎 𝜃 = 𝑏𝑎′ 𝜃 ′ . }
~ 195 ~
Expression (2.3.2-43) indicates that the second conjugate surface is also an involute helicoid
𝑟𝑏 𝑏
with 𝑟𝑏′ = as radius of base circle and 𝑏𝑎′ = − 𝑀𝑎 as lead. Therefore, two involute helicoids can
𝑀
be in line conjugate contact with each other as long as expression (2.3.2-42) is satisfied.
Given condition:
1 The first conjugate surface is an involute helicoid, that is, expression (2.3.2-11)
𝑯 = 𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ
−𝑟𝑏 [cos(Γ − 𝜃) + (Γ + 𝜎0 ) sin(Γ − 𝜃)]𝒊ℎ (2.3.2-11)
={ }
+𝑟𝑏 [sin(Γ − 𝜃) − (Γ + 𝜎0 ) cos(Γ − 𝜃)]𝒋ℎ + 𝑏𝑎 𝜃𝒌ℎ
𝑥ℎ = −𝑟𝑏 [cos(Γ − 𝜃) + (Γ + 𝜎0 ) sin(Γ − 𝜃)],

𝑦ℎ = 𝑟𝑏 [sin(Γ − 𝜃) − (Γ + 𝜎0 ) cos(Γ − 𝜃)], }
𝑧ℎ = 𝑏𝑎 𝜃.
2 Conjugate motion the same as right-flank of involute helicoid, that is,

𝑑𝜀2
𝑀= = 𝑐𝑜𝑛𝑠𝑡, 𝜎1 = 0, 𝜎2 = 0, 𝛼 = 0 ,
𝑑𝜀1 }
𝑓 = 𝑐𝑜𝑛𝑠𝑡, ℎ = 0.
Calculation Objects:
1 Instantaneous contact line

(2.3.2-44)
Where: 𝑥ℎ , 𝑦ℎ and 𝑧ℎ are calculated by expression (2.3.2-11) and Γ − 𝜃 = ∅, then,
𝑥ℎ𝑝 = −𝑟𝑏 [cos(∅ − 𝜀1 ) + (Γ + 𝜎0 ) sin(∅ − 𝜀1 )],

𝑦ℎ𝑝 = 𝑟𝑏 [sin(∅ − 𝜀1 ) − (Γ + 𝜎0 ) cos(∅ − 𝜀1 )], }
𝑧ℎ𝑝 = 𝑧ℎ = 𝑏𝑎 𝜃.
With help of expression (2.3.2-21), unit normal to the first conjugate surface at conjugate
~ 196 ~

(2.3.2-45)
Where: ∅ = Γ − 𝜃 and
𝑏𝑎 sin(∅−𝜀1 )
𝑏𝑎 cos(∅−𝜀1 )
𝐵ℎ𝑝 = 𝐴ℎ sin 𝜀1 + 𝐵ℎ cos 𝜀1 = − ,
𝑟𝑏
𝐶ℎ𝑝 = 𝐶ℎ = − .
√𝑟𝑏2 +𝑏𝑎2 }
𝒗12 1 2
1 1 𝑑𝜀1 (2.3.2-46)
12 12 12
= −(1 + 𝑀)𝑦ℎ𝑝 𝒊ℎ + [(1 + 𝑀)𝑥ℎ𝑝 − 𝑓𝑀]𝒋ℎ = 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑧 𝒌
Where: 𝑥ℎ𝑝 and 𝑦ℎ𝑝 are decided by expression (2.3.2-44) and ∅ = Γ − 𝜃, then,
12
𝑣𝑝𝑥 = −(1 + 𝑀)𝑟𝑏 [sin(∅ − 𝜀1 ) − (Γ + 𝜎0 ) cos(∅ − 𝜀1 )],
12
𝑣𝑝𝑦 = −(1 + 𝑀)𝑟𝑏 [cos(∅ − 𝜀1 ) + (Γ + 𝜎0 ) sin(∅ − 𝜀1 )] − 𝑓𝑀,}
12
𝑣𝑝𝑧 = 0.

𝑝 ∙ 𝑵ℎ𝑝 = 0, results in
(1 + 𝑀)𝑟𝑏 + 𝑓𝑀 cos(∅ − 𝜀1 ) = 0
Due to property of involute curve, i.e., 𝑟𝑏 = −𝑥0𝑝 cos 𝛼0, and expression (1.4.10-7), expression
above is updated as follow:
∅ − 𝜀1 = Γ − 𝜃 − 𝜀1 = 𝛼0 (2.3.2-47)
Instantaneous contact line at instant rotating angle 𝜀1 is generated by substituting expression

(2.3.2-47) into expression (2.3.2-44), that is,
~ 197 ~
Where:

𝑦ℎ𝑝 = 𝑟𝑏 [sin 𝛼0 − (Γ + 𝜎0 ) cos 𝛼0 ], }
𝑧ℎ𝑝 = 𝑧ℎ = 𝑏𝑎 𝜃 = 𝑏𝑎 (Γ − 𝛼0 − 𝜀1 ).
Likewise, unit normal to the first conjugate surface is yielded by substituting expression (2.3.2-
47) into expression (2.3.2-45), that is,
𝑵ℎ𝑝 = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ (2.3.2-49)
Where:
𝑏𝑎 sin 𝛼0
𝐴ℎ𝑝 = − ,
𝑏𝑎 cos 𝛼0
𝐵ℎ𝑝 = − ,
𝑟𝑏
𝐶ℎ𝑝 = 𝐶ℎ = − .
√𝑟𝑏2 +𝑏𝑎2 }
Unit tangent 𝜻𝑝 to involute helicoid at point 𝑃 along instantaneous contact line is derived by
rotating unit tangent 𝜻 in expression (2.3.2-15), that is,
𝜻𝑝 = (𝜀1 𝒌ℎ ) ⊗ 𝜻 = 𝜁𝑝𝑥 𝒊ℎ + 𝜁𝑝𝑦 𝒋ℎ + 𝜁𝑝𝑧 𝒌ℎ (2.3.2-50)

1 1 𝑏𝑎
Where: 𝜁𝑝𝑥 = − 𝑟𝑏 sin 𝛼0 , 𝜁𝑝𝑦 = − 𝑟𝑏 cos 𝛼0 and 𝜁𝑝𝑧 = .
2 The second conjugate surface 𝑯′
Where:
𝑥ℎ′ = −𝑟𝑏 [cos(𝛼0 − 𝑀𝜀1 ) + (Γ + 𝜎0 ) sin(𝛼0 − 𝑀𝜀1 )] − 𝑓 cos(𝑀𝜀1 ) ,

𝑦ℎ′ = +𝑟𝑏 [sin(𝛼0 − 𝑀𝜀1 ) − (Γ + 𝜎0 ) cos(𝛼0 − 𝑀𝜀1 )] − 𝑓 sin(𝑀𝜀1 ) , }
𝑧ℎ′ = 𝑏𝑎 𝜃.
~ 198 ~
Let
Γ′ = (1 + 𝑀)𝛼0 − 𝑀Γ,
𝜃′ = −𝑀𝜃, } (2.3.2-52)
𝑟𝑏 𝑏𝑎
𝑟𝑏′ = 𝑀
, 𝑏𝑎′ =−𝑀.
Employment of expressions (2.3.2-40), (2.3.2-47) and (2.3.2-52) leads

𝑟𝑏 (1+𝑀)
𝑓 cos(𝑀𝜀1 ) = − [cos[(1 + 𝑀)𝛼0 − 𝑀Γ + 𝑀𝜃] + sin[(1 + 𝑀)𝛼0 − 𝑀Γ + 𝑀𝜃] tan 𝛼0 ]
𝑀
= −𝑟′𝑏 (1 + 𝑀)[cos(Γ ′ − 𝜃 ′ ) + sin(Γ ′ − 𝜃 ′ ) tan 𝛼0 ],
𝑟𝑏 (1+𝑀)
𝑓 sin(𝑀𝜀1 ) = [sin[(1 + 𝑀)𝛼0 − 𝑀Γ + 𝑀𝜃] − cos[(1 + 𝑀)𝛼0 − 𝑀Γ + 𝑀𝜃] tan 𝛼0 ]
𝑀
= 𝑟′𝑏 (1 + 𝑀)[sin(Γ ′ − 𝜃 ′ ) − cos(Γ ′ − 𝜃 ′ ) tan 𝛼0 ]. }
Substitution of expression above into expression (2.3.2-51) generates the second conjugate
surface, that is,
𝑯′ = 𝑥ℎ′ 𝒊ℎ + 𝑦ℎ′ 𝒋ℎ + 𝑧ℎ′ 𝒌ℎ (2.3.2-53)
Where:
𝑥ℎ′ = 𝑟′𝑏 cos(Γ ′ − 𝜃 ′ ) + 𝑟′𝑏 (Γ ′ + 𝜎0 ) sin(Γ ′ − 𝜃 ′ ) ,

𝑦ℎ′ = −𝑟′𝑏 sin(Γ ′ − 𝜃 ′ ) + 𝑟′𝑏 (Γ ′ + 𝜎0 ) cos(Γ ′ − 𝜃 ′ ) ,}
𝑧ℎ′ = 𝑏′𝑎 𝜃 ′ .
2.3.3 Geometry Property of Archimedean Helicoid with Constant Lead

1 Unit Normal to Archimedean Helicoid
Curve of axial intersection of Archimedean helicoid is a straight as shown in figure 1.1.1-5.
Surface equation for Archimedean helicoid is expression (1.1.1-21), that is,
𝑯 = 𝜂 cos 𝜇 𝒊ℎ + 𝜂 sin 𝜇 𝒋ℎ + 𝑧ℎ 𝒌ℎ = 𝑥ℎ 𝒊ℎ + 𝑦ℎ 𝒋ℎ + 𝑧ℎ 𝒌ℎ
(1.1.1-21)
= −(𝑟0 + 𝑠 cos ∅0 ) cos 𝜃 𝒊ℎ − (𝑟0 + 𝑠 cos ∅0 ) sin 𝜃 𝒋ℎ + (𝑠 sin ∅0 + 𝜃𝑏𝑎 )𝒌ℎ .
Where: 𝑟0 is radius of pitch circle of the first Archimedean helicoid, then,
𝜂 = 𝑟0 + 𝑠 cos ∅0 , cos 𝜇 = − cos 𝜃 , sin 𝜇 = − sin 𝜃 , 𝜇 = 𝜋 + 𝜃,

𝑥ℎ = −(𝑟0 + 𝑠 cos ∅0 ) cos 𝜃 ,
(2.3.3-1)
𝑦ℎ = −(𝑟0 + 𝑠 cos ∅0 ) sin 𝜃 ,
𝑧ℎ = 𝑠 sin ∅0 + 𝜃𝑏𝑎 . }
~ 199 ~
Let 𝒘0 be as follow:
𝒘0 = 𝒌ℎ × (cos 𝜇 𝒊ℎ + sin 𝜇 𝒋ℎ ) = − sin 𝜇 𝒊ℎ + cos 𝜇 𝒋ℎ
𝒘0 is also expressed in expression (1.6.2-6) as follow:
𝒘0 = cos(𝜇 + 𝜎) 𝒊 + sin(𝜇 + 𝜎) 𝒋
Thus,
𝜋
𝜎= (2.3.3-2)
2
Unit tangent 𝜻 to generatrix of Archimedean helicoid is

𝑑𝑯
𝜻= = − cos ∅0 cos 𝜃 𝒊ℎ − cos ∅0 sin 𝜃 𝒋ℎ + sin ∅0 𝒌ℎ (2.3.3-3)
𝑑𝑠
Unit tangent 𝜻 to generatrix of Archimedean helicoid is also alternatively expressed in formula

(1.6.2-7), that is,
𝜻 = (𝛽𝒘0 ) ⊗ 𝒌 = sin 𝛽 sin(𝜇 + 𝜎) 𝒊 − sin 𝛽 cos(𝜇 + 𝜎) 𝒋 + cos 𝛽 𝒌

(2.3.3-4)
= sin 𝛽 cos 𝜇 𝒊 + sin 𝛽 sin 𝜇 𝒋 + cos 𝛽
Comparison between expressions (2.3.3-3) and (2.3.3-4) gives

𝜋
𝛽 = − ∅0 (2.3.3-5)
2
With help of expressions (2.3.3-1), (2.3.3-2) and (2.3.3-5), unit normal to Archimedean helicoid
is derived by application of expression (2.3.1-1), that is,
𝑵ℎ = 𝐴ℎ 𝒊ℎ + 𝐵ℎ 𝒋ℎ + 𝐶ℎ 𝒌ℎ (2.3.3-6)
Where:
1
𝐴ℎ = − 𝑄 [𝑏𝑎 sin 𝛽 cos(𝜇 + 𝜎) + 𝜂 cos 𝛽 cos 𝜇]
1
= − 𝑄 [𝑏𝑎 cos ∅0 sin 𝜃 − (𝑟0 + 𝑠 cos ∅0 ) sin ∅0 cos 𝜃]
1
𝐵ℎ = − 𝑄 [𝑏𝑎 sin 𝛽 sin(𝜇 + 𝜎) + 𝜂 cos 𝛽 sin 𝜇]
1
= 𝑄 [𝑏𝑎 cos ∅0 cos 𝜃 + (𝑟0 + 𝑠 cos ∅0 ) sin ∅0 sin 𝜃]
1 1
𝐶ℎ = 𝑄 𝜂 sin 𝛽 sin 𝜎 = 𝑄 (𝑟0 + 𝑠 cos ∅0 ) cos ∅0 ,
𝑄 = −√𝑏𝑎2 cos2 ∅0 + 𝜂2 = −√𝑏𝑎2 cos2 ∅0 + (𝑟0 + 𝑠 cos ∅0 )2 }
~ 200 ~
2 Curvature of Archimedean Helicoid
With consideration of 𝜅𝑐 = 0 in expression (2.3.1-3), normal curvature of Archimedean helicoid
in tangent direction 𝜻 is derived by application of expression (2.3.1-3)
𝐾1𝜁 = −𝜅𝑐 (𝑵1𝑝 ∙ 𝝃) = 0 (2.3.3-7)
Likewise, with help of expressions (2.3.3-1), (2.3.3-2), (2.3.3-5) and (2.3.3-7), torsional curvature
𝐺1𝜁 of Archimedean helicoid at point 𝑃 in direction 𝜻 is resulted from expression (2.3.1-4)
sin 𝛽 𝑏𝑎 cos2 ∅0
𝐺1𝜁 = (𝑏𝑎 sin 𝛽 + 𝜂 cos 𝜎 cos 𝛽) = 2 (2.3.3-8)
𝑄2 𝑏𝑎 cos ∅0 +(𝑟0 +𝑠 cos ∅0 )2
2
Normal curvature 𝐾1𝑞 of Archimedean helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is derived by

cos 𝛽+𝐺1𝜁 {𝑏𝑎 cos 𝛽−𝜂 cos 𝜎 sin 𝛽} cos 𝛽(1+𝐺1𝜁 𝑏𝑎 ) sin ∅0 (1+𝐺1𝜁 𝑏𝑎 )
𝐾1𝑞 = − =− = (2.3.3-9)
𝑄 𝑄
√𝑏𝑎2 cos2 ∅0 +(𝑟0 +𝑠 cos ∅0 )2
Torsional curvature 𝐺1𝑞 of Archimedean helicoid at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is
𝐺1𝑞 = −𝐺1𝜁 (2.3.3-10)
3 Conjugate Surface of Archimedean Helicoid in Line Contact between Parallel

Rotary Axes

(2.3.3-11)
Where: 𝑥ℎ , 𝑦ℎ and 𝑧ℎ are calculated by expression (2.3.3-1), and
𝑥ℎ𝑝 = −(𝑟0 + 𝑠 cos ∅0 ) cos(𝜃 + 𝜀1 ) ,

𝑦ℎ𝑝 = −(𝑟0 + 𝑠 cos ∅0 ) sin(𝜃 + 𝜀1 ) , }
𝑧ℎ𝑝 = 𝑧ℎ = 𝑠 sin ∅0 + 𝜃𝑏𝑎 .
𝒗12 12 12 12
𝑝 = −(1 + 𝑀)𝑦ℎ𝑝 𝒊ℎ + [(1 + 𝑀)𝑥ℎ𝑝 − 𝑓𝑀]𝒋ℎ = 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑧 𝒌 (2.3.3-12)
~ 201 ~
1+𝑀
Where: 𝑓 = 𝑟0 and
𝑀
12
𝑣𝑝𝑥 = (1 + 𝑀)(𝑟0 + 𝑠 cos ∅0 ) sin(𝜃 + 𝜀1 ) ,
12
𝑣𝑝𝑦 = −(1 + 𝑀)(2𝑟0 + 𝑠 cos ∅0 ) cos(𝜃 + 𝜀1 ) ,}
12
𝑣𝑝𝑧 = 0.
With help of expression ((2.3.3-6), unit normal to the first Archimedean helicoid at conjugate

(2.3.3-13)
Where:
1
𝐴ℎ𝑝 = − 𝑄 [𝑏𝑎 cos ∅0 sin(𝜃 + 𝜀1 ) − (𝑟0 + 𝑠 cos ∅0 ) sin ∅0 cos(𝜃 + 𝜀1 )],
1
𝐵ℎ𝑝 = 𝑄 [𝑏𝑎 cos ∅0 cos(𝜃 + 𝜀1 ) + (𝑟0 + 𝑠 cos ∅0 ) sin ∅0 sin(𝜃 + 𝜀1 )],
1
𝐶ℎ𝑝 = 𝑄 (𝑟0 + 𝑠 cos ∅0 ) cos ∅0 . }

𝑝 ∙ 𝑵ℎ𝑝 = 0, gives condition of instantaneous contact
line as follow:
(𝑟0 + 𝑠 cos ∅0 ) tan(𝜃 + 𝜀1 ) [𝑏𝑎 tan(𝜃 + 𝜀1 ) − (𝑟0 + 𝑠 cos ∅0 ) tan ∅0 ]

(2.3.3-14)
= (2𝑟0 + 𝑠 cos ∅0 )[𝑏𝑎 + (𝑟0 + 𝑠 cos ∅0 ) tan ∅0 tan(𝜃 + 𝜀1 )]
Where:
𝑥ℎ′ = (𝑥ℎ𝑝 − 𝑓) cos 𝜀2 − 𝑦ℎ𝑝 sin 𝜀2

= −(𝑟0 + 𝑠 cos ∅0 ) cos(𝜃 + 𝜀1 + 𝑀𝜀1 ) − 𝑓 cos(𝑀𝜀1 ) ,
𝑦ℎ′ = (𝑥ℎ𝑝 − 𝑓) sin 𝜀2 + 𝑦ℎ𝑝 cos 𝜀2
= −(𝑟0 + 𝑠 cos ∅0 ) sin(𝜃 + 𝜀1 + 𝑀𝜀1 ) − 𝑓 sin(𝑀𝜀1 ) ,
𝑧ℎ′ = 𝑠 sin ∅0 + 𝜃𝑏𝑎 . }
Expression (2.3.3-15) shows that the second conjugate surface is not an Archimedean helicoid.
~ 202 ~
Therefore, two Archimedean helicoids can’t become a pair of conjugate surfaces, and thus,
Archimedean hob is not able to generate a pair of accurate conjugate surfaces. But if lead of
Archimedean hob is very small, i.e., 𝑏𝑎 ≈ 0, then, expression (2.3.3-14) becomes as follow:
(3𝑟0 + 2𝑠 cos ∅0 ) tan(𝜃 + 𝜀1 ) ≈ 0
Due to 3𝑟0 + 2𝑠 cos ∅0 ≠ 0, then, 𝜃 + 𝜀1 ≈ 0, and expression (2.3.3-15) is updated as follow:

𝑏
Where: let 𝑏𝑎′ = − 𝑀𝑎 and 𝜃 ′ = 𝑀𝜀1 then,
𝑥ℎ′ ≈ −(𝑟0 + 𝑓 + 𝑠 cos ∅0 ) cos(𝑀𝜀1 ) = −(𝑟0 + 𝑓 + 𝑠 cos ∅0 ) cos 𝜃 ′ ,

𝑦ℎ′ ≈ −(𝑟0 + 𝑓 + 𝑠 cos ∅0 ) sin(𝑀𝜀1 ) = −(𝑟0 + 𝑓 + 𝑠 cos ∅0 ) sin 𝜃 ′ , , }
𝑧ℎ′ = 𝑠 sin ∅0 + 𝜃𝑏𝑎 ≈ 𝑠 sin ∅0 + 𝜃 ′ 𝑏𝑎′ .
Expression (2.3.3-16) represents an Archimedean helicoid. Therefore, Archimedean hob with

very small lead can generate a pair of approximate conjugate surfaces.
2.3.4 Effective Relative Velocity and Motion Requirements

Assume that 𝐶 and 𝐶̅ are a pair of involute hobs which can be in conjugate contact with each
other. Tooth profile 𝐴 of workpiece 1 is generated by 𝐶, and tooth profile 𝐴̅ of workpiece 2 is
generated by 𝐶̅ . 𝐶, 𝐶̅ , 𝐴 and 𝐴̅ are in contact with each other at the same instantaneous
conjugate contact point in whole manufacturing process. Hob 𝐶 is right-hand involute helicoid.
1 Establishing Coordinate System

As shown in figure 2.3.4 -1, workpiece 1 rotates by an angle 𝜀1 about 𝝎 = 𝒌 as an axis in fixed
coordinate system 𝑂 − 𝒊, 𝒋, 𝒌. Workpiece 2 rotates by an angle 𝜀2 about 𝝎′ = −𝒌 as an axis in
coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ . Relationship of coordinate system 𝑂′ − 𝒊′ , 𝒋′ , 𝒌′ with respect
to coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 is as follow
𝒊′ = 𝒊, 𝒋′ = 𝒋, 𝒌′ = 𝒌,
} (2.3.4-1)
(𝑙𝒑) = ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂′ = 𝑓 𝒊 + ℎ𝒋.
Hob 𝐶 rotates by an angle 𝜀ℎ about 𝝎ℎ = 𝒌ℎ as an axis in coordinate system 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ

shown in figure 2.3.4 -1. Hob 𝐶̅ rotates by an angle 𝜀ℎ′ about 𝝎′ℎ = −𝒌ℎ as an axis in
coordinate system 𝑂ℎ′ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ as shown in figure 2.3.4 -1. Relationship of coordinate
systems 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ and 𝑂ℎ′ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ with respect to coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 are
~ 203 ~
𝑵𝑝
𝐴̅ 𝑃 pitch curve 𝐴̅0 of workpiece 2
𝑹1𝑝 𝑯′𝑝 𝑯𝑝
𝑂 𝒋ℎ ∆𝑝 𝝎′ℎ 𝒋
(𝑙𝒑)′ℎ 𝑟0′
(𝑙𝒑)ℎ 𝑂ℎ′ 𝒌
(𝑙𝒑) 𝒌′ 𝒌ℎ 𝑹0𝑝 𝒋ℎ
𝑃0
𝒊 𝑂′ 𝒋′ 𝑟0 𝛼 𝑂ℎ
𝒌ℎ (= 𝝎ℎ ) 𝒊ℎ (𝑵0𝑝 )
𝒊′ 𝝎′ (= −𝒌) pitch curve 𝐴0 of workpiece 1
Figure 2.3.4 -1 Coordinate System
𝒊ℎ = 𝑵0𝑝 = 𝑁𝑜𝑝𝑥 𝒊 + 𝑁𝑜𝑝𝑦 𝒋,

𝒌ℎ = (𝛼𝒊ℎ ) ⊗ 𝒌 = cos 𝛼 𝒌 + sin 𝛼 𝒊ℎ × 𝒌 = (𝑁𝑜𝑝𝑦 𝒊 − 𝑁𝑜𝑝𝑥 𝒋) sin 𝛼 + cos 𝛼 𝒌,
𝒋ℎ = 𝒌ℎ × 𝒊ℎ = (−𝑁𝑜𝑝𝑦 𝒊 + 𝑁𝑜𝑝𝑥 𝒋) cos 𝛼 + sin 𝛼 𝒌,
𝑑ℎ 𝑑𝑓
𝑀𝑓+ 𝑀ℎ−
= ⃗⃗⃗⃗⃗⃗⃗
𝑑𝜀1 𝑑𝜀1
𝑹0𝑝 𝑂𝑃0 = 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋 = 𝒊+ 𝒋,
1+𝑀 1+𝑀
⃗⃗⃗⃗⃗⃗⃗⃗ℎ = (𝑙𝒑)ℎ = 𝑓ℎ 𝒊 + ℎℎ 𝒋 = 𝑹0𝑝 + 𝑟0 𝒊ℎ = (𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 )𝒊 + (𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 )𝒋,
𝑂𝑂 (2.3.4-2)
𝑑ℎ 𝑑𝑓
𝑑𝜀1 𝑑𝜀1
𝑓ℎ = 𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 = + 𝑟0 𝑁𝑜𝑝𝑥 , ℎℎ = 𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 = + 𝑟0 𝑁𝑜𝑝𝑦 ,
1+𝑀 1+𝑀
⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂ℎ′ = (𝑙𝒑)′ℎ = 𝑓ℎ′ 𝒊 + ℎℎ′ 𝒋 = 𝑹0𝑝 − 𝑟0′ 𝒊ℎ = (𝑥0𝑝 − 𝑟0′ 𝑁𝑜𝑝𝑥 )𝒊 + (𝑦0𝑝 − 𝑟0′ 𝑁𝑜𝑝𝑦 )𝒋,
𝑑ℎ 𝑑𝑓
𝑑𝜀1 𝑑𝜀1
𝑓ℎ′ = 𝑥0𝑝 − 𝑟0′ 𝑁𝑜𝑝𝑥 = − 𝑟0′ 𝑁𝑜𝑝𝑥 , ℎℎ′ = 𝑦0𝑝 − 𝑟0′ 𝑁𝑜𝑝𝑦 = − 𝑟0′ 𝑁𝑜𝑝𝑦 .}
1+𝑀 1+𝑀
Where: 𝑹0𝑝 is position vector of pitch point defined in expression (1.4.10-6) and 𝑵0𝑝 is unit
normal to pitch curve decided by expression (1.4.10-13).
~ 204 ~
2 Mounting Angle of Hobs
Let point 𝑃 (𝑹1𝑝 ) be a common conjugate contact point at instant rotating angle 𝜀1 among 𝐶,
𝐶̅ , 𝐴 and 𝐴̅ , 𝑵𝑝ℎ be unit normal to helicoid of hob 𝐶 at point 𝑃 and 𝑯𝑝 be position vector of
point 𝑃 on helicoid of hob 𝐶 with respect to coordinate system 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ as shown figure
2.3.4 -1.
With help of expression (2.3.4-2), unit normal 𝑵𝑝ℎ to helicoid of hob 𝐶 at point 𝑃 is as follow:
𝑵𝑝ℎ = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ

(𝐴ℎ𝑝 𝑁𝑜𝑝𝑥 − 𝐵ℎ𝑝 𝑁𝑜𝑝𝑦 cos 𝛼 + 𝐶ℎ𝑝 𝑁𝑜𝑝𝑦 sin 𝛼)𝒊 (2.3.4-3)
={ }
+(𝐴ℎ𝑝 𝑁𝑜𝑝𝑦 + 𝐵ℎ𝑝 𝑁𝑜𝑝𝑥 cos 𝛼 − 𝐶ℎ𝑝 𝑁𝑜𝑝𝑥 sin 𝛼)𝒋 + (𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼)𝒌
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are decided by expression (2.3.2-31) or (2.3.2-49).
Let unit normal to tooth profile 𝐴 at conjugate contact point 𝑃 be 𝑵𝑝 = 𝐴𝑝 𝒊 + 𝐵𝑝 𝒋, due to
requirement of conjugate contact, i.e., 𝑵𝑝 = −𝑵𝑝ℎ , then,
𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼 = 0 (2.3.4-4)
That is.
𝐶ℎ𝑝
tan 𝛼 = − 𝐵 (2.3.4-5)
ℎ𝑝
Position vector of point 𝑃 on helicoid of hob 𝐶 is as follow:
𝑯𝑝 = 𝑥ℎ𝑝 𝒊ℎ + 𝑦ℎ𝑝 𝒋ℎ + 𝑧ℎ𝑝 𝒌ℎ = ∆𝑝 − 𝑟0 𝑵0𝑝 = 𝑠𝑛 𝑵𝑝 − 𝑟0 𝑵0𝑝 = −𝑠𝑛 𝑵𝑝ℎ − 𝑟0 𝑵0𝑝 (2.3.4-6)
Here: 𝑠𝑛 is distance from pitch point 𝑃0 to conjugate contact point 𝑃 on tooth profile along unit
normal 𝑵𝑝 to tooth profile 𝐴.
With help of expressions (2.3.4-2), (2.3.4-3) and (2.3.4-5), expanding expression (2.3.4-6) gives
𝑥ℎ𝑝 = −𝑠𝑛 𝐴ℎ𝑝 − 𝑟0 , 𝑦ℎ𝑝 = −𝑠𝑛 𝐵ℎ𝑝 ,

} (2.3.4-7)
𝑧ℎ𝑝 = −𝑠𝑛 𝐶ℎ𝑝 = 𝑠𝑛 𝐵ℎ𝑝 tan 𝛼 = −𝑦ℎ𝑝 tan 𝛼 .
Where: 𝑥ℎ𝑝 , 𝑦ℎ𝑝 and 𝑧ℎ𝑝 are calculated by expression (2.3.2-34) for right-flank of hob 𝐶 and
expression (2.3.2-48) for left- flank of hob 𝐶 . 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are decided by expression
(2.3.2-35) for right-flank of hob 𝐶 and expression (2.3.2-49) for left- flank of hob 𝐶.
~ 205 ~
With aid of expressions (2.3.2-35) and (2.3.2-49), application of property of helicoid generates
formular as follow:
𝑏𝑎 𝐵ℎ𝑝
tan 𝛾0 = = (2.3.4-8)
𝑟0 𝐶ℎ𝑝
Where: 𝛾0 is lead angle of hob 𝐶. 𝑟0 and 𝑏𝑎 are radius and rate of lead of pitch cylinder of hob 𝐶
respectively.
Comparison of expression (2.3.4-8) with expression (2.3.4-5) generates the mounting angle 𝛼 of
hob is as follow:
𝜋
𝛼 = 2 + 𝛾0 (2.3.4-9)
3 Effective Relative Velocity

A. Effective Relative Velocity of Workpiece 1 with Respect to Hob 𝐶
Let point 𝑃 (𝑹1𝑝 ) be a common conjugate contact point at instant rotating angle 𝜀1 among
𝐶,𝐶̅ , 𝐴 and 𝐴̅ as shown figure 2.3.4 -1.
Let 𝜀1 be visualized as virtual time parameter, the velocity of point 𝑃 (𝑹1𝑝 ) as point on
workpiece 1 is 𝒗𝑝
𝑑𝜎 𝑑𝜎
𝒗𝑝 = 𝒌 × 𝑹1𝑝 + 𝑑𝜀 1 𝒌 = 𝒌 × (𝑹0𝑝 + ∆𝑝 ) + 𝑑𝜀 1 𝒌 (2.3.4-10)
1 1
Where:
𝑹1𝑝 = 𝑹0𝑝 + ∆𝑝 = 𝑯𝑝 + (𝑙𝒑)ℎ ,

} (2.3.4-11)
𝑯𝑝 = ∆𝑝 − 𝑟0 𝑵0𝑝 , ∆𝑝 = 𝑠𝑛 𝑵𝑝 .
Here: 𝑠𝑛 is distance from pitch point 𝑃0 to conjugate contact point 𝑃 on tooth profile along unit
normal 𝑵𝑝 to tooth profile 𝐴.
At instant 𝜀1 + ∆𝜀1 , point 𝑃(𝑹𝑝 ) on helicoid of hob 𝐶 reaches conjugate cutting position 𝑯𝑝 +
(𝑙𝒑)ℎ + ∆𝑯𝑝 + ∆(𝑙𝒑)ℎ with respect to origin 𝑂 of coordinate system 𝑂 − 𝒊 , 𝒋,𝒌, omitting the
second or higher order of infinitesimal quantity, then,
𝑯𝑝 + (𝑙𝒑)ℎ + ∆𝑯𝑝 + ∆(𝑙𝒑)ℎ = (−∆𝜑𝒌) ⊗ [(∆𝜀ℎ 𝒌ℎ ) ⊗ 𝑯𝑝 ] + (𝑙𝒑)ℎ + ∆(𝑙𝒑)ℎ

= (−∆𝜑𝒌) ⊗ (𝑯𝑝 + ∆𝜀ℎ 𝒌ℎ × 𝑯𝑝 ) + (𝑙𝒑)ℎ + ∆(𝑙𝒑)ℎ
= 𝑯𝑝 + ∆𝜀ℎ 𝒌ℎ × 𝑯𝑝 − ∆𝜑𝒌 × 𝑯𝑝 + (𝑙𝒑)ℎ + ∆(𝑙𝒑)ℎ
~206 ~
Then,
∆𝑯𝑝 + ∆(𝑙𝒑)ℎ = ∆𝜀ℎ 𝒌ℎ × 𝑯𝑝 − ∆𝜑𝒌 × 𝑯𝑝 + ∆(𝑙𝒑)ℎ = (∆𝜀ℎ 𝒌ℎ − ∆𝜑𝒌) × 𝑯𝑝 + ∆(𝑙𝒑)ℎ
With respect to origin 𝑂 of coordinate system 𝑂 − 𝒊 , 𝒋,𝒌 , the velocity of conjugate contact
point 𝑃 on helicoid of hob 𝐶 is 𝒗𝑝ℎ
∆𝑯𝑝 +∆(𝑙𝒑)ℎ 𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)ℎ

𝒗𝑝ℎ = lim = (𝑑𝜀ℎ 𝒌ℎ − 𝑑𝜀 𝒌) × 𝑯𝑝 +
∆𝜀1 →0 ∆𝜀1 1 1 𝑑𝜀1
𝑑𝜀 𝑑𝜑 𝑑𝜀 𝑑𝜑 𝑑𝜀 𝑑(𝑙𝒑)ℎ
(2.3.4-12)
= (𝑑𝜀ℎ 𝒌ℎ − 𝑑𝜀 𝒌) × ∆𝑝 − 𝑟0 (𝑑𝜀ℎ cos 𝛼 − 𝑑𝜀 ) 𝒌 × 𝑵0𝑝 − 𝑑𝜀ℎ 𝑟0 sin 𝛼 𝒌 +
1 1 1 1 1 𝑑𝜀1
𝑑𝜑
Where: 𝑯𝑝 = ∆𝑝 − 𝑟0 𝑵0𝑝 , 𝑑𝜀 is calculated by application of expression (1.4.10-24) with
1
𝑑𝜑 𝑑𝜀
consideration 𝜌20 = ∞ and = ( 𝑑𝑠2 ) , that is,
𝑑𝑠0 0 𝜏0
𝑑𝜑 𝑑𝜀
= 𝐾1𝑔0 − ( 𝑑𝑠1 ) ,
𝑑𝑠0 0 𝜏0
𝑑𝜑 𝑑𝜑 𝑑𝑠0 𝐾1𝑔0 (2.3.4-13)
= 𝑑𝑠 = 𝑑𝜀 − 1.
𝑑𝜀1 0 𝑑𝜀1 ( 1)
𝑑𝑠0 𝜏
0 }
𝑑𝜀
Here: 𝐾1𝑔0 is determined in expression (1.4.10-26) and ( 𝑑𝑠1 ) is calculated by expression
0 𝜏0
(1.4.10-16).
As shown in figure 2.3.4 -2,
𝑑𝑠0 = 𝑑𝜀ℎ 𝑏𝑎 cos 𝛾0 (2.3.4-14)
Thus,
𝑑𝜀ℎ
𝑑𝜀ℎ 𝑑𝑠0 1
= 𝑑𝜀1 = 𝑑𝜀1 (2.3.4-15)
𝑑𝜀1 𝑏𝑎 cos 𝛾0 ( )
𝑑𝑠0 𝑑𝑠0 𝜏
0
Relative velocity 𝒗1,ℎ

𝑝 of workpiece 1 with respect to hob 𝐶 at point 𝑃 is derived by application
of expressions (2.3.4-10) and (2.3.4-12) as follow:
𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)ℎ
𝒌 × 𝑹0𝑝 + 𝑟0 (𝑑𝜀ℎ cos 𝛼 − 𝑑𝜀 ) 𝒌 × 𝑵0𝑝 − 𝑑𝜀1
𝒗1,ℎ
𝑝 = 𝒗𝑝 − 𝒗𝑝ℎ = { 𝑑𝜑 𝑑𝜀ℎ
1
} 1
𝑑𝜎1 𝑑𝜀ℎ
(2.3.4-16)
+ [(𝑑𝜀 + 1) 𝒌 − 𝑑𝜀 𝒌ℎ ] × ∆𝑝 + ( 𝑑𝜀 + 𝑑𝜀 𝑟0 sin 𝛼) 𝒌
1 1 1 1
~ 207 ~
𝒌
𝑑𝑠0
𝛾0
𝒌ℎ
𝑑𝜀ℎ 𝑏𝑎
Figure 2.3.4 -2 Relationship of 𝑑𝑠0 with 𝑑𝜀ℎ
Due to ∆𝑝 ∥ 𝑵𝑝 , then,
𝑑𝜑 𝑑𝜀ℎ
{[( + 1) 𝒌 − 𝒌 ] × ∆𝑝 } ∙ 𝑵𝑝 = 0,
𝑑𝜀1 𝑑𝜀1 ℎ
𝑑𝜎1 𝑑𝜀ℎ
( + 𝑟 sin 𝛼) 𝒌 ∙ 𝑵𝑝 = 0.
𝑑𝜀1 𝑑𝜀1 0 }
Therefore, last two items in expression (2.3.4-16) have nothing with generation of tooth profile.
Tooth profile is generated under relative velocity composed by first three items which is
defined as effective relative velocity, that is,
𝒗1,ℎ ℎ
𝑝𝐸 = 𝒌 × 𝑹0𝑝 + 𝑟0 (𝑑𝜀 cos 𝛼 − 𝑑𝜀 ) 𝒌 × 𝑵0𝑝 − (2.3.4-17)
1 1 𝑑𝜀1
B. Effective Relative Velocity of Workpiece 2 with Respective to Hob 𝐶̅
Likewise, with help of expression (2.3.4-11), velocity 𝒗′𝑝 of common conjugate contact point
𝑃(𝑹1𝑝 ) on workpiece 2 with respect to coordinate system 𝑂 − 𝒊 , 𝒋,𝒌 is
𝑑𝜀 𝑑(𝑙𝒑) 𝑑𝜎 𝑑𝜀 𝑑(𝑙𝒑) 𝑑𝜎
𝒗′𝑝 = 𝑑𝜀2 𝝎′ × [𝑹1𝑝 − (𝑙𝒑)] + + 𝑑𝜀 2 𝒌 = − 𝑑𝜀2 𝒌 × [𝑹1𝑝 − (𝑙𝒑)] + + 𝑑𝜀 2 𝒌
1 𝑑𝜀1 1 1 𝑑𝜀1 1
𝑑(𝑙𝒑) 𝑑𝜎2
(2.3.4-18)
= −𝑀𝒌 × [𝑹0𝑝 + ∆𝑝 − (𝑙𝒑)] + + 𝑑𝜀 𝒌
𝑑𝜀1 1
At instant rotating angle of 𝜀1 + ∆𝜀1, point 𝑃(𝑹𝑝 ) on helicoid of hob 𝐶̅ reaches position 𝑯′𝑝 +
(𝑙𝒑)′ℎ + ∆𝑯′𝑝 + ∆(𝑙𝒑)′ℎ with respect to coordinate system 𝑂 − 𝒊,𝒋,𝒌, omitting the second or
higher order of infinitesimal quantity, then,
𝑯′𝑝 + (𝑙𝒑)′ℎ + ∆𝑯′𝑝 + ∆(𝑙𝒑)′ℎ = (−∆𝜑𝒌) ⊗ [(−∆𝜀ℎ′ 𝒌ℎ ) ⊗ 𝑯′𝑝 ] + (𝑙𝒑)′ℎ + ∆(𝑙𝒑)′ℎ

= 𝑯′𝑝 − ∆𝜀ℎ′ 𝒌ℎ × 𝑯′𝑝 − ∆𝜑𝒌 × 𝑯′𝑝 + (𝑙𝒑)′ℎ + ∆(𝑙𝒑)′ℎ
Then,
~ 208 ~
∆𝑯′𝑝 + ∆(𝑙𝒑)′ℎ = −∆𝜀ℎ′ 𝒌ℎ × 𝑯′𝑝 − ∆𝜑𝒌 × 𝑯′𝑝 + ∆(𝑙𝒑)′ℎ
With respect to origin 𝑂 of coordinate system 𝑂 − 𝒊 , 𝒋,𝒌 , the velocity of conjugate contact
point 𝑃 on helicoid of hob 𝐶̅ is 𝒗′ℎ𝑝
∆𝑯′𝑝 +∆(𝑙𝒑)′ℎ 𝑑𝜀 ′ 𝑑𝜑 𝑑(𝑙𝒑)′ℎ

𝒗′ℎ𝑝 = lim = − 𝑑𝜀ℎ 𝒌ℎ × 𝑯′𝑝 − 𝑑𝜀 𝒌 × 𝑯′𝑝 +
∆𝜀1 →0 ∆𝜀1 1 1 𝑑𝜀1
′
(2.3.4-19)
𝑑𝜀ℎ 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
= − (𝑑𝜀 𝒌ℎ + 𝑑𝜀 𝒌) × 𝑯′𝑝 +
1 1 𝑑𝜀1
Due to 𝑯′𝑝 = ∆𝑝 + 𝑟0′ 𝑵0𝑝 , thus,
𝑑𝜀 ′ 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
𝒗′ℎ𝑝 = − (𝑑𝜀ℎ 𝒌ℎ + 𝑑𝜀 𝒌) × (∆𝑝 + 𝑟0′ 𝑵0𝑝 ) +
1 1 𝑑𝜀1
′ ′ ′
𝑑𝜀ℎ 𝑑𝜑 𝑑𝜀ℎ 𝑑𝜀ℎ 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
= − (𝑑𝜀 𝒌ℎ + 𝑑𝜀 𝒌) × ∆𝑝 − 𝑟0′ 𝑑𝜀 sin 𝛼 𝒌 − 𝑟0′ (𝑑𝜀 cos 𝛼 + 𝑑𝜀 ) 𝒌 × 𝑵0𝑝 +
1 1 1 1 1 𝑑𝜀1
Where: 𝛼 is calculated by expression (2.3.4-9).

′
Relative velocity 𝒗2,ℎ
𝑝 of workpiece 2 with respect to hob 𝐶̅ at point 𝑃 is derived by application
of expressions (2.3.4-18) and (2.3.4-19) as follow:
𝑑𝜀 ′ 𝑑𝜑 𝑑(𝑙𝒑) 𝑑(𝑙𝒑)′ℎ
′
𝑟0′ (𝑑𝜀ℎ cos 𝛼 + 𝑑𝜀 ) 𝒌 × 𝑵0𝑝 − 𝑀𝒌 × [𝑹0𝑝 − (𝑙𝒑)] + −
𝑑𝜀1 𝑑𝜀1
𝒗2,ℎ
𝑝 = 𝒗′𝑝 − 𝒗′ℎ𝑝 = { 1
′
1
}
𝑑𝜀ℎ 𝑑𝜑 𝑑𝜀 ′ 𝑑𝜎2
+ [𝑑𝜀 𝒌ℎ + (𝑑𝜀 − 𝑀) 𝒌] × ∆𝑝 + (𝑟0′ 𝑑𝜀ℎ sin 𝛼 + 𝑑𝜀 ) 𝒌
1 1 1 1
Due to ∆𝑝 ∥ 𝑵𝑝 , then,
′
𝑑𝜀ℎ 𝑑𝜑
{[ 𝒌ℎ + (𝑑𝜀 − 𝑀) 𝒌] × ∆𝑝 } ∙ 𝑵𝑝 = 0,
𝑑𝜀1 1
′ }
𝑑𝜀 𝑑𝜎
(𝑟0′ 𝑑𝜀ℎ sin 𝛼 + 𝑑𝜀 2 ) 𝒌 ∙ 𝑵𝑝 = 0.
1 1
Therefore, effective relative velocity of workpiece 2 with respect to hob 𝐶̅ is

′
′ 𝑑𝜀ℎ 𝑑𝜑 𝑑(𝑙𝒑) 𝑑(𝑙𝒑)′ℎ
𝒗2,ℎ ′
𝑝𝐸 = 𝑟0 ( cos 𝛼 + ) 𝒌 × 𝑵0𝑝 − 𝑀𝒌 × [𝑹0𝑝 − (𝑙𝒑)] + − (2.3.4-20)
𝑑𝜀 𝑑𝜑
Where: 𝑀 = 𝑑𝜀2. is calculated by expression (2.3.4-13). 𝑹0𝑝 is decided by expression
1 𝑑𝜀1
(1.4.10-6) and 𝑵0𝑝 is determined by expression (1.4.10-13).
Due to hobs 𝐶 and 𝐶̅ being a pair of conjugate involute helicoids, application of expression
~209 ~
(2.3.2-42) gives
′
𝑑𝜀ℎ 𝑑𝜀 ′ 𝑑𝜀 𝑟𝑏 𝑑𝜀ℎ 𝑏 𝑑𝜀
= 𝑑𝜀ℎ 𝑑𝜀ℎ = = − 𝑏𝑎′ 𝑑𝜀ℎ (2.3.4-21)
𝑑𝜀1 ℎ 1 𝑟𝑏′ 𝑑𝜀1 𝑎 1
𝑑𝜀ℎ
Where: is decided by expression (2.3.4-15).
𝑑𝜀1
4 Motion Requirement
With help of expressions (2.3.4-3) and (2.3.4-17), application of requirement of conjugate
contact between workpiece 1 and hob 𝐶 gives
𝒗1,ℎ ℎ
𝑝𝐸 ∙ 𝑵𝑝ℎ = {𝒌 × 𝑹0𝑝 + 𝑟0 (𝑑𝜀 cos 𝛼 − 𝑑𝜀 ) 𝒌 × 𝑵0𝑝 − } ∙ 𝑵𝑝ℎ = 0 (2.3.4-22)
1 1 𝑑𝜀1
Expanding equation above yields
𝑑ℎℎ 𝑑𝑓ℎ
) 𝑁𝑜𝑝𝑦 − (𝑦0𝑝 +
𝐴ℎ𝑝 [(𝑥0𝑝 − )𝑁 ]
𝑑𝜀1 𝑑𝜀1 𝑜𝑝𝑥
𝑑ℎℎ 𝑑𝑓ℎ 𝑑𝜀ℎ 𝑑𝜑
= + [(𝑥0𝑝 − ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + ) 𝑁𝑜𝑝𝑦 + 𝑟0 ( cos 𝛼 − )] 𝐵ℎ𝑝 cos 𝛼 = 0
𝑑ℎℎ 𝑑𝑓ℎ 𝑑𝜀ℎ 𝑑𝜑
− [(𝑥0𝑝 − ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + ) 𝑁𝑜𝑝𝑦 + 𝑟0 ( cos 𝛼 − )] 𝐶ℎ𝑝 sin 𝛼
{ 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 }
Due to 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 being constant, equation above generates simultaneous equation as
follow:
𝑑ℎℎ 𝑑𝑓ℎ
(𝑥0𝑝 − ) 𝑁𝑜𝑝𝑦 − (𝑦0𝑝 + ) 𝑁𝑜𝑝𝑥 = 0,
𝑑𝜀1 𝑑𝜀1
𝑑ℎℎ 𝑑𝑓ℎ 𝑑𝜀 𝑑𝜑
}
(𝑥0𝑝 − ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + ) 𝑁𝑜𝑝𝑦 + 𝑟0 (𝑑𝜀ℎ cos 𝛼 − 𝑑𝜀 ) = 0.
𝑑𝜀1 𝑑𝜀1 1 1
Solving equation above gives

𝑑𝑓ℎ 𝑑𝜀 𝑑𝜑
= −𝑦0𝑝 − (𝑑𝜀ℎ cos 𝛼 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑦 ,
𝑑𝜀1 1 1
𝑑ℎℎ 𝑑𝜀ℎ 𝑑𝜑
} (2.3.4-23)
= 𝑥0𝑝 + (𝑑𝜀 cos 𝛼 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥 .
𝑑𝜀1 1 1
Likewise, with help of expressions (2.3.4-3) and (2.3.4-20), application of requirement of

conjugate contact between workpiece 2 and hob 𝐶̅ gives
′
𝒗2,ℎ
𝑝𝐸 ∙ 𝑵𝑝ℎ = 0 (2.3.4-24)
~ 210 ~
Expanding equation above results in
𝑑𝑓 𝑑𝑓 ′ 𝑑ℎ 𝑑ℎ′
𝐴ℎ𝑝 {[𝑀(𝑦0𝑝 − ℎ) + − 𝑑𝜀ℎ ] 𝑁𝑜𝑝𝑥 + [−𝑀(𝑥0𝑝 − 𝑓) + − 𝑑𝜀ℎ ] 𝑁𝑜𝑝𝑦 }
𝑑𝜀1 1 𝑑𝜀1 1
′ ′
𝑑𝜀ℎ 𝑑𝜑 𝑑ℎ 𝑑ℎℎ
𝑟0′ (𝑑𝜀 cos 𝛼 + 𝑑𝜀 ) + [−𝑀(𝑥0𝑝 − 𝑓) + 𝑑𝜀 − 𝑑𝜀 ] 𝑁𝑜𝑝𝑥
1 1 1 1
+{ } 𝐵ℎ𝑝 cos 𝛼
𝑑𝑓 𝑑𝑓ℎ′
= − [𝑀(𝑦0𝑝 − ℎ) + 𝑑𝜀 − 𝑑𝜀 ] 𝑁𝑜𝑝𝑦 =0
1 1
𝑑𝜀 ′ 𝑑𝜑 𝑑ℎ 𝑑ℎ′
𝑟0′ (𝑑𝜀ℎ cos 𝛼 + 𝑑𝜀 ) + [−𝑀(𝑥0𝑝 − 𝑓) + − 𝑑𝜀ℎ ] 𝑁𝑜𝑝𝑥
1 1 𝑑𝜀1 1
−{ } 𝐶ℎ𝑝 sin 𝛼
𝑑𝑓 𝑑𝑓ℎ′
− [𝑀(𝑦0𝑝 − ℎ) + − 𝑑𝜀 ] 𝑁𝑜𝑝𝑦
{ 𝑑𝜀1 1 }
Due to 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 being constant, equation above generates simultaneous equation as
follow:
𝑑𝑓 𝑑𝑓 ′ 𝑑ℎ 𝑑ℎ′
[𝑀(𝑦0𝑝 − ℎ) + − 𝑑𝜀ℎ ] 𝑁𝑜𝑝𝑥 + [−𝑀(𝑥0𝑝 − 𝑓) + − 𝑑𝜀ℎ ] 𝑁𝑜𝑝𝑦 = 0,
𝑑𝜀1 1 𝑑𝜀1 1
′ ′
𝑑𝜀ℎ 𝑑𝜑 𝑑ℎ 𝑑ℎℎ
𝑟0′ (𝑑𝜀 cos 𝛼 + 𝑑𝜀 ) + [−𝑀(𝑥0𝑝 − 𝑓) + − 𝑑𝜀 ] 𝑁𝑜𝑝𝑥 (2.3.4-25)
1 1 𝑑𝜀1 1
{ }=0
𝑑𝑓 𝑑𝑓 ′
− [𝑀(𝑦0𝑝 − ℎ) + − 𝑑𝜀ℎ ] 𝑁𝑜𝑝𝑦
𝑑𝜀1 1 }
Solving equation above leads
𝑑𝑓ℎ′ 𝑑𝑓 𝑑𝜀 ′ 𝑑𝜑
= 𝑀(𝑦0𝑝 − ℎ) + − 𝑟0′ (𝑑𝜀ℎ cos 𝛼 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑦 ,
𝑑𝜀1 𝑑𝜀1 1 1
′ } (2.3.4-26)
𝑑ℎℎ 𝑑ℎ 𝑑𝜀 ′ 𝑑𝜑
= −𝑀(𝑥0𝑝 − 𝑓) + + 𝑟0′ (𝑑𝜀ℎ cos 𝛼 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑥 .
𝑑𝜀1 𝑑𝜀1 1 1
𝑑𝜀 ′
Where: 𝑑𝜀ℎ is calculated by expression (2.3.4-21).
1
With help of expressions (2.3.4-10), (2.3.4-12), (2.3.4-18) and (2.3.4-19), relative velocity of
workpiece 1 with respect to workpiece 2 is as follow:
𝒗𝑝 − 𝒗′𝑝 = 𝒗𝑝 − 𝒗𝑝ℎ + 𝒗𝑝ℎ − 𝒗′ℎ𝑝 + 𝒗′ℎ𝑝 − 𝒗′𝑝
Due to hobs 𝐶 and 𝐶̅ being a pair of conjugate surfaces, then, (𝒗𝑝ℎ − 𝒗′ℎ𝑝 ) ∙ 𝑵𝑝ℎ = 0.
application of expressions (2.3.4-22) and (2.3.4-24) gives
(𝒗𝑝 − 𝒗′𝑝 ) ∙ 𝑵𝑝ℎ = (𝒗𝑝 − 𝒗𝑝ℎ ) ∙ 𝑵𝑝ℎ + (𝒗𝑝ℎ − 𝒗′ℎ𝑝 ) ∙ 𝑵𝑝ℎ + (𝒗′ℎ𝑝 − 𝒗′𝑝 ) ∙ 𝑵𝑝ℎ = 0
Therefore, tooth profiles of workpiece 1 and 2 are a pair of conjugate surfaces.
~ 211 ~
Combination of expressions (2.3.4-2), (2.3.4-9), (2.3.4-13), (2.3.4-15), (2.3.4-21), (2.3.4-23) and
(2.3.4-25) generates motion requirements for hobs 𝐶 and 𝐶̅ , that is,
𝐾1𝑔0 ′
𝜋 𝑑𝜑 𝑑𝜀ℎ 1 𝑑𝜀ℎ 𝑏 𝑑𝜀
𝛼 = 2 + 𝛾0 , =
𝑑𝜀 − 1, = 𝑑𝜀 , = − 𝑏𝑎′ 𝑑𝜀ℎ ,
𝑑𝜀1 ( 1) 𝑑𝜀1 𝑏𝑎 cos 𝛾0 ( 1 ) 𝑑𝜀1 𝑎 1
0 0
𝑑ℎ 𝑑𝑓
𝑑𝜀1 𝑑𝜀1
𝑓ℎ = 𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 = + 𝑟0 𝑁𝑜𝑝𝑥 , ℎℎ = 𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 = + 𝑟0 𝑁𝑜𝑝𝑦 ,
1+𝑀 1+𝑀
𝑑ℎ 𝑑𝑓
𝑑𝜀1 𝑑𝜀1
𝑓ℎ′ = 𝑥0𝑝 − 𝑟0′ 𝑁𝑜𝑝𝑥 = − 𝑟0′ 𝑁𝑜𝑝𝑥 , ℎℎ′ = 𝑦0𝑝 − 𝑟0′ 𝑁𝑜𝑝𝑦 = − 𝑟0′ 𝑁𝑜𝑝𝑦 , (2.3.4-27)
1+𝑀 1+𝑀
𝑑𝑓ℎ 𝑑𝜀ℎ 𝑑𝜑 𝑑ℎℎ 𝑑𝜀ℎ 𝑑𝜑
= −𝑦0𝑝 − (𝑑𝜀 cos 𝛼 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑦 , = 𝑥0𝑝 + (𝑑𝜀 cos 𝛼 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥 ,
𝑑𝜀1 1 1 𝑑𝜀1 1 1
𝑑𝑓ℎ′ 𝑑𝑓 𝑑𝜀 ′ 𝑑𝜑
= 𝑀(𝑦0𝑝 − ℎ) + − 𝑟0′ (𝑑𝜀ℎ cos 𝛼 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑦 ,
𝑑𝜀1 𝑑𝜀1 1 1
′ ′
𝑑ℎℎ 𝑑ℎ 𝑑𝜀ℎ 𝑑𝜑
= −𝑀(𝑥0𝑝 − 𝑓) + + 𝑟0′ (𝑑𝜀 cos 𝛼 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑥 . }
𝑑𝜀1 𝑑𝜀1 1 1
Where: 𝑠0 is arc-length of pitch curve, 𝛾0 is lead angle of hob 𝐶.
2.3.5 Calculation of Tooth Profiles and Machine Setting Parameters

Because a pair of involute hobs satisfy requirement of line conjugate contact, i.e., expression
(2.3.2-42), involute hobs are used to make a pair of conjugate tooth profiles.
1 Calculation of Conjugate Cutting Point on Helicoid of Hob

A. Tooth Profile of Left-Flank of Tooth Space on Workpiece 1
1) Calculation of Surface Parameters
Tooth profile 𝐴 for left-flank of tooth space on workpiece 1 is generated by right-flank of

involute helicoid of hob 𝐶. Let hob for 𝑞th-tooth of workpiece 1 be initially located in position
where pitch point 𝑃0,𝑞 on 𝑞th tooth profile reaches conjugate contact position. Common unit
normal to tooth profile at any conjugate cutting point 𝑃 must pass through corresponding pitch
point 𝑃0 , therefore, with help of expression (2.3.2-34), conjugate cutting position can be
decided by application of expression (2.3.4-7), that is,
1
−𝑟𝑏 [cos 𝛼0 + (Γ + 𝜎0 ) sin 𝛼0 ] = 𝑠𝑛 𝑏𝑎 sin 𝛼0 − 𝑟0 ,
𝑟𝑏 𝑠𝑛 (2.3.5-1)
𝑏𝑎 𝜃 = − ,
√𝑟𝑏2 +𝑏𝑎2 Γ + 𝜃 + ∆𝜀ℎ = 𝛼0 .
}
~ 212 ~
Where: ∆𝜀ℎ is rotating angle of hob. Because hob is initially located in position corresponding to
conjugate cutting position of pitch point 𝑃0,𝑞 on 𝑞th tooth profile, ∆𝜀ℎ = 0 is corresponding to
pitch point 𝑃0 .
Guven ∆𝜀ℎ , there are three variables, i.e., 𝑠𝑛 , 𝜃 and Γ and three equations in simultaneous
equation (2.3.5-1). Therefore, with help of expression (2.3.4-14), parameters for conjugate
cutting point at instant rotating angle ∆𝜀ℎ of hob can be uniquely solved from equation (2.3.5-
1), that is,
𝑟𝑏 𝑏𝑎 ∆𝜀ℎ 𝑟𝑏 ∆𝑠0 𝑟 2 ∆𝜀 𝑟 2 ∆𝑠
𝑠𝑛 = = , 𝜃 = − 𝑟𝑏2 +𝑏ℎ2 = − (𝑟 2+𝑏2𝑏)𝑏 0cos 𝛾 ,
√𝑟𝑏2 +𝑏𝑎2 cos 𝛾0 √𝑟𝑏2 +𝑏𝑎2 𝑏 𝑎 𝑏 𝑎 𝑎 0
(2.3.5-2)
𝑏𝑎2 𝑏𝑎 ∆𝑠0
Γ = 𝛼0 − 𝑟 2 +𝑏2 ∆𝜀ℎ = 𝛼0 − (𝑟 2+𝑏2) cos 𝛾
𝑏 𝑎 𝑏 𝑎 0 }
Where: ∆𝑠0 is arc-length of pitch curve and ∆𝑠0 = 0 is corresponding to pitch point on tooth
profile.
With respect to coordinate system 𝑂 − 𝒊 , 𝒋,𝒌 , conjugate cutting point on 𝑞th-tooth of

workpiece 1 corresponding to ∆𝜀ℎ is derived as follow:
𝑹1𝑝 |∆𝜀 = 𝑹0𝑝 |∆𝜀 + ∆𝑝 |∆𝜀 = 𝑥𝑝 |∆𝜀 𝒊 + 𝑦𝑝 |∆𝜀 𝒋 (2.3.5-3)

1,𝑞 1,𝑞 1,𝑞 1,𝑞 1,𝑞
Here: 𝑹0𝑝 | is vector of point on pitch curve 𝐴0 of workpiece 1 corresponding to ∆𝜀1 + 𝜀1,𝑞
∆𝜀1,𝑞
of 𝑞th-tooth and is calculated by application of expression (1.4.10-5), that is,
𝑹0𝑝 |∆𝜀 = 𝑥0𝑝 |∆𝜀 𝒊 + 𝑦0𝑝 |∆𝜀 𝒋 (2.3.5-4)

1,𝑞 1,𝑞 1,𝑞
∆𝜀1,𝑞 and 𝜀1,𝑞 are calculated by application of expression (1.4.10-16), that is,
𝑆 𝑑𝜀 𝑆 (1±𝑀)
𝜀1,𝑞 = ∫0 𝑞 (𝑑𝑠1 ) 𝑑𝑠0 = ∫0 𝑞 |𝑱0 |
𝑑𝑠0 ,
0 𝜏0
∆𝑠0 +𝑆𝑞 𝑑𝜀1 ∆𝑠0 +𝑆𝑞 (1±𝑀)
} (2.3.5-5)
∆𝜀1,𝑞 = ∫𝑆 (𝑑𝑠 ) 𝑑𝑠0 = ∫𝑆 |𝑱0 |
𝑑𝑠0
𝑞 0 𝜏0 𝑞
Where: 𝑞 = 0,1,2,3, ⋯ (𝑁 − 1). 𝑁 is tooth number of workpiece. 𝑆𝑞 is arc-length from points

̂
𝑃0,1 to 𝑃0,𝑞 on pitch curve, i.e., 𝑆𝑞 = 𝑃0,1 𝑃0,𝑞 = 𝑞𝑝 and 𝑝 is pitch of workpiece as shown in
figure 2.3.5-1. Integration above can be carried out numerically.
2) Calculation of Unit Normal 𝑵𝑝 |∆𝜀 to Tooth Profile at Conjugate Cutting Position

1,𝑞
~ 213 ~
Let 𝑵𝑝 |∆𝜀 be unit normal to 𝑞th tooth profile 𝐴 of workpiece 1 at conjugate cutting point 𝑃
1,𝑞
corresponding to ∆𝜀1,𝑞 + 𝜀1,𝑞 in conjugate cutting position and 𝑵ℎ𝑝 be unit normal to helicoid
of hob corresponding to conjugate cutting point 𝑃 on 𝑞th tooth profile 𝐴 of workpiece 1.
Method 1:
Let original reference position of hob for 𝑞th tooth be position of pitch point 𝑃𝑜 on hob
coincident to pitch point 𝑃𝑜 of workpiece at 𝜀1 = 𝜀1,𝑞 . With help of expressions (2.3.4-2), (2.3.4-
5), (2.3.4-9) and (2.3.2-35), application of expression (2.3.4-3) gives
𝑵𝑝ℎ = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ = 𝐴ℎ𝑝 |𝜀 𝒊 + 𝐵ℎ𝑝 |𝜀 𝒋

1,𝑞 1,𝑞
[𝐴ℎ𝑝 𝑁0𝑝𝑥 | + 𝑁0𝑝𝑦 | (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 )] 𝒊 (2.3.5-6)

𝜀1,𝑞 𝜀1,𝑞
={ }
+ [𝐴ℎ𝑝 𝑁0𝑝𝑦 |𝜀 − 𝑁0𝑝𝑥 |𝜀 (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 )] 𝒋
1,𝑞 1,𝑞
Where: 𝑞 = 0,1,2,3, ⋯ (𝑁 − 1). 𝜀1,𝑞 is calculated by expression (2.3.5-5). 𝑁0𝑝𝑥 |𝜀 and 𝑁0𝑝𝑦 |𝜀
1,𝑞 1,𝑞
are calculated by expression (1.4.10-13) and evaluated at 𝜀1 = 𝜀1,𝑞 , then,
𝐴ℎ𝑝 |𝜀 = 𝐴ℎ𝑝 𝑁0𝑝𝑥 |𝜀 + 𝑁0𝑝𝑦 |𝜀 (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 ),

1,𝑞 1,𝑞 1,𝑞
𝐵ℎ𝑝 | = 𝐴ℎ𝑝 𝑁0𝑝𝑦 | − 𝑁0𝑝𝑥 | (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 ),

𝜀1,𝑞 𝜀1,𝑞 𝜀1,𝑞
𝑏𝑎 cos 𝛼0 𝑟𝑏
𝐴ℎ𝑝 = −
𝑏𝑎 sin 𝛼0
, 𝐵ℎ𝑝 = , 𝐶ℎ𝑝 =
√𝑟𝑏2 +𝑏𝑎2 √𝑟𝑏2 +𝑏𝑎2 ,
𝒊ℎ = 𝑵0𝑝 |𝜀 = 𝑁0𝑝𝑥 |𝜀 𝒊 + 𝑁0𝑝𝑦 |𝜀 𝒋, 𝒋ℎ = (𝑁0𝑝𝑦 |𝜀 𝒊 − 𝑁0𝑝𝑥 |𝜀 𝒋) sin 𝛾0 + cos 𝛾0 𝒌,

1,𝑞 1,𝑞 1,𝑞 1,𝑞 1,𝑞
𝒌ℎ = (𝑁0𝑝𝑦 |𝜀 𝒊 − 𝑁0𝑝𝑥 |𝜀 𝒋) cos 𝛾0 − sin 𝛾0 𝒌.

1,𝑞 1,𝑞 }
With aid of requirement of conjugate contact, 𝑵𝑝 |∆𝜀 is derived by rotating (−𝑵ℎ𝑝 ) from
1,𝑞
initial reference position to conjugate cutting position through an angle (−∆𝜑|∆𝜀1,𝑞 ) about 𝒌 as
an axis, that is,
𝑵𝑝 |∆𝜀 = (−∆𝜑|∆𝜀1,𝑞 𝒌) ⊗ (−𝑵ℎ𝑝 ) = 𝐴𝑝 |∆𝜀 𝒊 + 𝐵𝑝 |∆𝜀 𝒋 (2.3.5-7)

1,𝑞 1,𝑞 1,𝑞
Where: 𝑵ℎ𝑝 is decided by expression (2.3.5-6), thus,
~214 ~
𝐴𝑝 |∆𝜀 = −𝐴ℎ𝑝 |𝜀 cos (∆𝜑|∆𝜀1,𝑞 ) − 𝐵ℎ𝑝 |𝜀 sin (∆𝜑|∆𝜀1,𝑞 ) ,
1,𝑞 1,𝑞 1,𝑞
}
𝐵𝑝 |∆𝜀 = 𝐴ℎ𝑝 |𝜀 sin (∆𝜑|∆𝜀1,𝑞 ) − 𝐵ℎ𝑝 |𝜀 cos (∆𝜑|∆𝜀1,𝑞 ) .
1,𝑞 1,𝑞 1,𝑞
And
∆𝜑|∆𝜀1,𝑞 is decided by application of expression (2.3.4-13), that is,
𝑆 +∆𝑠0 𝑑𝜀
∆𝜑|∆𝜀1,𝑞 = ∫𝑆 𝑞 [𝐾1𝑔0 − ( 𝑑𝑠1 ) ] 𝑑𝑠0 (2.3.5-8)
𝑞 0 𝜏0
Integration above can be carried out numerically.
Method 2:
Establish new coordinate system 𝑂ℎ |∆𝜀1,𝑞 − 𝒊ℎ |∆𝜀1,𝑞 , 𝒋ℎ |∆𝜀1,𝑞 , 𝒌ℎ |∆𝜀1,𝑞 as follow:
⃗⃗⃗⃗⃗⃗⃗⃗ℎ |
𝑂𝑂 = 𝑹0𝑝 |∆𝜀 + 𝑟0 𝒊ℎ |∆𝜀1,𝑞 ,
∆𝜀 1,𝑞 1,𝑞
𝒊ℎ |∆𝜀1,𝑞 = 𝑵0𝑝 |∆𝜀 = 𝑁0𝑝𝑥 |∆𝜀 𝒊 + 𝑁0𝑝𝑦 |∆𝜀 𝒋,

1,𝑞 1,𝑞 1,𝑞
(2.3.5-9)
𝒌ℎ |∆𝜀1,𝑞 = (𝑁0𝑝𝑦 |∆𝜀 𝒊 − 𝑁0𝑝𝑥 |∆𝜀 𝒋) sin 𝛼 + cos 𝛼 𝒌,
1,𝑞 1,𝑞
𝒋ℎ |∆𝜀1,𝑞 = (−𝑁0𝑝𝑦 |∆𝜀 𝒊 + 𝑁0𝑝𝑥 |∆𝜀 𝒋) cos 𝛼 + sin 𝛼 𝒌.

1,𝑞 1,𝑞 }
Where: 𝑹0𝑝 |∆𝜀 is position vector of pitch point defined in expression (1.4.10-6) and 𝑵0𝑝 |∆𝜀
1,𝑞 1,𝑞
is unit normal to pitch curve decided by expression (1.4.10-13). Both 𝑹0𝑝 |∆𝜀 and 𝑵0𝑝 |∆𝜀 are
1,𝑞 1,𝑞
evaluated at rotating angle ∆𝜀1,𝑞 + 𝜀1,𝑞 .
With help of expressions (2.3.4-5) and (2.3.5-9), 𝑵𝑝 |∆𝜀 is derived as follow:

1,𝑞
𝑵𝑝 |∆𝜀 = −𝑵𝑝ℎ = 𝐴𝑝 |∆𝜀 𝒊 + 𝐵𝑝 |∆𝜀 𝒋

1,𝑞 1,𝑞 1,𝑞
(2.3.5-10)
= − (𝐴ℎ𝑝 𝒊ℎ |∆𝜀1,𝑞 + 𝐵ℎ𝑝 𝒋ℎ |∆𝜀1,𝑞 + 𝐶ℎ𝑝 𝒌ℎ |∆𝜀1,𝑞 )
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are calculated by expression (2.3.2-35) and,
𝐴𝑝 |∆𝜀 = −𝐴ℎ𝑝 𝑁0𝑝𝑥 |∆𝜀 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁0𝑝𝑦 |∆𝜀 ,
1,𝑞 1,𝑞 1,𝑞
}
𝐵𝑝 |∆𝜀 = −𝐴ℎ𝑝 𝑁0𝑝𝑦 |∆𝜀 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁0𝑝𝑥 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞
~ 215 ~
Then,
∆𝑝 |∆𝜀 = 𝑠𝑛 𝑵𝑝 |∆𝜀 = 𝑠𝑛 (𝐴𝑝 |∆𝜀 𝒊 + 𝐵𝑝 |∆𝜀 𝒋) (2.3.5-11)

1,𝑞 1,𝑞 1,𝑞 1,𝑞
Where: 𝑠𝑛 is calculated by expression (2.3.5-2). 𝐴𝑝 |∆𝜀 and 𝐵𝑝 |∆𝜀 are decided by expression
1,𝑞 1,𝑞
(2.3.5-7) or (2.3.5-10).
𝒌 Tooth profile of workpiece 1
𝑃 Conjugate cutting point

𝑞
𝑹1𝑝 |𝜀
ℎ
𝑂 𝒋
𝑞
∆𝑝 |𝜀 𝑝 𝑃0,1 1th pitch point
ℎ
𝑞
𝑹0𝑝 |𝜀 ∆𝑠0 𝑃0,2 2nd pitch point
ℎ
Pitch curve 𝐴0 of workpiece 1 𝑃0,𝑞 𝑞th pitch point
Figure 2.3.5-1 Conjugate Cutting Point 𝑃 on left-flank of tooth space of workpiece 1
3) Conjugate Cutting Point
Conjugate cutting point 𝑃 on 𝑞th-tooth profile of workpiece 1 corresponding to ∆𝜀1,𝑞 + 𝜀1,𝑞 is

derived by substitution of expressions (2.3.5-4) and (2.3.5-11) into (2.3.5-3) as follow:

1,𝑞 1,𝑞 1,𝑞 1,𝑞 1,𝑞
Where: arc-length 𝑠0 of pitch curve is used as independent variable.
𝑥𝑝 |∆𝜀 = 𝑥0𝑝 |∆𝜀 + 𝑠𝑛 𝐴𝑝 |∆𝜀 ,

1,𝑞 1,𝑞 1,𝑞
}
𝑦𝑝 |∆𝜀 = 𝑦0𝑝 |∆𝜀 + 𝑠𝑛 𝐵𝑝 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞
B. Tooth Profile of Right-Flank of Tooth Space on Workpiece 1
~ 216 ~
Tooth profile 𝐴 of right-flank of tooth space on workpiece 1 is generated by left-flank of
involute helicoid of hob 𝐶. Similar to tooth profile of left-flank of tooth space on workpiece 1,
with help of expressions (2.3.2-47) and (2.3.4-5), conjugate cutting position can be decided by

𝑠𝑛 𝑏𝑎 sin 𝛼0
−𝑟𝑏 [cos 𝛼0 + (Γ + 𝜎0 ) sin 𝛼0 ] = − 𝑟0 ,
𝑠𝑛 𝑟𝑏 (2.3.5-13)
𝑏𝑎 𝜃 = ,
∅ − 𝜀ℎ = Γ − 𝜃 − ∆𝜀ℎ = 𝛼0 . }
Where: ∆𝜀ℎ = 0 is initial rotating angle of hob 𝐶 corresponding to pitch point 𝑃0 .
Guven ∆𝜀ℎ , there are three variables, i.e., 𝑠𝑛 , 𝜃 and Γ and three equations in simultaneous
equation (2.3.5-13). Therefore, with help of expression (2.3.4-14), parameters for conjugate
cutting point at instant rotating angle ∆𝜀ℎ can be uniquely solved from equation (2.3.5-13), that
is,
𝑟𝑏 𝑏𝑎 𝑟𝑏 ∆𝑠0
𝑠𝑛 = − ∆𝜀ℎ = − ,
√𝑟𝑏2 +𝑏𝑎2 cos 𝛾0 √𝑟𝑏2 +𝑏𝑎2
𝑏 𝑟2 𝑏 0 𝑟 2 ∆𝑠 (2.3.5-14)
𝜃 = − 𝑟 2+𝑏 2 ∆𝜀ℎ = − (𝑟 2 +𝑏 2 )𝑏 cos 𝛾 ,
𝑏 𝑎 𝑏 𝑎 𝑎 0
𝑏𝑎2 𝑏 ∆𝑠
Γ = 𝛼0 + ∆𝜀ℎ = 𝛼0 + (𝑟 2+𝑏𝑎2) cos
0
𝑟𝑏2 +𝑏𝑎2 𝑏 𝛾 𝑎 0 }
Where: ∆𝑠0 is arc-length of pitch curve and ∆𝑠0 = 0 is corresponding to pitch point on tooth
profile.
With respect to coordinate system 𝑂 − 𝒊 , 𝒋,𝒌 , conjugate cutting point 𝑃 on 𝑞th-tooth of

workpiece 1 corresponding to ∆𝜀ℎ is derived as follow:

1,𝑞 1,𝑞 1,𝑞 1,𝑞 1,𝑞
Here: 𝑹0𝑝 | is vector of point on pitch curve 𝐴0 of workpiece 1 corresponding to ∆𝜀1 + 𝜀1,𝑞
∆𝜀1,𝑞
of 𝑞th-tooth and is calculated by application of expression (1.4.10-5), that is,
𝑹0𝑝 |∆𝜀 = 𝑥0𝑝 |∆𝜀 𝒊 + 𝑦0𝑝 |∆𝜀 𝒋 (2.3.5-16)

1,𝑞 1,𝑞 1,𝑞
∆𝜀1,𝑞 and 𝜀1,𝑞 are calculated by application of expression (1.4.10-16), that is,
~ 217 ~
𝑆 𝑑𝜀 𝑆 (1±𝑀)
𝜀1,𝑞 = ∫0 𝑞 (𝑑𝑠1 ) 𝑑𝑠0 = ∫0 𝑞 |𝑱0 |
𝑑𝑠0 ,
0 𝜏0
∆𝑠 +𝑆𝑞 𝑑𝜀1 ∆𝑠 +𝑆𝑞 (1±𝑀)
} (2.3.5-17)
∆𝜀1,𝑞 = ∫𝑆 0 (𝑑𝑠 ) 𝑑𝑠0 = ∫𝑆 0 |𝑱0 |
𝑑𝑠0
𝑞 0 𝑞
𝜏0
Where: 𝑞 = 0,1,2,3, ⋯ (𝑁 − 1). 𝑁 is tooth number of workpiece. 𝑆𝑞 is arc-length of pitch curve

corresponding to 𝑞th pitch point 𝑃0,𝑞 as shown in figure 2.3.5-2, that is,
𝑝 𝑝
̂
𝑆𝑞 = 𝑃0,1 𝑃0,𝑞 + 2 = 𝑞𝑝 + 2 (2.3.5-18)
𝒌 Tooth profile of workpiece 1
𝑃 Conjugate cutting point

𝑞
𝑹1𝑝 |𝜀
ℎ
𝑝
𝑂 𝒋 2
𝑞
∆𝑝 |𝜀 𝑝 𝑃0,1 1th pitch point
ℎ
𝑞
𝑹0𝑝 |𝜀 ∆𝑠0 𝑃0,2 2nd pitch point
ℎ
Pitch curve 𝐴0 of workpiece 1 𝑃0,𝑞 𝑞th pitch point
Figure 2.3.5-2 Conjugate Cutting Point 𝑃 on right-flank of tooth space of workpiece 1
2) Calculation of Unit Normal 𝑵𝑝 |∆𝜀 to Tooth Profile at Conjugate Cutting Position

1,𝑞
Let 𝑵𝑝 |∆𝜀 be unit normal to 𝑞th tooth profile 𝐴 of workpiece 1 at conjugate cutting point 𝑃
1,𝑞
corresponding to ∆𝜀1,𝑞 + 𝜀1,𝑞 in conjugate cutting position and 𝑵ℎ𝑝 be unit normal to helicoid
of hob corresponding to conjugate cutting point 𝑃 on 𝑞th tooth profile 𝐴 of workpiece 1.
Method 1:
Let original reference position of hob for 𝑞th tooth be position of pitch point 𝑃𝑜 on hob
coincident to pitch point 𝑃𝑜 of workpiece at 𝜀1 = 𝜀1,𝑞 . With help of expressions (2.3.4-2), (2.3.4-
5), (2.3.4-9) and (2.3.2-49), application of expression (2.3.4-3) gives
~ 218 ~
𝑵𝑝ℎ = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ = 𝐴ℎ𝑝 |𝜀 𝒊 + 𝐵ℎ𝑝 |𝜀 𝒋 (2.3.5-19)
1,𝑞 1,𝑞
Where: 𝑞 = 0,1,2,3, ⋯ (𝑁 − 1). 𝜀1,𝑞 is calculated by expression (2.3.5-17). 𝑁0𝑝𝑥 |𝜀 and

1,𝑞
𝑁0𝑝𝑦 |𝜀 are calculated by expression (1.4.10-13), then,

1,𝑞
𝐴ℎ𝑝 |𝜀 = 𝐴ℎ𝑝 𝑁0𝑝𝑥 |𝜀 + 𝑁0𝑝𝑦 |𝜀 (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 ),

1,𝑞 1,𝑞 1,𝑞
𝐵ℎ𝑝 |𝜀 = 𝐴ℎ𝑝 𝑁0𝑝𝑦 |𝜀 − 𝑁0𝑝𝑥 |𝜀 (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 ),

1,𝑞 1,𝑞 1,𝑞
𝑏𝑎 sin 𝛼0 𝑏𝑎 cos 𝛼0 𝑟𝑏
𝐴ℎ𝑝 = − , 𝐵ℎ𝑝 = − , 𝐶ℎ𝑝 = − ,
𝒊ℎ = 𝑵0𝑝 |𝜀 = 𝑁0𝑝𝑥 |𝜀 𝒊 + 𝑁0𝑝𝑦 |𝜀 𝒋,

1,𝑞 1,𝑞 1,𝑞
𝒋ℎ = (𝑁0𝑝𝑦 |𝜀 𝒊 − 𝑁0𝑝𝑥 |𝜀 𝒋) sin 𝛾0 + cos 𝛾0 𝒌,

1,𝑞 1,𝑞
𝒌ℎ = (𝑁0𝑝𝑦 |𝜀 𝒊 − 𝑁0𝑝𝑥 |𝜀 𝒋) cos 𝛾0 − sin 𝛾0 𝒌.

1,𝑞 1,𝑞 }
With aid of requirement of conjugate contact, 𝑵𝑝 |∆𝜀 is derived by rotating (−𝑵ℎ𝑝 ) from
1,𝑞
initial reference position to conjugate cutting position through an angle (−∆𝜑|∆𝜀1,𝑞 ) about 𝒌 as
an axis, that is,
𝑵𝑝 |∆𝜀 = (−∆𝜑|∆𝜀1,𝑞 𝒌) ⊗ (−𝑵ℎ𝑝 ) = 𝐴𝑝 |∆𝜀 𝒊 + 𝐵𝑝 |∆𝜀 𝒋 (2.3.5-20)

1,𝑞 1,𝑞 1,𝑞
Where: 𝑵ℎ𝑝 is decided by expression (2.3.5-19), thus,

1,𝑞 1,𝑞 1,𝑞
}
1,𝑞 1,𝑞 1,𝑞
∆𝜑|∆𝜀1,𝑞 is decided by application of expression (2.3.4-13), that is,
𝑆 +∆𝑠0 𝑑𝜀
∆𝜑|∆𝜀1,𝑞 = ∫𝑆 𝑞 [𝐾1𝑔0 − ( 𝑑𝑠1 ) ] 𝑑𝑠0 (2.3.5-21)
𝑞 0 𝜏0
Where: 𝑆𝑞 is calculated by expression (2.3.5-18). Integration above can be carried out

numerically.
Method 2:
~ 219 ~
Establish new coordinate system 𝑂ℎ |∆𝜀1,𝑞 − 𝒊ℎ |∆𝜀1,𝑞 , 𝒋ℎ |∆𝜀1,𝑞 , 𝒌ℎ |∆𝜀1,𝑞 as follow:
⃗⃗⃗⃗⃗⃗⃗⃗ℎ |
𝑂𝑂 = 𝑹0𝑝 |∆𝜀 + 𝑟0 𝒊ℎ |∆𝜀1,𝑞 ,
∆𝜀 1,𝑞 1,𝑞
𝒊ℎ |∆𝜀1,𝑞 = 𝑵0𝑝 |∆𝜀 = 𝑁0𝑝𝑥 |∆𝜀 𝒊 + 𝑁0𝑝𝑦 |∆𝜀 𝒋,

1,𝑞 1,𝑞 1,𝑞
(2.3.5-22)
𝒌ℎ |∆𝜀1,𝑞 = (𝑁0𝑝𝑦 |∆𝜀 𝒊 − 𝑁0𝑝𝑥 |∆𝜀 𝒋) sin 𝛼 + cos 𝛼 𝒌,
1,𝑞 1,𝑞
𝒋ℎ |∆𝜀1,𝑞 = (−𝑁0𝑝𝑦 |∆𝜀 𝒊 + 𝑁0𝑝𝑥 |∆𝜀 𝒋) cos 𝛼 + sin 𝛼 𝒌.

1,𝑞 1,𝑞 }
Where: 𝑹0𝑝 |∆𝜀 is position vector of pitch point defined in expression (1.4.10-6) and 𝑵0𝑝 |∆𝜀
1,𝑞 1,𝑞
is unit normal to pitch curve decided by expression (1.4.10-13). Both 𝑹0𝑝 |∆𝜀 and 𝑵0𝑝 |∆𝜀 are
1,𝑞 1,𝑞
evaluated at rotating angle ∆𝜀1,𝑞 + 𝜀1,𝑞 .
With help of expressions (2.3.4-5) and (2.3.5-22), 𝑵𝑝 |∆𝜀 is derived as follow:

1,𝑞
𝑵𝑝 |∆𝜀 = 𝐴𝑝 |∆𝜀 𝒊 + 𝐵𝑝 |∆𝜀 𝒋 = − (𝐴ℎ𝑝 𝒊ℎ |∆𝜀1,𝑞 + 𝐵ℎ𝑝 𝒋ℎ |∆𝜀1,𝑞 + 𝐶ℎ𝑝 𝒌ℎ |∆𝜀1,𝑞 ) (2.3.5-23)
1,𝑞 1,𝑞 1,𝑞
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are calculated by expression (2.3.2-49) and,
𝐴𝑝 |∆𝜀 = −𝐴ℎ𝑝 𝑁0𝑝𝑥 |∆𝜀 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁0𝑝𝑦 |∆𝜀 ,
1,𝑞 1,𝑞 1,𝑞
}
𝐵𝑝 |∆𝜀 = −𝐴ℎ𝑝 𝑁0𝑝𝑦 |∆𝜀 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁0𝑝𝑥 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞
Then,
∆𝑝 |∆𝜀 = 𝑠𝑛 𝑵𝑝 |∆𝜀 = 𝑠𝑛 (𝐴𝑝 |∆𝜀 𝒊 + 𝐵𝑝 |∆𝜀 𝒋) (2.3.5-24)

1,𝑞 1,𝑞 1,𝑞 1,𝑞
Where: 𝑠𝑛 is calculated by expression (2.3.5-14). 𝐴𝑝 |∆𝜀 and 𝐵𝑝 |∆𝜀 are decided by expression
1,𝑞 1,𝑞
(2.3.5-20) or (2.3.5-23).
Conjugate cutting point 𝑃 on tooth profile of right-flank of tooth space of workpiece 1

corresponding to ∆𝜀1,𝑞 + 𝜀1,𝑞 is derived by substitution of expressions (2.3.5-16) and (2.3.5-24)
into (2.3.5-15) as follow:

1,𝑞 1,𝑞 1,𝑞 1,𝑞 1,𝑞
~ 220~
Where: arc-length 𝑠0 of pitch curve is used as independent variable.
𝑥𝑝 |∆𝜀 = 𝑥0𝑝 |∆𝜀 + 𝑠𝑛 𝐴𝑝 |∆𝜀 ,

1,𝑞 1,𝑞 1,𝑞
}
𝑦𝑝 |∆𝜀 = 𝑦0𝑝 |∆𝜀 + 𝑠𝑛 𝐵𝑝 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞

Point 𝑹1 |∆𝜀1,𝑞 on 𝑞th tooth profile of workpiece 1 in initial position is obtained by rotating
𝑹1𝑝 |∆𝜀 an angle −(∆𝜀1,𝑞 + 𝜀1,𝑞 ) about 𝒌 as an axis, that is,
1,𝑞
𝑹1 |∆𝜀1,𝑞 = [−(∆𝜀1,𝑞 + 𝜀1,𝑞 ) 𝒌 ] ⊗ 𝑹1𝑝 |∆𝜀 = 𝑥|∆𝜀1,𝑞 𝒊 + 𝑦|∆𝜀1,𝑞 𝒋 (2.3.5-26)

1,𝑞
Where: ∆𝜀1,𝑞 + 𝜀1,𝑞 is calculated by expression (2.3.5-5) for left-flank and expression (2.3.5-17)
for right-flank. 𝑥𝑝 |∆𝜀 and 𝑦𝑝 |∆𝜀 are decided by expression (2.3.5-12) for left-flank and
1,𝑞 1,𝑞
expression (2.3.5-25) for right-flank, then,
𝑥|∆𝜀1,𝑞 = 𝑥𝑝 |∆𝜀 cos(∆𝜀1,𝑞 + 𝜀1,𝑞 ) + 𝑦𝑝 |∆𝜀 sin(∆𝜀1,𝑞 + 𝜀1,𝑞 ) ,

1,𝑞 1,𝑞
}
𝑦|∆𝜀1,𝑞 = −𝑥𝑝 |∆𝜀 sin(∆𝜀1,𝑞 + 𝜀1,𝑞 ) + 𝑦𝑝 |∆𝜀 cos(∆𝜀1,𝑞 + 𝜀1,𝑞 ) .
1,𝑞 1,𝑞
Likewise, unit normal 𝑵1 |∆𝜀1,𝑞 to 𝑞th tooth profile of workpiece 1 in initial position is derived as
follow:
𝑵1 |∆𝜀1,𝑞 = [−(∆𝜀1,𝑞 + 𝜀1,𝑞 ) 𝒌 ] ⊗ 𝑵𝑝 |∆𝜀 = 𝐴|∆𝜀1,𝑞 𝒊 + 𝐵|∆𝜀1,𝑞 𝒋 (2.3.5-27)

1,𝑞
Where: 𝐴𝑝 |∆𝜀 and 𝐵𝑝 |∆𝜀 are calculated by expression (2.3.5-7) or (2.3.5-10) for left-flank
1,𝑞 1,𝑞
and expression (2.3.5-20) or (2.3.5-23) for right-flank, thus,
𝐴|∆𝜀1,𝑞 = 𝐴𝑝 |∆𝜀 cos(∆𝜀1,𝑞 + 𝜀1,𝑞 ) + 𝐵𝑝 |∆𝜀 sin(∆𝜀1,𝑞 + 𝜀1,𝑞 ) ,

1,𝑞 1,𝑞
}
𝐵|∆𝜀1,𝑞 = −𝐴𝑝 |∆𝜀 sin(∆𝜀1,𝑞 + 𝜀1,𝑞 ) + 𝐵𝑝 |∆𝜀 cos(∆𝜀1,𝑞 + 𝜀1,𝑞 ) .
1,𝑞 1,𝑞

Point 𝑹2 |∆𝜀1,𝑞 on 𝑞th tooth profile of workpiece 2 in initial position is obtained as follow:
𝑹2 |∆𝜀1,𝑞 = [−(∆𝜀2,𝑞 + 𝜀2,𝑞 )𝝎′ ] ⊗ [𝑹1𝑝 |∆𝜀 − (𝑙𝒑)|∆𝜀1,𝑞 ] = 𝑥 ′ |∆𝜀1,𝑞 𝒊 + 𝑦 ′ |∆𝜀1,𝑞 𝒋 (2.3.5-28)
1,𝑞
~ 221 ~
Where: 𝑹1𝑝 |∆𝜀 is decided by expression (2.3.5-12) for right-flank of tooth thickness of
1,𝑞
workpiece 2 and expression (2.3.5-25) for left-flank of tooth thickness of workpiece 2, then,
𝑥 ′ |∆𝜀1,𝑞 = (𝑥𝑝 |∆𝜀 − 𝑓|∆𝜀1,𝑞 ) cos(∆𝜀2,𝑞 + 𝜀2,𝑞 ) − (𝑦𝑝 |∆𝜀 − ℎ|∆𝜀1,𝑞 ) sin(∆𝜀2,𝑞 + 𝜀2,𝑞 ) ,
1,𝑞 1,𝑞
}
′|
𝑦 ∆𝜀1,𝑞 = (𝑥𝑝 | − 𝑓|∆𝜀1,𝑞 ) sin(∆𝜀2,𝑞 + 𝜀2,𝑞 ) + (𝑦𝑝 | − ℎ|∆𝜀1,𝑞 ) cos(∆𝜀2,𝑞 + 𝜀2,𝑞 ) .
∆𝜀1,𝑞 ∆𝜀1,𝑞
and
∆𝜀1,𝑞 +𝜀1,𝑞 𝑑𝜀2 ∆𝜀1,𝑞 +𝜀1,𝑞
∆𝜀2,𝑞 + 𝜀2,𝑞 = ∫0 𝑑𝜀1 = ∫0 𝑀 𝑑𝜀1 (2.3.5-29)
𝑑𝜀1
Here: ∆𝜀1,𝑞 + 𝜀1,𝑞 is calculated by expression (2.3.5-5) for right-flank of tooth thickness of
workpiece 2 and expression (2.3.5-17) for left-flank of tooth thickness of workpiece 2.
Unit normal 𝑵2 |∆𝜀1,𝑞 to 𝑞th tooth profile of workpiece 2 in initial position is derived as follow:
𝑵2 |∆𝜀1,𝑞 = −[−(∆𝜀2,𝑞 + 𝜀2,𝑞 )𝝎′ ] ⊗ 𝑵𝑝 |∆𝜀 = 𝐴′ |∆𝜀1,𝑞 𝒊 + 𝐵 ′ |∆𝜀1,𝑞 𝒋 (2.3.5-30)

1,𝑞
Where: ∆𝜀2,𝑞 + 𝜀2,𝑞 is calculated by expression (2.3.5-29). 𝑵𝑝 |∆𝜀 is calculated by expression

1,𝑞
(2.3.5-7) or (2.3.5-10) for right-flank of tooth thickness of workpiece 2 and expression (2.3.5-20)
or (2.3.5-23) for left-flank of tooth thickness of workpiece 2, then,
𝐴′ |∆𝜀1,𝑞 = −𝐴𝑝 |∆𝜀 cos(∆𝜀2,𝑞 + 𝜀2,𝑞 ) + 𝐵𝑝 |∆𝜀 sin(∆𝜀2,𝑞 + 𝜀2,𝑞 ) ,

1,𝑞 1,𝑞
}
𝐵 ′ |∆𝜀1,𝑞 = −𝐴𝑝 |∆𝜀 sin(∆𝜀2,𝑞 + 𝜀2,𝑞 ) − 𝐵𝑝 |∆𝜀 cos(∆𝜀2,𝑞 + 𝜀2,𝑞 ) .
1,𝑞 1,𝑞

1) Motion of Machining
Hobbing process of tooth profile is composed of six basic motions with respect to machine
coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ) as shown in figure 2.3.5 -3, that is,
A. Rotary movement of workpiece about an axis 𝑲𝑚 of work table.

B. Rotary movement of hob spindle about axis 𝒌𝑛 of hob.
C. Radial movement along distance of rotating centers between workpiece and hob.
D. Circumference movement of Hob.
E. Axial stroke of hob.
F. Relief movement of hob.
~222 ~
Motion 𝐴
𝑲𝑚 𝑂𝑚 𝑱𝑚
Motion 𝐶
Motion 𝐵 (𝑙𝒑)ℎ 𝑃0
𝐷 𝑂ℎ
𝒌ℎ Motion 𝐷
𝒊ℎ (𝑵0𝑝 )
𝑰𝑚
Figure 2.3.5 -3 Motion of Hob process
With respect to machine coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ), rotary angle of both

workpiece 1 and 2 should be adjusted by a compensate angle ∆𝜀𝑚,𝑞 as shown in figure 2.2.1-4,
that is,
𝑁0𝑝𝑦 |
∆𝜀1,𝑞
∆𝜀𝑚,𝑞 = tan−1 (𝑁 ) (2.3.5-31)
0𝑝𝑥 |∆𝜀
1,𝑞
2) Machine Setting Parameters for Workpiece 1 (as shown in figure 2.3.5-4)
A. Calculation of Rotating Angle 𝜀1𝑚 of workpiece 1
With respect to machine coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ), rotating angle 𝜀1𝑚 of

workpiece 1 about 𝑲𝑚 as an axis is
𝜀1𝑚 = 𝜀1,𝑞 + ∆𝜀1,𝑞 − ∆𝜀𝑚,𝑞 (2.3.5-32)
Where: 𝜀1,𝑞 and ∆𝜀1,𝑞 are calculated by expression (2.3.5-5) for left-flank and expression (2.3.5-
17) for right-flank of workpiece 1. ∆𝜀𝑚,𝑞 is decided by expression (2.3.5-31).
~223 ~
𝑹0𝑝 |∆𝜀 rotating axis of hob 2 𝒌 × 𝑵0𝑝 |∆𝜀
1,𝑞 1,𝑞
𝑂 ∆𝜀𝑚,𝑞
(𝑙𝒑)′ℎ 𝑓1𝑚 𝒋
∆𝑠2 rotating axis of hob 1
𝑂ℎ′
𝑃0 (𝑙𝒑)ℎ
𝒌ℎ (𝑙𝒑) ∆𝑠1
𝑓2𝑚 𝑂ℎ 𝒋′
𝑂′
𝒌ℎ 𝑵0𝑝 |∆𝜀
1,𝑞
Pitch curve of workpiece 1 𝒊 𝒊′ Pitch curve of workpiece 2
Figure 2.3.5-4 Machine Setting Parameters
B. Calculation of Translation parameter 𝑓1𝑚 of Motion 𝐶 and ∆𝑠1of Motion 𝐷 for Hob 𝐶
𝑓1𝑚 𝑵0𝑝 |∆𝜀 = 𝑹0𝑝 |∆𝜀 + 𝑟0 𝑵0𝑝 |∆𝜀 + ∆𝑠1 (𝒌 × 𝑵0𝑝 |∆𝜀 )
1,𝑞 1,𝑞 1,𝑞 1,𝑞
Thus, 𝑓1𝑚 and ∆𝑠1 are obtained from solution to equation above as follow:
𝑓1𝑚 = 𝑥0𝑝 |∆𝜀 𝑁0𝑝𝑥 |∆𝜀 + 𝑦0𝑝 |∆𝜀 𝑁0𝑝𝑦 |∆𝜀 + 𝑟0 ,

1,𝑞 1,𝑞 1,𝑞 1,𝑞
} (2.3.5-33)
∆𝑠1 = 𝑥0𝑝 |∆𝜀 𝑁0𝑝𝑦 |∆𝜀 − 𝑦0𝑝 |∆𝜀 𝑁0𝑝𝑥 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞 1,𝑞
C Rotating Angle 𝜀ℎ of Hob 𝐶 for Workpiece 1
Rotating angle 𝜀ℎ of hob 𝐶 for workpiece 1 is calculated by expression (2.3.4-14)

𝑠0
𝜀ℎ = 𝑏 (2.3.5-34)
𝑎 cos 𝛾0
~ 224~
Where: 𝑠0 is arc-length of pitch curve which is independent variable.
Manufacturing process of workpiece 1 is as shown in figure 2.3.5-5
𝑂𝑚 𝑱𝑚
𝑓1𝑚
𝑃0
𝑂ℎ
𝒌ℎ 𝑑𝑠1 𝒌 × 𝑵0𝑝 |∆𝜀

1,𝑞
𝑰𝑚
Figure 2.3.5-5 Manufacturing Process of Workpiece 1
3) Machine Setting Parameters for Workpiece 2 (as shown in figure 2.3.5-4)
A. Calculation of Rotating Angle 𝜀2𝑚 of workpiece 2
about 𝝎′ = −𝑲𝑚 is 𝜀2𝑚 , that is,
𝜀2𝑚 = ∆𝜀2,𝑞 + 𝜀2,𝑞 + ∆𝜀𝑚,𝑞 (2.3.5-35)
Where: 𝜀2,𝑞 and ∆𝜀2,𝑞 are calculated by expression (2.3.5-29). ∆𝜀𝑚,𝑞 is decided by expression
(2.3.5-35).
B. Calculation of Translation parameter 𝑓2𝑚 of Motion 𝐶 and ∆𝑠2of Motion 𝐷 for Hob 2
𝑓2𝑚 𝑵0𝑝 |∆𝜀 = (𝑙𝒑)|∆𝜀1,𝑞 − 𝑹0𝑝 |∆𝜀 + 𝑟0 𝑵0𝑝 |∆𝜀 + ∆𝑠2 (𝒌 × 𝑵0𝑝 |∆𝜀 )
1,𝑞 1,𝑞 1,𝑞 1,𝑞
~ 245 ~
Thus, 𝑓2𝑚 and ∆𝑠2 are obtained from solution to equation above as follow:
𝑓2𝑚 = 𝑟0 + (𝑓|∆𝜀1,𝑞 − 𝑥0𝑝 |∆𝜀 ) 𝑁0𝑝𝑥 |∆𝜀 + (ℎ|∆𝜀1,𝑞 − 𝑦0𝑝 |∆𝜀 ) 𝑁0𝑝𝑦 |∆𝜀 ,
1,𝑞 1,𝑞 1,𝑞 1,𝑞
} (2.3.5-36)
𝑑𝑠2 = (𝑓|∆𝜀1,𝑞 − 𝑥0𝑝 |∆𝜀 ) 𝑁0𝑝𝑦 |∆𝜀 − (ℎ|∆𝜀1,𝑞 − 𝑦0𝑝 |∆𝜀 ) 𝑁0𝑝𝑥 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞 1,𝑞
C. Rotating Angle 𝜀ℎ′ of Hob 𝐶̅ for Workpiece 2
Rotating angle 𝜀ℎ′ of hob 𝐶̅ for workpiece 2 is calculated by expressions (2.3.4-14) and (2.3.4-21)
𝑟𝑏 𝑠0 𝑠
𝜀ℎ′ = 0
= − 𝑏′ cos (2.3.5-37)
𝑟𝑏′ 𝑏𝑎 cos 𝛾0 𝑎 𝛾 0
Alternatively, if a pair of left-hand hob 𝐶 and right-hand hob 𝐶̅ are used to generate same a pair
of tooth profiles 𝐴 and 𝐴̅, then, left-flank of tooth space of workpiece 1 is made by left-flank of
helicoid of hob 𝐶 and right-flank of tooth space of workpiece 1 is made by right-flank of helicoid
of hob 𝐶 , therefore, unit normal to helicoid of hob 𝐶 with left-hand is
𝑵′𝑝ℎ = 𝐴′𝑝ℎ 𝒊ℎ + 𝐵𝑝ℎ

′ ′
𝒋ℎ + 𝐶𝑝ℎ 𝒌ℎ = 𝐴ℎ𝑝 𝒊ℎ − 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ (2.3.5-38)
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are components of unit normal to corresponding helicoid of right-
hand hob 𝐶.
Accordingly, mounting angle of hobs 𝛼 is as follow:

𝜋
𝛼 = 2 − 𝛾0 (2.3.5-39)
𝒌ℎ 𝑂ℎ′ 𝒌 × 𝑵0𝑝 |∆𝜀

1,𝑞
𝑃0
𝑓2𝑚
𝑑𝑠2
𝑂𝑚 𝑱𝑚
𝑰𝑚
Figure 2.3.5-6 Motion Parameters for Workpiece 2
~ 226 ~
𝑑𝜀 𝑑𝜀 ′
Also, direction of rotating angle of hobs changes opposite way, that is, 𝑑𝜀ℎ < 0 and 𝑑𝜀ℎ < 0,
1 1
Substitution of expressions (2.3.5-38) and (2.3.5-39) into expressions (2.3.4-17), (2.3.4-20) and
expression (2.3.5-10) or (2.3.5-23) shows that corresponding effective relative velocities and
unit normal to tooth profile keep unchanged. Therefore, tooth profiles of workpieces made by a
pair of right-hand hob 𝐶 and left-hand hob 𝐶̅ are identical to tooth profiles made by a pair of
left-hand hob 𝐶 and right-hand hob 𝐶̅ but with same radius of base circle and rate of helical
lead.
Manufacturing process of workpiece 2 is as shown in figure 2.3.5-6.

Let point 𝑃(𝑹1𝑝 ) be conjugate contact point on tooth profile 𝐴 of workpiece 1 at instant
rotating angle 𝜀1 , 𝑵𝑝 be unit normal to tooth profile 𝐴 of workpiece 1 at corresponding point
𝑃(𝑹1𝑝 ) and 𝝉 be unit tangent to tooth profile 𝐴 at corresponding point 𝑃(𝑹1𝑝 ) as shown in
𝝉 = 𝑵𝑝 × 𝒌 (2.3.6-1)
Point 𝑃0 is a pitch point on pitch curve 𝐴0 of tooth profile 𝐴 corresponding to point 𝑃(𝑹1𝑝 ) and
𝑵0𝑝 is unit normal to pitch curve 𝐴0 of tooth profile 𝐴. 𝝉0 is unit tangent to pitch curve 𝐴0 of
tooth profile 𝐴 corresponding to 𝑵0𝑝 , that is,
𝝉0 = 𝑵0𝑝 × 𝒌 (2.3.6-2)
Let point 𝑃′ be a point on tooth profile 𝐴 adjacent to point 𝑃 as shown in figure 2.3.6-1.
Unit normal to tooth profile 𝐴 at point 𝑃′ is as follow:

𝑑𝑵𝑝 1
𝑵𝑝′ = 𝑵𝑝 + ( ) 𝑑𝑠𝜏 = 𝑵𝑝 + 𝑑𝑠𝜏 𝝉 (2.3.6-3)
𝑑𝑠 𝝉 𝜌1
Where: 𝜌1 is curvature radius of tooth profile 𝐴 at point 𝑃.
Unit normal to tooth profile 𝐴 at point 𝑃′ in conjugate contact position is as follow:

𝑝 1
𝑵𝑝′ = (𝑑𝜀1 𝒌) ⊗ 𝑵𝑝′ = 𝑵𝑝′ + 𝑑𝜀1 𝒌 × 𝑵𝑝′ = 𝑵𝑝 + 𝜌 𝑑𝑠𝜏 𝝉 + 𝑑𝜀1 𝒌 × 𝑵𝑝 (2.3.6-4)
1
~ 227 ~
Where: 𝑑𝜀1 is calculated by expression (1.4.10-16), that is,
𝑑𝜀 1+𝑀
( 𝑑𝑠1) = |𝑱0 |
0 𝜏0
𝑂 𝒋
𝑹1𝑝 𝑹0𝑝 (𝑃0 ) 𝑠𝑛
Pitch curve 𝐴0 of tooth profile 𝐴 𝝉0 𝑑𝑠0 𝑃 Tooth profile 𝐴
𝑑𝑠𝜏
𝑃′ 𝑵0𝑝 𝑵𝑝
𝑑𝑵𝑝
𝒊 𝝉 𝑵𝑝 + ( ) 𝑑𝑠𝜏
𝑑𝑠 𝝉
Figure 2.3.6-1 Differential Region of Conjugate Contact Point 𝑃 on Tooth Profile 𝐴
Corresponding to point 𝑃 on tooth profile 𝐴, point 𝑃 is also a point on involute helicoid of hob
𝐶. Unit normal 𝑵ℎ𝑝 to involute helicoid of hob 𝐶 at point 𝑃 is parallel to 𝑵𝑝 in conjugate
contact position, that is,
𝑵𝑝 = −𝑵𝑝ℎ (2.3.6-5)
Where: 𝑵𝑝ℎ is decided by expression (2.3.2-35) for right-flank of helicoid of hob 𝐶 and
expression (2.3.2-49) for left-flank of helicoid of hob 𝐶.
Point 𝑃′′ on involute helicoid of hob 𝐶 adjacent to point 𝑃 is a conjugate point to point 𝑃′ on
tooth profile 𝐴 as shown in figure 2.3.6-2. By neglecting second or higher order infinitesimal,
point 𝑃′′ on involute helicoid of hob 𝐶 is expressed as
⃗⃗⃗⃗⃗⃗⃗⃗
𝑃𝑃′′ = 𝑑𝑠𝜏′ 𝝉′ (2.3.6-6)
Unit tangent 𝝉′ to involute helicoid of hob 𝐶 at point 𝑃 is as shown figure 2.3.6-2, that is,
𝝉′ = cos 𝜆 𝜻𝑝 + sin 𝜆 𝑵ℎ𝑝 × 𝜻𝑝 (2.3.6-7)
Where: 𝜻𝑝 is determined by expression (2.3.2-36) for right-flank of helicoid of hob 𝐶 and
~ 228 ~
expression (2.3.2-50) for left-flank of helicoid of hob 𝐶.
Unit normal to involute helicoid of hob 𝐶 at point 𝑃′′ is as shown figure 2.3.6-2, that is,
𝑑𝑵
𝑵ℎ𝑝′′ = 𝑵ℎ𝑝 + ( 𝑑𝑠ℎ𝑝 ) 𝑑𝑠𝜏′ (2.3.6-8)
𝜏′ 𝜏′
𝑵ℎ𝑝′′ reaches instantaneous contact position with point 𝑃′ on tooth profile 𝐴 as follow:
𝑑𝑵ℎ𝑝 𝑑𝑵
(𝑑𝜀ℎ 𝒌ℎ ) ⊗ [𝑵ℎ𝑝 + ( ) 𝑑𝑠𝜏′ ] = 𝑵ℎ𝑝 + ( ℎ𝑝 ) 𝑑𝑠𝜏′ + (𝑑𝜀ℎ 𝒌ℎ ) × 𝑵ℎ𝑝 (2.3.6-9)
𝑑𝑠𝜏′ 𝑑𝑠 𝜏′
𝜏′ 𝜏′
Because unit normal to involute helicoid of hob 𝐶 at instantaneous contact point is constant
with respect to hob 𝐶 coordinate system 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ , that is,
𝑑𝑵
𝑵ℎ𝑝 = (𝑑𝜀ℎ 𝒌ℎ ) ⊗ [𝑵ℎ𝑝 + ( 𝑑𝑠ℎ𝑝 ) 𝑑𝑠𝜏′ ] (2.3.6-10)
𝜏′ 𝜏′
Tangent plane to involute helicoid of hob 𝐶 at point 𝑃
𝑵ℎ𝑝 𝑵ℎ𝑝 × 𝜻𝑝 𝑵ℎ𝑝′′
𝒌ℎ 𝑑𝑠𝜏′ 𝝉′
𝑃 𝜆 𝑃′′
𝜻𝑝
𝑃0 −𝑠𝑛 𝑵ℎ𝑝
𝑟0
𝑂ℎ 𝒋ℎ
𝒊ℎ
Figure 2.3.6-2 Tangent Plane to Involute Helicoid of Hob 𝐶 at Point 𝑃
~ 229 ~
𝑑𝑵ℎ𝑝
( ) 𝑑𝑠𝜏′ + (𝑑𝜀ℎ 𝒌ℎ ) × 𝑵ℎ𝑝 = 0 (2.3.6-11)
𝑑𝑠𝜏′
𝜏′
𝑑𝑵
Due to expressions (1.2.1-10), that is, ( 𝑑𝑠ℎ𝑝 ) = 𝛀𝜏′ × 𝑵ℎ𝑝 , then expression (2.3.6-11)
𝜏′ 𝜏′
becomes
𝑑𝑠 ′ 𝑑𝜀
[𝛀𝜏′ ( 𝑑𝑠𝜏 ) + ( 𝑑𝑠ℎ ) 𝒌ℎ ] × 𝑵ℎ𝑝 = 0 (2.3.6-12)
0 𝜏0 0 𝜏0
Point 𝑃′′ reaches conjugate cutting position with point 𝑃′ on tooth profile 𝐴 and with help of
expression (2.3.6-9) and neglecting second or higher order infinitesimal, unit normal 𝑵ℎ𝑝′′ to
involute helicoid of hob 𝐶 at point 𝑃′′ in conjugate cutting position is updated as follow:
𝑝 𝑑𝑵
𝑵ℎ𝑝′′ = (−𝑑𝜑𝒌) ⊗ {(𝑑𝜀ℎ 𝒌ℎ ) ⊗ [𝑵ℎ𝑝 + ( 𝑑𝑠ℎ𝑝 ) 𝑑𝑠𝜏′ ]}
𝜏′ 𝜏′
𝑑𝑵
= (−𝑑𝜑𝒌) ⊗ [𝑵ℎ𝑝 + ( 𝑑𝑠ℎ𝑝 ) 𝑑𝑠𝜏′ + (𝑑𝜀ℎ 𝒌ℎ ) × 𝑵ℎ𝑝 ]
𝜏′ 𝜏′
(2.3.6-13)
𝑑𝑵
= 𝑵ℎ𝑝 + ( 𝑑𝑠ℎ𝑝 ) 𝑑𝑠𝜏′ + (𝑑𝜀ℎ 𝒌ℎ ) × 𝑵ℎ𝑝 − 𝑑𝜑𝒌 × 𝑵ℎ𝑝
𝜏′ 𝜏′
= 𝑵ℎ𝑝 + (𝛀𝜏′ 𝑑𝑠𝜏′ + 𝑑𝜀ℎ 𝒌ℎ − 𝑑𝜑𝒌) × 𝑵ℎ𝑝
𝑝 𝑝
Due to 𝑵𝑝′ = −𝑵ℎ𝑝′′ , application of expressions (2.3.6-4), (2.3.6-5) and (2.3.6-13) results in
1
𝑑𝑠𝜏 𝝉 + 𝑑𝜀1 𝒌 × 𝑵𝑝 = (𝛀𝜏′ 𝑑𝑠𝜏′ + 𝑑𝜀ℎ 𝒌ℎ − 𝑑𝜑𝒌) × 𝑵𝑝
𝜌1
That is,
1 𝑑𝑠 𝑑𝜀 𝑑𝜑 𝑑𝑠 ′ 𝑑𝜀
(𝑑𝑠𝜏 ) 𝝉 = {− [( 𝑑𝑠1 ) + (𝑑𝑠 ) ] 𝒌 + [𝛀𝜏′ ( 𝑑𝑠𝜏 ) + ( 𝑑𝑠ℎ ) 𝒌ℎ ]} × 𝑵𝑝
𝜌1 0 𝜏0 0 𝜏0 0 𝜏0 0 𝜏0 0 𝜏0
Due to expressions (2.3.4-13), (2.3.6-1) and (2.3.6-12), dot product on both sides of equation
above with 𝝉 gives
1 𝑑𝑠
(𝑑𝑠𝜏 ) = 𝐾1𝑔0 (2.3.6-14)
𝜌1 0 𝜏0
~230 ~
𝝉 ∙𝝉 𝑵0𝑝 ∙𝑵𝑝
𝜌1 = 𝐾0 + 𝑠𝑛 = + 𝑠𝑛 (2.3.6-15)
1𝑔0 𝐾1𝑔0
Where: 𝑠𝑛 is calculated by expression (2.3.5-2) for left-flank of tooth space of workpiece 1 and
expression (2.3.5-12) for right-flank of tooth space of workpiece 1. 𝑵0𝑝 is determined by
expression (1.4.10-13). 𝐾1𝑔0 is determined by expression (1.4.10-26).

Curvature radius 𝜌2 of tooth profile 𝐴̅ of workpiece 2 is calculated by application of expression
(1.4.10-31), that is,
1
𝜌2 = 1 1 1 1 − 𝑠𝑛 (2.3.6-16)
(𝜌 + ) −
10 𝜌20 𝝉0∙𝝉 𝜌1−𝑠𝑛
1 1
Where: 𝜌 and 𝜌 are calculated by formular (1.4.10-29).
10 20
2.3.7 Limit Tooth Profile Angle of Hob

In order to generate tooth profile on both sides of pitch curve, it is necessary for tooth profile
to intersect with pitch curve as shown in figure 2.3.7-1.
Let 𝑵𝑝 be unit normal to tooth profile 𝐴 at point 𝑃 as shown in figure 2.3.7-1 and 𝑵ℎ𝑝 be unit
normal to involute helicoid of hob 𝐶, that is, 𝑵𝑝 = −𝑵ℎ𝑝 .
𝝉0 is unit tangent to pitch curve at pitch point 𝑃0 corresponding to point 𝑃 on tooth profile 𝐴
and is calculated as follow:
𝝉0 = (−𝛾0 𝒊ℎ ) ⊗ 𝒌ℎ = sin 𝛾0 𝒋ℎ + cos 𝛾0 𝒌ℎ (2.3.7-1)
Distance between 𝑃0 and 𝐷 is as shown in figure 2.3.7-1, that is,
̅̅̅̅̅
𝑃0 𝐷 = |𝑠𝑛 𝑵𝑝 ∙ 𝝉0 | = |𝑠𝑛 𝑵ℎ𝑝 ∙ 𝝉0 | = |𝑠𝑛 (𝐵ℎ𝑝 sin 𝛾0 + 𝐶ℎ𝑝 cos 𝛾0 )|
𝑠𝑛 𝑠𝑛 (2.3.7-2)
=| cos 𝛾0 (𝑏𝑎 cos 𝛼0 tan 𝛾0 + 𝑟𝑏 )| = | 𝑟0 cos 𝛼0 |
Where: 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are decided by expression (2.3.2-35) for right-hand hob and expression
(2.3.2-40) for left-hand hob. 𝑠𝑛 is calculated by expression (2.3.5-2) for right-hand hob and
expression (2.3.5-12) for left-hand hob.
~ 231 ~
tooth profile 𝐴 inside of pitch curve 𝐴0 tooth profile 𝐴 outside of pitch curve 𝐴0
𝑃
𝑠𝑛 𝑵𝑝 Σ
𝜌0
𝐷
𝑃0
𝝉0 𝒊ℎ (𝑵0𝑝 )
Figure 2.3.7-1 Limit Tooth Profile Angle
And
1
̅̅̅̅̅
Σ = 2𝜌 (𝑃 0 𝐷)
2
(2.3.7-3)
0
Distance between 𝑃 and 𝐷 is as follow:
1 1
̅̅̅̅
𝑃𝐷 = |𝑠𝑛 𝑵𝑝 ∙ 𝒊ℎ | = |𝑠𝑛 𝐴ℎ𝑝 | = | 𝑠𝑛 𝑏𝑎 sin 𝛼0 | = | 𝑠𝑛 𝑟0 tan 𝛾0 sin 𝛼0 | (2.3.7-4)
Limit condition is as follow:
̅̅̅̅
𝑃𝐷 ≥ Σ
That is,
2
1 1 𝑠𝑛
| 𝑠𝑛 𝑟0 tan 𝛾0 sin 𝛼0 | ≥ 2𝜌 ( 𝑟0 cos 𝛼0 )
√𝑟𝑏2 +𝑏𝑎2 0 cos 𝛾0 √𝑟𝑏2 +𝑏𝑎2
Then, equation above is reduced to as follow:

1
tan 𝛾0 sin 𝛼0 ≥ |𝑠𝑛 |𝑟0 cos2 𝛼0
2𝜌0 √𝑟𝑏2 +𝑏𝑎2 cos2 𝛾0
~ 232 ~
Substitution of expression (2.3.5-2) or (2.3.5-14) into expression above is
1 |∆𝑠0 |
tan3 𝛼0 + sin2 𝛾 tan 𝛼0 − 2𝜌 3𝛾
≥0 (2.3.7-5)
0 0 sin 0
1 |∆𝑠0 | |𝑖𝛿𝑠0 |
Let 𝐹 = sin2 𝛾 and 𝐺 = − 2𝜌 3
= − 2𝜌 3𝛾
0 0 sin 𝛾0 0 sin 0
Then
𝐺 2 𝐹 3 √ 𝐺 𝐺 2 𝐹 3
𝟑 𝟑
√ 𝐺
tan 𝛼0𝑚𝑖𝑛 √ √
= − + ( ) +( ) + − − ( ) +( )
2 2 3 2 2 3
𝜌0
𝑃0 tooth profile 𝐴
𝝉0 𝒊ℎ (𝑵0𝑝 )
Figure 2.3.7-2 Tooth Profile 𝐴 in Case of 𝛼0 = 𝛼0𝑚𝑖𝑛
That is,
𝟑 2 3 𝟑 2 3
𝐺 𝐺 𝐹 𝐺 𝐺 𝐹
𝛼0𝑚𝑖𝑛 = tan−1 [ √− 2 + √( 2 ) + (3) + √− 2 − √( 2 ) + ( 3) ] (2.3.7-6)
If 𝛼0 < 𝛼0𝑚𝑖𝑛 for helicoid of hob, tooth profile 𝐴 generated by such hob is as shown in figure
2.3.7-2.
Example 2.3.1 continue Example 1.4.1.
Given Condition:
Parameters of Hob
~ 233 ~
In sum:
1 𝑏
𝑃𝑑 = 0.4, 𝑏𝑎 = 2𝑃 = 1.25, 𝑟0 = 35.0 𝑚 = 40, 𝛾0 = tan−1 ( 𝑟𝑎) = 2.04(𝑑𝑒𝑔. ),
𝑑 0
𝜋 𝑝 }
𝑝 = 𝑃 cos 𝛾0 , 𝛿𝑠0 = 𝑚, 𝑠0 = 123.438, 𝑁 = 15.
𝑑
𝑑𝜀 𝜀
1 1
Step 3. Calculation of Limit Tooth Profile Angle 𝛼0𝑚𝑖𝑛
𝛼0𝑚𝑖𝑛 = 0.0;
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 < 𝑁; 𝑞 + +)
{
1 0 |𝑖𝛿𝑠 |
𝑞
𝐹 = sin2 𝛾 , 𝐺 = − 𝐾1𝑔0,𝑖−1
0 2 sin3 𝛾 0
𝟑 2 3 𝟑 2 3
𝑖𝑓(tan−1 [ √− 2 + √( 2 ) + ( 3) + √− 2 − √( 2 ) + (3) ] > 𝛼0𝑚𝑖𝑛 )
𝟑 2 3 𝟑 2 3
𝛼0𝑚𝑖𝑛 = tan−1 [ √− 2 + √( 2 ) + ( 3) + √− 2 − √( 2 ) + ( 3) ] Exp. (2.3.7-6)
~ 234 ~
}
Solution: 𝛼0𝑚𝑖𝑛 = 82.23.
Select: 𝛼0 = 85.00.
Step 4: Calculation of Parameters for Helicoid of Hob.
𝑟𝑏 = 𝑟0 cos 𝛼0
For right-flank of involute helicoid of hob

1
𝐴ℎ𝑝 = − 𝑏𝑎 sin 𝛼0 ,
1 𝑟𝑏 exp. (2.3.2-35)
𝐵ℎ𝑝 = 𝑏𝑎 cos 𝛼0 , 𝐶ℎ𝑝 = .
}
And for left-flank of involute helicoid of hob
1
𝐴ℎ𝑝 = − 𝑏𝑎 sin 𝛼0 ,
1 𝑟𝑏 Exp. (2.3.2-45)
𝐵ℎ𝑝 = − 𝑏𝑎 cos 𝛼0 , 𝐶ℎ𝑝 = − .
}
Step 5. Calculation for Rotary Angle of Hob, that is, expression (2.3.5-8)
𝑁𝑜𝑝𝑦 |
𝜀1,0
𝜑𝑞=0 = − tan−1 ( 𝑁 )
𝑜𝑝𝑥 | 𝜀10
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 < 𝑁; 𝑞 + +)
∆0 𝜑𝑞 = 0,
~ 235 ~
𝑑𝜀1
∆𝑖 𝜑𝑞 = ∆𝑖−1 𝜑𝑞 + [𝐾1𝑔0 | −( ) | ] 𝛿𝑠0 Exp. (2.3.5-8)
∆𝑖−1 𝜀1,𝑞 𝑑𝑠0
𝜏0
∆𝑖−1 𝜀1,𝑞
If (𝑞 > 0)
𝜑𝑞 = 𝜑𝑞−1 + ∆𝑚 𝜑𝑞
Step 6. Calculation for Unit Normal to Tooth Profile in Cutting Position, i.e., expression (2.3.5-7)
or expression (2.3.5-10)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 < 𝑁; 𝑞 + +)

1,𝑞 1,𝑞 1,𝑞
}
1,𝑞 1,𝑞 1,𝑞
Step 7. Calculation for Point on Helicoid of Hob in Cutting Position, i.e., expression (2.3.5-10)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 < 𝑁; 𝑞 + +)
~ 236 ~
𝑖𝑟𝑏 𝛿𝑠0
𝑠𝑛,𝑖 =
cos 𝛾0 √𝑟𝑏2 +𝑏𝑎2
𝑖𝛿𝑠0 𝑟𝑏
𝑠𝑛,𝑖 = −
cos 𝛾0 √𝑟𝑏2 +𝑏𝑎2
𝑥𝑝 |∆𝜀 = 𝑥0𝑝 |∆𝜀 + 𝑠𝑛 𝐴𝑝 |∆𝜀 ,

1,𝑞 1,𝑞 1,𝑞
}
𝑦𝑝 |∆𝜀 = 𝑦0𝑝 |∆𝜀 + 𝑠𝑛 𝐵𝑝 |∆𝜀 .
1,𝑞 1,𝑞 1,𝑞
Step 8. Calculation for Tooth Profiles of Workpiece 1 & 2
Same as Step 6 in Example 2. 1-1.
Example 2.3.1-a A Pair of Gear Sets
~ 237 ~
Example 2.3.1-b Manufacturing Process of Workpiece
Example 2.3.1-c Manufacturing Process of Workpiece 2
~ 238 ~
Chapter 4
Non-Circular Helical Gear Manufactured by Involute Hob
2.4.1 Effective Relative Velocity and Motion Requirements

1 Relative Motion of Workpieces with Respect to Hobs
Relative motion relationship among driving gear, driven gear, hob 𝐶 and hob 𝐶̅ are as follow:
Driving gear takes one motion:
1) Rotating by an angle 𝜀1 about 𝝎 = 𝒌 as an axis as shown in figure 2.4.1-1.
𝒋ℎ 𝒌 𝜑
𝒌 𝛼 −𝒌ℎ
𝜀1 𝑂ℎ′ 𝒌 𝜀ℎ
𝒌ℎ (𝜆𝒒)′ℎ 𝜎ℎ 𝜓 𝚪
(𝑙𝒑)′ℎ
𝑂 (𝜆𝒒)ℎ 𝒋ℎ 𝑟0 𝒋
(𝑙𝒑)ℎ 𝑹0𝑝
𝑃0 𝑂ℎ
𝑟0
𝒌ℎ 𝜀ℎ 𝜎ℎ
pitch curve of workpiece 1 𝜑 𝒊ℎ (𝑵0𝑝 )
−𝒌 𝒊ℎ (𝑵0𝑝 )
Figure 2.4.1-1 Coordinate System
~ 239 ~
Driven gear takes two motions
1) Rotating by an angle 𝜀2 about 𝝎′ = −𝒌 as an axis.

2) Displacement (𝑙𝒑).
Hob 𝐶 takes three motions as shown in figure 2.4.1-1
1) Rotating by an angle 𝜀ℎ about 𝒌ℎ , that is, rotation on its own axis.

2) Rotating by an angle 𝜑 about (−𝒌) as an axis.
3) Translation by (𝜆𝒒)ℎ = (𝑙𝒑)ℎ + 𝜎ℎ 𝒌 = 𝑓ℎ 𝒊 + ℎℎ 𝒋 + 𝜎ℎ 𝒌.
Hob 𝐶̅ takes three motions as shown in figure 2.4.1-1
1) Rotating by an angle 𝜀ℎ about −𝒌ℎ , that is, rotation on its own axis.
2) Rotating by an angle 𝜑 about (−𝒌) as an axis.
3) Translation by (𝜆𝒒)′ℎ = (𝑙𝒑)′ℎ + 𝜎ℎ 𝒌 = 𝑓ℎ′ 𝒊 + ℎℎ′ 𝒋 + 𝜎ℎ 𝒌.
Hibbing process is motion with two degrees of freedom, rotation angle 𝜀ℎ and axial feed 𝜎ℎ of
hob can be selected as two independent motion variables.
2 Establishing Coordinate System
Coordinate system 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ is for hob 𝐶 and 𝑂ℎ′ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ is for hob 𝐶̅ and their
relationships with coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 are as shown in figure 2.4.1-1, that is,
𝒊ℎ = 𝑵0𝑝 = 𝑁𝑜𝑝𝑥 𝒊 + 𝑁𝑜𝑝𝑦 𝒋,

𝒌ℎ = (𝛼𝒊ℎ ) ⊗ 𝒌 = cos 𝛼 𝒌 + sin 𝛼 𝒊ℎ × 𝒌 = (𝑁𝑜𝑝𝑦 𝒊 − 𝑁𝑜𝑝𝑥 𝒋) sin 𝛼 + cos 𝛼 𝒌,
𝒋ℎ = 𝒌ℎ × 𝒊ℎ = (−𝑁𝑜𝑝𝑦 𝒊 + 𝑁𝑜𝑝𝑥 𝒋) cos 𝛼 + sin 𝛼 𝒌,
⃗⃗⃗⃗⃗⃗⃗⃗ℎ = (𝑙𝒑)ℎ + 𝜎ℎ 𝒌 = 𝑓ℎ 𝒊 + ℎℎ 𝒋 + 𝜎ℎ 𝒌 = 𝑹0𝑝 + 𝑟0 𝒊ℎ + 𝜎ℎ 𝒌
(𝜆𝒒)ℎ = 𝑂𝑂
(2.4.1-1)
= (𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 )𝒊 + (𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 )𝒋 + 𝜎ℎ 𝒌.
𝑓ℎ = 𝑥0𝑝 + 𝑟0 𝑁𝑜𝑝𝑥 , ℎℎ = 𝑦0𝑝 + 𝑟0 𝑁𝑜𝑝𝑦 ,
(𝜆𝒒)ℎ = (𝑙𝒑)′ℎ + 𝜎ℎ 𝒌 = 𝑹0𝑝 − 𝑟0 𝒊ℎ + 𝜎ℎ 𝒌 = 𝑓ℎ′ 𝒊 + ℎℎ′ 𝒋 + 𝜎ℎ 𝒌,
′
𝑓ℎ′ = 𝑥0𝑝 − 𝑟0 𝑁𝑜𝑝𝑥 , ℎℎ′ = 𝑦0𝑝 − 𝑟0 𝑁𝑜𝑝𝑦 . }
Where: 𝑹0𝑝 = 𝑥0𝑝 𝒊 + 𝑦0𝑝 𝒋 is conjugate contact point on pitch curve and calculated in
expression (1.4.10-6). 𝑵0𝑝 = 𝑁𝑜𝑝𝑥 𝒊 + 𝑁𝑜𝑝𝑦 𝒋 is unit normal to pitch curve at conjugate contact
point and is calculated by expression (1.4.10-13).
A. Calculation of Mounting Angle 𝛼 of hobs:
~ 240 ~
Let 𝜓 be helical angle of workpiece 1 at pitch point 𝑃0 and 𝚪 be unit tangent to helical curve of
tooth profile 𝐴 of workpiece 1 at pitch point 𝑃0 , that is,
𝚪 = (−𝜓𝒊ℎ ) ⊗ 𝒌 = sin 𝜓 𝒌 × 𝒊ℎ + cos 𝜓 𝒌 = sin 𝜓 (𝑁𝑜𝑝𝑥 𝒋 − 𝑁𝑜𝑝𝑦 𝒊) + cos 𝜓 𝒌 (2.4.1-2)
Unit normal 𝑵ℎ𝑝 to helicoid of hob 𝐶 at corresponding conjugate cutting position is expressed
in formular (2.3.2-35) or (2.3.2-45). Application of expression (2.4.1-1) gives
𝑵ℎ𝑝 = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ

(𝐴ℎ𝑝 𝑁𝑜𝑝𝑥 − 𝐵ℎ𝑝 𝑁𝑜𝑝𝑦 cos 𝛼 + 𝐶ℎ𝑝 𝑁𝑜𝑝𝑦 sin 𝛼)𝒊 (2.4.1-3)
={ }
+(𝐴ℎ𝑝 𝑁𝑜𝑝𝑦 + 𝐵ℎ𝑝 𝑁𝑜𝑝𝑥 cos 𝛼 − 𝐶ℎ𝑝 𝑁𝑜𝑝𝑥 sin 𝛼)𝒋 + (𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼)𝒌
Due to 𝑵ℎ𝑝 ∙ 𝚪 = 0, that is,
(𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼) sin 𝜓 + (𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼) cos 𝜓 = 0
Then, with help of expression (2.3.4-8), application of equation above leads
𝐵 sin 𝛼+𝐶 cos 𝛼 tan 𝛾 sin 𝛼+cos 𝛼 𝜋

tan 𝜓 = 𝐶 ℎ𝑝 sin 𝛼−𝐵ℎ𝑝 cos 𝛼 = sin 𝛼−tan
0
= cot(𝛼 − 𝛾0 ) = tan ( 2 + 𝛾0 − 𝛼) (2.4.1-4)
ℎ𝑝 ℎ𝑝 𝛾 0 cos 𝛼
Then, mounting angle 𝛼 of hobs is derived as follow:
𝜋
𝛼 = 2 + 𝛾0 − 𝜓 (2.4.1-5)
Where: 𝛾0 is lead angle of involute helicoid on pitch cylinder.
B. Calculation of Rotation Angle of Driving Gear
In order to generate tooth profile with prescribed helical angle 𝜓, hob needs an additional
rotating angle 𝑑𝜀1,𝜓 corresponding to axial feeding 𝑑𝜎ℎ , in addition to 𝑑𝜀1,ℎ caused by rotating
angle 𝑑𝜀ℎ of hob as shown in figure 2.4.1-2.
1) Rate of Angular Increment 𝑑𝜀1,𝜓 of Driving Gear with Respect to Axial Feeding 𝑑𝜎ℎ ,
𝑑𝜀1,𝜓
that is, .
𝑑𝜎ℎ
At instant rotating angle 𝜀1 of driving gear, hob gives axial feeding 𝑑𝜎ℎ , accordingly, there is an
~ 241 ~
additional rotating angle 𝑑𝜀1,𝜓 of driving gear due to helical angle 𝜓.
Due to definition of helical angle 𝜓 of workpiece as shown in figure 2.4.1-2

𝑑𝑠 𝑑𝜀1,𝜓 𝑑𝑠𝜓
tan 𝜓 = − 𝑑𝜎𝜓 = −
ℎ 𝑑𝜎ℎ 𝑑𝜀1,𝜓
Then, rate of angular increment 𝑑𝜀1,𝜓 of driving gear with respect to axial feeding 𝑑𝜎ℎ is
𝑑𝜀1,𝜓 𝑑𝜀1,𝜓 𝑑𝜀
=− tan 𝜓 = − ( 𝑑𝑠1 ) tan 𝜓 (2.4.1-6)
𝑑𝜎ℎ 𝑑𝑠𝜓 0 𝜏0
𝑑𝜀1
Where: ( ) is decided by expression (1.4.10-16) and evaluated at rotating angle 𝜀1 of
𝑑𝑠0 𝜏
0
driving gear. 𝜎ℎ is axial feeding in direction of 𝒌 .
𝒌 𝜓 𝚪
𝑑𝑠𝜓
𝒊ℎ × 𝒌 𝛾0 − 𝜓
𝒌ℎ 𝛼 −𝑑𝜎ℎ
𝒊ℎ × 𝒌 𝑑𝑠0 𝛾0 − 𝜓
𝒌ℎ 𝑑𝜀ℎ 𝑏𝑎
Figure 2.4.1-2 Relationships of 𝑑𝑠0 with 𝜀ℎ and 𝑑𝑠𝜓 with 𝑑𝜎ℎ
2) Rate of Angular Increment 𝑑𝜀1,ℎ of Driving Gear with Respect to Angular Increment
𝑑𝜀ℎ of Hob 𝐶
Rate of angular increment of hob 𝐶 with respect to arc-length 𝑠0 of pitch curve is as shown in
𝑑𝜀ℎ 1
=𝑏 (2.4.1-7)
𝑑𝑠0 𝑎 cos(𝛾0 −𝜓 )
Where: 𝑏𝑎 is rate of lead of helicoid of hob 𝐶.
Thus, with help of expression (2.4.1-7), rotating angle 𝜀1,ℎ of driving gear caused by rotating
angle 𝑑𝜀ℎ of hob is calculated as follow:
~ 242~
𝑑𝜀1,ℎ 𝑑𝜀1,ℎ 𝑑𝑠0 𝑑𝜀
= = ( 𝑑𝑠1 ) | 𝑏𝑎 cos(𝛾0 − 𝜓 ) (2.4.1-8)
𝑑𝜀ℎ 𝑑𝑠0 𝑑𝜀ℎ 0 𝜏0 𝜀 +𝑑𝜀
1 1,𝜓
𝑑𝜀
Where: ( 𝑑𝑠1) | is decided by expression (1.4.10-16) and evaluated at rotating angle
0 𝜏0 𝜀 +𝑑𝜀
1 1,𝜓
𝜀1 + 𝑑𝜀1,𝜓 of driving gear.
3) Total Angular Increment 𝑑𝜀1 of Driving Gear
With help of expressions (2.4.1-6) and (2.4.1-8), total angular increment 𝑑𝜀1 of driving gear is as
follow:
𝑑𝜀 𝑑𝜀
𝑑𝜀1 = 𝑑𝜀1,𝜓 + 𝑑𝜀1,ℎ = − ( 𝑑𝑠1 ) tan 𝜓 𝑑𝜎ℎ + ( 𝑑𝑠1) | 𝑏𝑎 cos(𝛾0 − 𝜓 ) 𝑑𝜀ℎ (2.4.1-9)
0 𝜏0 0 𝜏0 𝜀 +𝑑𝜀
1 1,𝜓
𝑑𝜀 𝑑𝜀
Where: 𝑑𝜀1,𝜓 = ( 𝑑𝑠1 ) tan 𝜓 𝑑𝜎ℎ and ( 𝑑𝑠1) is decided by expression (1.4.10-16) and
0 𝜏0 0 𝜏0
evaluated at rotating angle 𝜀1 of driving gear.
C. Manufacturing Process
In manufacturing process, whole height of workpiece can be equally divided by 𝑚 steps as

1 0
𝑂 𝛿
𝑖 𝐷
Figure 2.4.1-3 Axial Feeding 𝑑𝜎ℎ
Axial feeding for every cycle of generating motion of tooth profile is 𝛿, that is,
𝐷
𝛿=𝑚 (2.4.1-10)
Where: 𝐷 is height of workpiece.
~ 243 ~
Let 𝑝 be pitch of hob and equally divided by 𝑛 steps. Corresponding to every step, rotating
angle of hob is 𝛿𝜀ℎ , that is,
2𝜋
𝛿𝜀ℎ = (2.4.1-11)
𝑛
Initial cycle of generating motion of tooth profile is corresponding to zero axial feeding, that is,
𝑑𝜎ℎ = 𝑑𝜎ℎ,0 = 0
Application of expression (2.4.1-6) gives angular increment 𝑑𝜀1,𝜓 of driving gear caused by axial
0
feeding 𝑑𝜎ℎ,0 at initial cycle is 𝑑𝜀1,𝜓 , that is,
0 𝑑𝜀
𝑑𝜀1,𝜓 = − (𝑑𝑠1) tan 𝜓 𝑑𝜎ℎ,0 = 0
0 𝜏0
0
Therefore, total rotating angle 𝜀1,𝑗 of driving gear at 𝑗 th step of hob in initial cycle is as follow:
0 0 0
𝜀1,𝑗 = 𝜀1,𝑗−1 + 𝛿𝜀1,𝑗−1 (2.4.1-12)
0 0
Where: 𝜀1,0 = 0 . 𝑗 = 0,1,2,3, ⋯ , 𝑛 × 𝑁. 𝑁 is tooth number of workpiece. 𝛿𝜀1,𝑗 is calculated by
0
application of expressions (1.4.10-16), (2.4.1-7) and evaluated at rotating angle 𝜀1,𝑗 , that is,
0 𝑑𝜀 𝑑𝜀
𝛿𝜀1,𝑗 = ( 𝑑𝑠1 ) 𝛿𝑠0 = (𝑑𝑠1 ) 𝑏𝑎 cos(𝛾0 − 𝜓 ) 𝛿𝜀ℎ (2.4.1-13)
0 𝜏0 0 𝜏0
For 𝑖th cycle, hob gives only one axial feed 𝛿 at the beginning of cycle, therefore, workpiece 1
𝑖
has one additional angular increment 𝑑𝜀1,𝜓 for all 𝑖th cycle. Application of expression (2.4.1-6)
generates
𝑖 𝑑𝜀 𝑑𝜀
𝑑𝜀1,𝜓 = − (𝑑𝑠1) tan 𝜓 𝑑𝜎ℎ,𝑖 = ( 𝑑𝑠1 ) 𝛿 tan 𝜓 (2.4.1-14)
0 𝜏0 0 𝜏0
𝑑𝜀
Where: 𝑖 = 1,2,3, ⋯ , 𝑚. 𝛿 is decided by expression (2.4.1-10). ( 𝑑𝑠1) is calculated by
0 𝜏0
𝑖−1
expression (1.4.10-16) and evaluated at rotating angle 𝜀1 = 𝜀1,0 .
𝑖
Consequently, total rotating angle 𝜀1,𝑗 of driving gear at 𝑗 th step of hob in 𝑖th cycle is as follow:
𝑖 𝑖 𝑖
𝜀1,𝑗 = 𝜀1,𝑗−1 + 𝛿𝜀1,𝑗−1 (2.4.1-15)
𝑖 𝑖−1 𝑖 𝑖
Where: 𝑗 = 0,1,2,3, ⋯ , 𝑛 × 𝑁. 𝜀1,0 = 𝜀1,0 + 𝑑𝜀1,𝜓 . 𝑑𝜀1,𝜓 is calculated by expression (2.4.1-14)
𝑖
and 𝛿𝜀1,𝑗−1 is decided by expression (2.4.1-8), that is,
~ 244 ~
𝑖 𝑑𝜀
𝛿𝜀1,𝑗 = ( 𝑑𝑠1 ) 𝑏𝑎 cos(𝛾0 − 𝜓 ) 𝛿𝜀ℎ (2.4.1-16)
0 𝜏0
𝑑𝜀 𝑖
Here: (𝑑𝑠1) is determined by expression (1.4.10-16) and evaluated at 𝜀1 = 𝜀1,𝑗−1 .
0 𝜏0
Thus, Relationship of coordinate systems, i.e., expression (2.4.1-1), is updated as follow:
𝒊𝑖ℎ = 𝑵𝑖𝑜𝑝 = 𝑁𝑜𝑝𝑥

𝑖 𝑖
𝒊 + 𝑁𝑜𝑝𝑦 𝒋,
𝒌𝑖ℎ = (𝛼𝒊𝑖ℎ ) ⊗ 𝒌 = cos 𝛼 𝒌 + sin 𝛼 𝒊𝑖ℎ × 𝒌 = (𝑁𝑜𝑝𝑦
𝑖 𝑖
𝒊 − 𝑁𝑜𝑝𝑥 𝒋) sin 𝛼 + cos 𝛼 𝒌,
𝒋𝑖ℎ = 𝒌𝑖ℎ × 𝒊𝑖ℎ = (−𝑁𝑜𝑝𝑦
𝑖 𝑖
𝒊 + 𝑁𝑜𝑝𝑥 𝒋) cos 𝛼 + sin 𝛼 𝒌,
(𝜆𝒒)𝑖ℎ = ⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂ℎ𝑖 = (𝜆𝒑)𝑖ℎ + 𝜎ℎ𝑖 𝒌 = 𝑓ℎ𝑖 𝒊 + ℎℎ𝑖 𝒋 + 𝜎ℎ𝑖 𝒌 = 𝑹𝑖𝑜𝑝 + 𝑟0 𝒊𝑖ℎ + 𝜎ℎ𝑖 𝒌
(2.4.1-17)
𝑖
= (𝑥𝑜𝑝 𝑖
+ 𝑟0 𝑁𝑜𝑝𝑥 𝑖
)𝒊 + (𝑦𝑜𝑝 𝑖
+ 𝑟0 𝑁𝑜𝑝𝑦 )𝒋 + 𝜎ℎ𝑖 𝒌.
𝑓ℎ𝑖 = 𝑥𝑜𝑝
𝑖 𝑖
+ 𝑟0 𝑁𝑜𝑝𝑥 , ℎℎ𝑖 = 𝑦𝑜𝑝 𝑖 𝑖
+ 𝑟0 𝑁𝑜𝑝𝑦 ,
(𝜆𝒒)′𝑖ℎ = (𝑙𝒑)′𝑖ℎ + 𝜎ℎ𝑖 𝒌 = 𝑓ℎ′𝑖 𝒊 + ℎℎ′𝑖 𝒋 + 𝜎ℎ𝑖 𝒌 = 𝑹𝑖𝑜𝑝 − 𝑟0 𝒊𝑖ℎ + 𝜎ℎ𝑖 𝒌,
𝑓ℎ′𝑖 = 𝑥𝑜𝑝
𝑖 𝑖
− 𝑟0 𝑁𝑜𝑝𝑥 , ℎℎ′𝑖 = 𝑦𝑜𝑝
𝑖 𝑖
− 𝑟0 𝑁𝑜𝑝𝑦 . }
𝑖
Where: 𝑹𝑖𝑜𝑝 is calculated by expression (1.4.10-5) and evaluated at rotating angle 𝜀1,𝑗 of
workpiece 1 at 𝑖th cycle, i.e., expression (2.4.1-15). 𝑵𝑖𝑜𝑝 is calculated by expression (1.4.10-14)
𝑖
and evaluated at rotating angle 𝜀1,𝑗 of workpiece 1 at 𝑖th cycle. 𝜎ℎ𝑖 = −𝑖𝛿 for right-hand driving
gear (𝜓 > 0), and 𝜎ℎ𝑖 = 𝑖𝛿 for left-hand driving gear (𝜓 > 0).
3 Effective Relative Velocity
A. Effective Relative Velocity of Driving Gear with Respect to Hob 𝐶
Point 𝑃 (𝑹𝑝 ) is an arbitrary common conjugate contact point at instant rotating angle 𝜀1
among tooth profiles 𝐴 of driving Gear, 𝐴̅ of driven gear, helicoid 𝑯 of hob 𝐶 and
helicoid 𝑯′ of hob 2 as shown in figure 2.4.1-4
The velocity of 𝑹𝑝 as point on tooth profile 𝐴 of driving gear is 𝒗𝑝 , that is,
𝒗𝑝 = 𝒌 × 𝑹𝑝 (2.4.1-18)
𝑯𝑝 is point vector of conjugate contact point 𝑃 (𝑹𝑝 ) at instant rotating angle 𝜀1 with respect to
coordinate system 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ , that is,
~ 245 ~
𝐴̅
𝒌 𝐴 𝒌 𝒌
𝑃 𝒌
𝑹𝑝 𝑯′𝑝 𝑯𝑝 𝝎′ℎ
𝒋ℎ ∆𝑝 𝜓 𝚪
𝑂 𝑂ℎ′ 𝒋ℎ 𝒋
(𝑙𝒑)′ℎ 𝑃0 𝛼
𝒌ℎ (𝑙𝒑)ℎ 𝑹0𝑝 𝑂ℎ
pitch curve of driving gear 𝜎ℎ
𝒊 𝒌ℎ pitch curve of driven gear 𝒊ℎ (𝑵0𝑝 )
Figure 2.4.1-4 Motion Relationship
𝑯𝑝 = −𝑟0 𝒊ℎ + ∆𝑝 ,
} (2.4.1-19)
∆𝑝 = 𝑠𝑛 𝑵𝑝 = −𝑠𝑛 𝑵ℎ𝑝 .
Where: 𝑵𝑝 is unit normal to tooth profile of workpiece at instant contact point 𝑃. 𝑵ℎ𝑝 is unit
normal to helicoid of hob 𝐶 at instant common contact point 𝑃. 𝑠𝑛 is distance from pitch point
𝑃0 to common instant contact point 𝑃 along 𝑵𝑝 .
Due to point 𝑃 (𝑹𝑝 ) being a common instant contact point as shown in figure 2.4.1-4, then,
𝑹𝑝 = 𝑹0𝑝 + 𝜎ℎ 𝐤 + ∆𝑝 = (𝑙𝒑)ℎ + 𝜎ℎ 𝐤 + 𝑯𝑝 = 𝑓ℎ 𝒊 + ℎℎ 𝒋 + 𝜎ℎ 𝐤 + 𝑯𝑝 (2.4.1-20)
Where: (𝑙𝒑)ℎ = 𝑓ℎ 𝒊 + ℎℎ 𝒋.
At instant rotating angle of 𝜀1 + ∆𝜀1, conjugate contact point 𝑃(𝑹𝑝 ) as point on helicoid of
hob 𝐶 reaches position 𝑹𝑝 + ∆𝑯𝑝 with respect to origin 𝑂 of coordinate system 𝑂 − 𝒊 , 𝒋,𝒌,
omitting the second or higher order of infinitesimal quantity, that is,
~ 246 ~
𝑹𝑝 + ∆𝑯𝑝 = (−∆𝜑𝒌) ⊗ [( ∆𝜀ℎ 𝒌ℎ ) ⊗ 𝑯𝑝 ] + (𝑙𝒑)ℎ + ∆(𝑙𝒑)ℎ + 𝜎ℎ 𝒌
= (−∆𝜑𝒌) ⊗ (𝑯𝑝 + ∆𝜀ℎ 𝒌ℎ × 𝑯𝑝 ) + (𝑙𝒑)ℎ + ∆(𝑙𝒑)ℎ + 𝜎ℎ 𝒌
= 𝑯𝑝 + ∆𝜀ℎ 𝒌ℎ × 𝑯𝑝 − ∆𝜑𝒌 × 𝑯𝑝 + (𝑙𝒑)ℎ + ∆(𝑙𝒑)ℎ + 𝜎ℎ 𝒌.
With help of expression (2.4.1-20), application of expression above gives
∆𝑯𝑝 = ∆𝜀ℎ 𝒌ℎ × 𝑯𝑝 − ∆𝜑𝒌 × 𝑯𝑝 + ∆(𝑙𝒑)ℎ
Velocity 𝒗𝑝ℎ of conjugate contact point 𝑃(𝑹𝑝 ) on helicoid of hob 𝐶 is derived as follow:
∆𝑯𝑝 𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)ℎ
𝒗𝑝ℎ = lim = 𝑑𝜀ℎ 𝒌ℎ × 𝑯𝑝 − 𝑑𝜀 𝒌 × 𝑯𝑝 + (2.4.1-21)
∆𝜀1 →0 ∆𝜀1 1 1 𝑑𝜀1
Relative velocity 𝒗𝑝ℎ

𝑝 of conjugate contact point 𝑃(𝑹𝑝 ) on driving gear with respect to hob 𝐶 is
𝒗𝑝ℎ ℎ
𝑝 = 𝒗𝑝 − 𝒗𝑝ℎ = 𝒌 × 𝑹𝑝 − (𝑑𝜀 𝒌ℎ × 𝑯𝑝 − 𝑑𝜀 𝒌 × 𝑯𝑝 + ) (2.4.1-22)
1 1 𝑑𝜀1
Substitution of expressions (2.4.1-19) and (2.4.1-20) into expression above yields

𝑑𝜑 𝑑𝜀 𝑑𝜑 𝑑𝜀 𝑑(𝑙𝒑)ℎ
𝒗𝑝ℎ ℎ ℎ
𝑝 = 𝒌 × 𝑹0𝑝 − 𝑟0 (𝑑𝜀 𝒌 − 𝑑𝜀 𝒌ℎ ) × 𝒊ℎ + [(1 + 𝑑𝜀 ) 𝒌− 𝑑𝜀 𝒌ℎ ] × ∆𝑝 −
1 1 1 1 𝑑𝜀1
𝑑𝜑 𝑑𝜀
Due to ∆𝑝 ∥ 𝑵ℎ𝑝 , then, {[(1 + 𝑑𝜀 ) 𝒌− 𝑑𝜀ℎ 𝒌ℎ ] × ∆𝑝 } ∙ 𝑵ℎ𝑝 = 0, therefore, generation of tooth
1 1
𝑑𝜑 𝑑𝜀
profile is not affected by term of [(1 + 𝑑𝜀 ) 𝒌− 𝑑𝜀ℎ 𝒌ℎ ] × ∆𝑝 in expression above. Therefore,
1 1
effective relative velocity 𝒗1,ℎ

𝑝𝐸 of driving gear with respect to hob 𝐶 is as follow:
𝑑𝜑 𝑑𝜀 𝑑(𝑙𝒑)ℎ
𝒗1,ℎ ℎ
𝑝𝐸 = 𝒌 × 𝑹0𝑝 − 𝑟0 (𝑑𝜀 𝒌 − 𝑑𝜀 𝒌ℎ ) × 𝒊ℎ −
1 1 𝑑𝜀1
𝑑𝜀ℎ 𝑑𝜑 𝑑𝑓ℎ
[−𝑦0𝑝 − (𝑑𝜀 cos 𝛼 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑦 − 𝑑𝜀 ] 𝒊 (2.4.1-23)
1 1 1
={ 𝑑𝜀 𝑑𝜑 𝑑ℎ 𝑑𝜀
}
+ [𝑥0𝑝 + (𝑑𝜀ℎ cos 𝛼 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥 − 𝑑𝜀ℎ ] 𝒋 + 𝑑𝜀ℎ 𝑟0 sin 𝛼 𝒌
1 1 1 1
B. Effective Relative Velocity of Driven Gear with Respect to Hob 𝐶̅
Likewise, with help of expression (2.4.1-20), velocity 𝒗′𝑝 of point 𝑃 (𝑹𝑝 ) as point on tooth
profile 𝐴̅ of driven gear is as follow:
𝑑𝜀 𝑑(𝑙𝒑)
𝒗′𝑝 = − 𝑑𝜀2 𝒌 × [𝑹𝑝 − (𝑙𝒑)] +
1 𝑑𝜀1
𝑑𝜀2 𝑑𝜀2 𝑑(𝑙𝒑)
(2.4.1-24)
= − 𝑑𝜀 𝒌 × ∆𝑝 − 𝑑𝜀 𝒌 × [𝑹0𝑝 − (𝑙𝒑)] +
1 1 𝑑𝜀1
~ 247 ~
𝑑𝜀 𝑑(𝑙𝒑)
Because 𝒗′0𝑝 = − 𝑑𝜀2 𝒌 × [𝑹0𝑝 − (𝑙𝒑)] + is velocity of pitch point on driven gear and
1 𝑑𝜀1
𝒗0𝑝 = 𝒌 × 𝑹0𝑝 is velocity of pitch point on driving, thus, 𝒗′0𝑝 = 𝒗0𝑝 . Therefore, expression
(2.4.1-24) is updated as follow:

𝑑𝜀
𝒗′𝑝 = − 𝑑𝜀2 𝒌 × ∆𝑝 + 𝒌 × 𝑹0𝑝 (2.4.1-25)
1
𝑯′𝑝 is point vector of conjugate contact point 𝑃 (𝑹𝑝 ) on helicoid of hob 𝐶̅ at instant rotating
angle 𝜀1 with respect to coordinate system 𝑂ℎ′ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ , that is,
𝑯′𝑝 = 𝑟0 𝒊ℎ + ∆𝑝 (2.4.1-26)
Due to point 𝑃 (𝑹𝑝 ) being a common instant contact point as shown in figure 2.4.1-4, then,
𝑹𝑝 = (𝑙𝒑)′ℎ + 𝜎ℎ 𝒌 + 𝑯′𝑝 = 𝑹0𝑝 + 𝜎ℎ 𝒌 + ∆𝑝 (2.4.1-27)
At instant rotating angle of 𝜀1 + ∆𝜀1, conjugate contact point 𝑃(𝑹𝑝 ) as a point on helicoid of
hob 𝐶̅ reaches position 𝑹𝑝 + ∆𝑯′𝑝 with respect to origin 𝑂 of coordinate system 𝑂 − 𝒊 , 𝒋,𝒌,
omitting the second or higher order of infinitesimal quantity,
𝑹𝑝 + ∆𝑯′𝑝 = (−∆𝜑𝒌) ⊗ [(−∆𝜀ℎ 𝒌ℎ ) ⊗ 𝑯′𝑝 ] + (𝑙𝒑)′ℎ + ∆(𝑙𝒑)′ℎ + 𝜎ℎ 𝒌

= 𝑯′𝑝 − ∆𝜀ℎ 𝒌ℎ × 𝑯′𝑝 − ∆𝜑𝒌 × 𝑯′𝑝 + (𝑙𝒑)′ℎ + ∆(𝑙𝒑)′ℎ + 𝜎ℎ 𝒌
With help of expression (2.4.1-26), application of expression above leads
∆𝑯′𝑝 = −∆𝜀ℎ 𝒌ℎ × 𝑯′𝑝 − ∆𝜑𝒌 × 𝑯′𝑝 + ∆(𝑙𝒑)′ℎ
Thus, velocity 𝒗′𝑝ℎ of conjugate contact point 𝑃(𝑹𝑝 ) on helicoid of hob 𝐶̅ is generated as follow
∆𝑯′𝑝 𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
𝒗′𝑝ℎ = lim = − 𝑑𝜀ℎ 𝒌ℎ × 𝑯′𝑝 − 𝑑𝜀 𝒌 × 𝑯′𝑝 +
∆𝜀1 →0 ∆𝜀1 1 1 𝑑𝜀1
(2.4.1-28)
𝑑𝜀ℎ 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
= − (𝑑𝜀 𝒌ℎ + 𝑑𝜀 𝒌) × (𝑟0 𝒊ℎ + ∆𝑝 ) +
1 1 𝑑𝜀1
𝑑(𝑙𝒑)′ℎ 𝑑𝑓ℎ′ ′
𝑑ℎℎ
Where: = 𝒊+ 𝒋.
Thus, with help of expression (2.4.1-25), relative velocity of conjugate contact point 𝑃(𝑹𝑝 ) on
workpiece 2 with respect to hob 𝐶̅ is as follow:
~ 248 ~
𝑑𝜀 𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
𝒗′𝑝 − 𝒗′𝑝ℎ = − 𝑑𝜀2 𝒌 × ∆𝑝 + 𝒌 × 𝑹0𝑝 + (𝑑𝜀ℎ 𝒌ℎ + 𝑑𝜀 𝒌) × (𝑟0 𝒊ℎ + ∆𝑝 ) −
1 1 1 𝑑𝜀1
𝑑𝜀 𝑑𝜑 𝑑𝜀 𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
= [𝑑𝜀ℎ 𝒌ℎ + (𝑑𝜀 − 𝑑𝜀2 ) 𝒌] × ∆𝑝 + 𝒌 × 𝑹0𝑝 + 𝑟0 (𝑑𝜀ℎ 𝒌ℎ + 𝑑𝜀 𝒌) × 𝒊ℎ −
1 1 1 1 1 𝑑𝜀1
Due to ∆𝑝 ∥ 𝑵ℎ𝑝 , then, generation of tooth profile is not affected by term of
𝑑𝜀 𝑑𝜑 𝑑𝜀
[𝑑𝜀ℎ 𝒌ℎ + (𝑑𝜀 − 𝑑𝜀2 ) 𝒌] × ∆𝑝 in expression above. Therefore, effective relative velocity 𝒗2,ℎ
𝑝𝐸 of
1 1 1
driven gear with respect to hob 𝐶̅ is as follow:
′ 𝑑𝜀 𝑑𝜑 𝑑(𝑙𝒑)′ℎ
𝒗2,ℎ ℎ
𝑝𝐸 = 𝒌 × 𝑹0𝑝 + 𝑟0 (𝑑𝜀 𝒌ℎ + 𝑑𝜀 𝒌) × 𝒊ℎ −
1 1 𝑑𝜀1
𝑑𝜑 𝑑𝜀 𝑑𝑓ℎ′
[−𝑦0𝑝 − (𝑑𝜀 + 𝑑𝜀ℎ cos 𝛼) 𝑟0 𝑁𝑜𝑝𝑦 − 𝑑𝜀 ] 𝒊 (2.4.1-29)
1 1 1
={ }
𝑑𝜀 𝑑𝜑 𝑑ℎ′ 𝑑𝜀
+ [𝑥0𝑝 + (𝑑𝜀ℎ cos 𝛼 + 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥 − 𝑑𝜀ℎ ] 𝒋 + 𝑑𝜀ℎ 𝑟0 sin 𝛼 𝒌
1 1 1 1
4 Motion Requirements
Due to requirement of conjugate contact, i.e., expression (1.3.7-3), that is,
𝑵ℎ𝑝 ∙ 𝒗1,ℎ
𝑝𝐸 = 0,
′ } (2.4.1-30)
𝑵ℎ𝑝 ∙ 𝒗2,ℎ
𝑝𝐸 = 0.
With help of expressions (2.4.1-4) and (2.4.1-5), substitution of expressions (2.4.1-3), (2.4.1-23)
and (2.4.1-29) into expression (2.4.1-30) gives
𝑑ℎ 𝑑𝑓
𝐴ℎ𝑝 [(𝑥0𝑝 − 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑦 − (𝑦0𝑝 + 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑥 ]
1 1
{ 𝑑ℎℎ 𝑑𝑓ℎ 𝑑𝜀 sin 𝛾0 𝑑𝜑
}=0
+(𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼) [(𝑥0𝑝 − 𝑑𝜀 ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑦 − (𝑑𝜀ℎ cos 𝜓 + 𝑑𝜀 ) 𝑟0 ]
1 1 1 1
And
𝑑ℎ′ 𝑑𝑓 ′
𝐴ℎ𝑝 [(𝑥0𝑝 − 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑦 − (𝑦0𝑝 + 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑥 ]
1 1
{ ′ }=0
𝑑ℎℎ 𝑑𝑓ℎ′ 𝑑𝜑 𝑑𝜀ℎ sin 𝛾0
+(𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼) [(𝑥0𝑝 − ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + ) 𝑁𝑜𝑝𝑦 + ( − ) 𝑟0 ]
𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 cos 𝜓
Due to 𝐴ℎ𝑝 and (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼) being constant, thus,
𝑑ℎ 𝑑𝑓
(𝑥0𝑝 − 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑦 − (𝑦0𝑝 + 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑥 = 0,
1 1
𝑑ℎℎ 𝑑𝑓ℎ 𝑑𝜀 sin 𝛾 𝑑𝜑
}
(𝑥0𝑝 − 𝑑𝜀 ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑦 − (𝑑𝜀ℎ cos 𝜓0 + 𝑑𝜀 ) 𝑟0 = 0.
1 1 1 1
~ 249 ~
And
𝑑ℎ′ 𝑑𝑓 ′
(𝑥0𝑝 − 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑦 − (𝑦0𝑝 + 𝑑𝜀ℎ ) 𝑁𝑜𝑝𝑥 = 0,
1 1
′ }=0
𝑑ℎℎ 𝑑𝑓ℎ′ 𝑑𝜑 𝑑𝜀 sin 𝛾
(𝑥0𝑝 − 𝑑𝜀 ) 𝑁𝑜𝑝𝑥 + (𝑦0𝑝 + 𝑑𝜀 ) 𝑁𝑜𝑝𝑦 + (𝑑𝜀 − 𝑑𝜀ℎ cos 𝜓0 ) 𝑟0 = 0.
1 1 1 1
Solving two equations above yields

𝑑𝑓ℎ 𝑑𝜀 sin 𝛾 𝑑𝜑
= (𝑑𝜀ℎ cos 𝜓0 + 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑦 − 𝑦0𝑝 ,
𝑑𝜀1 1 1
𝑑ℎℎ 𝑑𝜀ℎ sin 𝛾0 𝑑𝜑
= − (𝑑𝜀 + 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥 + 𝑥0𝑝 ,
𝑑𝜀1 1 cos 𝜓 1
𝑑𝑓ℎ′ 𝑑𝜑 𝑑𝜀ℎ sin 𝛾0
(2.4.1-31)
= − (𝑑𝜀 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑦 − 𝑦0𝑝 ,
𝑑𝜀1 1 1 cos 𝜓
′
𝑑ℎℎ 𝑑𝜑 𝑑𝜀ℎ sin 𝛾0
= (𝑑𝜀 − 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥 + 𝑥0𝑝 . }
𝑑𝜀1 1 1 cos 𝜓
Combination of expressions (2.4.1-8), (2.4.1-17) and (2.4.1-31) generates motion requirements

at 𝑗th step of 𝑖th cycle as follow:
𝑖 𝑖 𝑖 𝑖 𝑖 𝑖
𝑓ℎ,𝑗 = 𝑥𝑜𝑝,𝑗 + 𝑟0 𝑁𝑜𝑝𝑥,𝑗 , ℎℎ,𝑗 = 𝑦𝑜𝑝,𝑗 + 𝑟0 𝑁𝑜𝑝𝑦,𝑗 ,
′𝑖 𝑖 𝑖 ′𝑖 𝑖 𝑖
𝑓ℎ,𝑗 = 𝑥𝑜𝑝,𝑗 − 𝑟0 𝑁𝑜𝑝𝑥,𝑗 , ℎℎ,𝑗 = 𝑦𝑜𝑝,𝑗 − 𝑟0 𝑁𝑜𝑝𝑦,𝑗 ,
𝑖
𝑑𝑓ℎ,𝑗 𝑑𝜀 sin 𝛾 𝑖 𝑖 𝑑𝜑
= (𝑑𝜀ℎ cos 𝜓0 + 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑦,𝑗 − 𝑦𝑜𝑝,𝑗 ,
𝑑𝜀1 1 1
𝑖
𝑑ℎℎ,𝑗 𝑑𝜀ℎ sin 𝛾0 𝑑𝜑 𝑖 𝑖 (2.4.1-32)
= − (𝑑𝜀 + 𝑑𝜀 ) 𝑟0 𝑁𝑜𝑝𝑥,𝑗 + 𝑥𝑜𝑝,𝑗 ,
𝑑𝜀1 1 cos 𝜓 1
′𝑖
𝑑𝑓ℎ,𝑗 𝑑𝜑 𝑖𝑑𝜀 sin 𝛾𝑖
= − (𝑑𝜀 − 𝑑𝜀ℎ cos 𝜓0 ) 𝑟0 𝑁𝑜𝑝𝑦,𝑗 − 𝑦𝑜𝑝,𝑗 ,
𝑑𝜀1 1 1
′𝑖
𝑑ℎℎ,𝑗 𝑑𝜑 𝑖𝑑𝜀 sin 𝛾𝑖
= (𝑑𝜀 − 𝑑𝜀ℎ cos 𝜓0 ) 𝑟0 𝑁𝑜𝑝𝑥,𝑗 + 𝑥𝑜𝑝,𝑗 }
𝑑𝜀1 1 1
𝑖 𝑖 𝑖 𝑖
Where: 𝑥𝑜𝑝,𝑗 , 𝑦𝑜𝑝,𝑗 are calculated by expression (1.4.10-6), 𝑁𝑜𝑝𝑥,𝑗 and 𝑁𝑜𝑝𝑦,𝑗 are decided by
𝑑𝜑 𝑑𝜀
expression (1.4.10-13), 𝑑𝜀 is determined by expression (2.3.4-13) and 𝑑𝜀ℎ is calculated by
1 1
𝑖
expression (2.4.1-8) and they are all evaluated at 𝜀1,𝑗 which is calculated by expression (2.4.1-
15), that is,
𝐾1𝑔0 | 𝑖
𝑑𝜑 𝜀 1,𝑗 𝑑𝜀1,ℎ 𝑑𝜀
= − 1, = ( 𝑑𝑠1) | 𝑏𝑎 cos(𝛾0 − 𝜓 ) ,
𝑑𝜀1 𝑑𝜀 𝑑𝜀ℎ
( 1) | 0 𝜏0 𝜀 𝑖
(2.4.1-33)
𝑑𝑠0 𝜏 1,𝑗
0 𝜀𝑖
1,𝑗
𝑖 𝑖 𝑖
𝜀1,𝑗 = 𝜀1,𝑗−1 + 𝛿𝜀1,𝑗−1 . }
~ 250 ~
Axial feed 𝜎ℎ and 𝜀ℎ are used as two independent variables, that is,
𝜎ℎ = ±𝑖𝛿,
} (2.4.1-34)
𝜀ℎ = 𝑗𝛿𝜀ℎ .
Where: 𝛿 and 𝛿𝜀ℎ are defined by expressions (2.4.1-10) and (2.4.1-11) respectively, and they
are corresponding to pulse increment of CNC device. " ± " is equal to positive " + " for left-
hand workpiece and negative " − " for right-hand workpiece.
Application of expressions (2.4.1-30) gives requirement of conjugate contact between

workpiece 1 and 2 as follow:
(𝒗𝑝 − 𝒗′𝑝 ) ∙ 𝑵ℎ𝑝 = (𝒗𝑝 − 𝒗𝑝ℎ + 𝒗𝑝ℎ − 𝒗′𝑝ℎ + 𝒗′𝑝ℎ − 𝒗′𝑝 ) ∙ 𝑵ℎ𝑝
′
= 𝒗1,ℎ ′ 2,ℎ
𝑝𝐸 ∙ 𝑵ℎ𝑝 + (𝒗𝑝ℎ − 𝒗𝑝ℎ ) ∙ 𝑵ℎ𝑝 + 𝒗𝑝𝐸 ∙ 𝑵ℎ𝑝 = 0
Therefore, tooth profiles of workpiece 1 and 2 are a pair of conjugate surfaces.
2.4.2 Calculation of Tooth Profiles and Machine Setting Parameters

1 Calculation of Conjugate Cutting Point on Helicoid of Hob
Let original reference position of hob for 𝑞th tooth at 𝑖th cycle be position of pitch point 𝑃𝑜 on
𝑖,𝑞
hob coincident to pitch point 𝑃𝑜 of workpiece at instant rotating 𝜀1,0 .
𝑖,0 𝑖−1,0 𝑑𝜀
𝜀1,0 = 𝜀1,0 + ( 𝑑𝑠1) | 𝛿 tan 𝜓 (2.4.2-1)
0 𝜏0 𝜀 𝑖−1,0
1,0
0,0
Where: 𝜀1,0 = 0,
If hobbing process starts from left-flank of tooth space of driving gear, then,
For left-flank of tooth space of driving gear

𝑖,𝑞 𝑖,𝑞−1 𝑖
𝜀1,0 = 𝜀1,𝑛 = 𝜀1,𝑗 ,
} (2.4.2-2)
𝑗 = 𝑞𝑛,
And for right-flank of tooth space of driving gear
~ 251 ~
𝜀1,0 = 𝜀1,𝑛 = 𝜀1,𝑗 ,
𝑛 } (2.4.2-3)
𝑗 = 𝑞𝑛 + 2 .
Otherwise, if hobbing process starts from right-flank of tooth space of driving gear, then,
For right-flank of tooth space of driving gear

𝜀1,0 = 𝜀1,𝑛 = 𝜀1,𝑗 ,
} (2.4.2-4)
𝑗 = 𝑞𝑛.
And for left-flank of tooth space of driving gear

𝜀1,0 = 𝜀1,𝑛 = 𝜀1,𝑗 ,
𝑛 } (2.4.2-5)
𝑗 = 𝑞𝑛 + 2 .
Where: 𝑛 is defined in expression (2.4.1-11). 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1. 𝑁 is tooth number of

𝑖
workpiece. 𝜀1,𝑗 is calculated by expression (2.4.1-33).
Relationship of coordinate system 𝑂ℎ − 𝒊ℎ , 𝒋ℎ , 𝒌ℎ of hob as shown in figure 2.3.2-3 for 𝑞th

tooth at 𝑖th cycle in initial position with respect to coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 is as follow:
⃗⃗⃗⃗⃗⃗ ℎ = 𝑹𝑖,𝑞
𝑂𝑂 𝑜𝑝,0 + 𝑟0 𝒊ℎ + 𝜎ℎ 𝒌, 𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑜𝑝,0 = 𝑥𝑜𝑝,0 𝒊 + 𝑦𝑜𝑝,0 𝒋,
𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝒊ℎ = 𝑵𝑜𝑝,0 = 𝑁𝑜𝑝𝑥,0 𝒊 + 𝑁𝑜𝑝𝑦,0 𝒋, 𝒋ℎ = (−𝑁𝑜𝑝𝑦,0 𝒊 + 𝑁𝑜𝑝𝑥,0 𝒋) cos 𝛼 + sin 𝛼 𝒌, (2.4.2-6)
𝑖,𝑞 𝑖,𝑞
𝒌ℎ = (𝑁𝑜𝑝𝑦,0 𝒊 − 𝑁𝑜𝑝𝑥,0 𝒋) sin 𝛼 + cos 𝛼 𝒌. }
Where: 𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑜𝑝,0 is pitch point at 𝜀1,0 and calculated by expression (1.4.10-5). 𝑵𝑜𝑝,0 is unit normal
𝑖,𝑞
to pitch curve at 𝜀1,0 and calculated by expression (1.4.10-13). 𝛼 is defined in expression (2.4.1-
5). 𝜎ℎ = ±𝑖𝛿 .
A. Tooth Profile of Left-Flank of Tooth Space of Driving Gear
For 𝑘th step of rotating angle of hob with respect to original reference position of hob for 𝑞th
tooth, solving equation (2.3.5-1) generates surface parameters of left-flank helicoid of hob 𝐶 at
conjugate cutting point corresponding to 𝑘th step of rotating angle of hob, that is,
~ 272 ~
𝑟𝑏 𝑏𝑎 ∆𝜀ℎ 𝑟𝑏 𝑏𝑎 𝑘𝛿𝜀ℎ 𝑟 2 ∆𝜀 𝑟𝑏2 𝑘𝛿𝜀ℎ
𝑠𝑛,𝑘 = = , 𝜃𝑘 = − 𝑟𝑏2 +𝑏ℎ2 = − ,
𝑟𝑏2 +𝑏𝑎2
√𝑟𝑏2 +𝑏𝑎2 √𝑟𝑏2 +𝑏𝑎2 𝑏 𝑎
(2.4.2-7)
𝑏𝑎2 𝑏𝑎2
Γ𝑘 = 𝛼0 − 𝑟 2 +𝑏2 ∆𝜀ℎ = 𝛼0 − 𝑟 2+𝑏2 𝑘𝛿𝜀ℎ .
𝑏 𝑎 𝑏 𝑎 }
Where: ∆𝜀ℎ = 𝑘𝛿𝜀ℎ and 𝛿𝜀ℎ is defined in expression (2.4.1-11). 𝑘 = 0, ±1, ±2, ±3, ⋯.
2) Calculation of Unit Normal 𝑵𝑖,𝑞

𝑝,𝑘 to Tooth Profile at Conjugate Cutting Position
Let 𝑵𝑖,𝑞
𝑝,𝑘 be unit normal to tooth profile of workpiece 1 at instant conjugate cutting point
corresponding to 𝑞th tooth at 𝑖th cycle and 𝑘th step of rotating angle of hob 𝐶. and 𝑵ℎ𝑝 be unit
normal to helicoid of hob 𝐶 corresponding to conjugate cutting point 𝑃.
Method 1:
With help of expression (2.4.2-5), unit normal 𝑵ℎ𝑝 to helicoid of hob 𝐶 corresponding to cutting
point is as follow:
𝑵ℎ𝑝 = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ = 𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

ℎ𝑝 𝒊 + 𝐵ℎ𝑝 𝒋 + 𝐶ℎ𝑝 𝒌
𝑖,𝑞 𝑖,𝑞
[𝐴ℎ𝑝 𝑁𝑜𝑝𝑥,0 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑦,0 ]𝒊 (2.4.2-8)
={ 𝑖,𝑞 𝑖,𝑞
}
+[𝐴ℎ𝑝 𝑁𝑜𝑝𝑦,0 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑥,0 ]𝒋 + (𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼)𝒌
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are (2.3.2-35), and
𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

ℎ𝑝 = 𝐴ℎ𝑝 𝑁𝑜𝑝𝑥,0 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑦,0 ,
𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝐵ℎ𝑝 = 𝐴ℎ𝑝 𝑁𝑜𝑝𝑦,0 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑥,0 (2.4.2-9)
𝑖,𝑞
𝐶ℎ𝑝 = 𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼 . }
𝑵𝑖,𝑞
𝑝,𝑘 is derived by rotating (−𝑵ℎ𝑝 ) from initial reference position to conjugate cutting position
𝑖,𝑞
through an angle (−∆𝜑𝑝,𝑘 ) about 𝒌 as an axis, that is,
𝑵𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑝,𝑘 = 𝐴𝑝,𝑘 𝒊 + 𝐵𝑝,𝑘 𝒋 + 𝐶𝑝,𝑘 𝒌 = (−∆𝜑𝑝,𝑘 𝒌)⨂(−𝑵ℎ𝑝 )
𝑖,𝑞
(2.4.2-10)
𝒌)⨂(𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
= −(−∆𝜑𝑝,𝑘 ℎ𝑝 𝒊 + 𝐵ℎ𝑝 𝒋 + 𝐶ℎ𝑝 𝒌)
Where:
~ 273 ~
𝐴𝑝,𝑘 = −𝐴ℎ𝑝 cos(∆𝜑𝑝,𝑘 ) − 𝐵ℎ𝑝 sin(∆𝜑𝑝,𝑘 ) ,
𝑖,𝑞
= 𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝐵𝑝,𝑘 ℎ𝑝 sin(∆𝜑𝑝,𝑘 ) − 𝐵ℎ𝑝 cos(∆𝜑𝑝,𝑘 ) ,
𝑖,𝑞 𝑖,𝑞
𝐶𝑝,𝑘 = −𝐶ℎ𝑝 . }
𝑖,𝑞
∆𝜑𝑝,𝑘 is calculated by application of expression (2.4.1-33), that is,
𝑖,𝑞 𝑖,𝑞 𝑑𝜑 𝑖,𝑞 𝑑𝜀 𝑖,𝑞

∆𝜑𝑝,𝑘 = ∆𝜑𝑝,𝑘−1 + (𝑑𝜀 ) ( 𝑑𝜀1 ) 𝛿𝜀ℎ
1 𝑘 ℎ 𝑘
(2.4.2-11)
𝑖,𝑞 𝑑𝜀1
= ∆𝜑𝑝,𝑘−1 + [𝐾1𝑔0 | 𝑖,𝑞 − ( 𝑑𝑠 ) | ] 𝑏𝑎 cos(𝛾0 − 𝜓 ) 𝛿𝜀ℎ
𝜀1,𝑘−1 0 𝜏0 𝜀 𝑖,𝑞
1,𝑘−1
𝑖,𝑞
Where: 𝛿𝜀ℎ is defined in expression (2.4.1-11). ∆𝜑𝑝,0 = 0. 𝐾1𝑔0 | 𝑖,𝑞 is calculated by
𝜀1,𝑘−1
𝑑𝜀
expression of (1.4.10-26). ( 𝑑𝑠1 ) | is decided by expression (1.4.10-16). Both𝐾1𝑔0 | 𝑖,𝑞
0 𝜏0 𝜀 𝑖,𝑞 𝜀1,𝑘−1
1,𝑘−1
𝑑𝜀 𝑖,𝑞
and (𝑑𝑠1 ) | are evaluated at 𝜀1,𝑘−1 , and
0 𝜏0 𝜀 𝑖,𝑞
1,𝑘−1
𝑖,𝑞 𝑖,𝑞 𝑑𝜀 𝑖
𝜀1,𝑘 = 𝜀1,𝑘−1 + ( 𝑑𝑠1) | 𝑏𝑎 cos(𝛾0 − 𝜓 ) 𝛿𝜀ℎ = 𝜀1,𝑗 ,
0 𝜏0 𝜀 𝑖,𝑞 } (2.4.2-12)
1,𝑘−1
𝑗 = 𝑞𝑛 + 𝑘.
𝑖
Here: 𝜀1,𝑗 is calculated by expression (2.4.1-15). 𝑘 = 0, ±1, ±2, ±3, ⋯. 𝑞 = 0,1,2,3, ⋯ , 𝑁 − 1.
Method 2:
𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
Establish new coordinate system 𝑂ℎ,𝑘 − 𝒊ℎ,𝑘 , 𝒋ℎ,𝑘 , 𝒌ℎ,𝑘 as follow:
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂ℎ,𝑘 𝑖,𝑞
= 𝑹𝑖,𝑞 𝑖,𝑞
𝑜𝑝,𝑘 + 𝑟0 𝒊ℎ,𝑘 + 𝜎ℎ 𝒌,
𝒊𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝒋𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
ℎ,𝑘 = 𝑵𝑜𝑝,𝑘 = 𝑁𝑜𝑝𝑥,𝑘 𝒊 + 𝑁𝑜𝑝𝑦,𝑘 𝒋, ℎ,𝑘 = (−𝑁𝑜𝑝𝑦,𝑘 𝒊 + 𝑁𝑜𝑝𝑥,𝑘 𝒋) cos 𝛼 + sin 𝛼 𝒌,
(2.4.2-13)
𝒌𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
ℎ,𝑘 = (𝑁𝑜𝑝𝑦,𝑘 𝒊 − 𝑁𝑜𝑝𝑥,𝑘 𝒋) sin 𝛼 + cos 𝛼 𝒌. }

𝑜𝑝,𝑘 is pitch point at 𝜀1,𝑘 and calculated by expression (1.4.10-5). 𝑵𝑜𝑝,𝑘 is unit normal
𝑖,𝑞 𝑖,𝑞
to pitch curve at 𝜀1,𝑘 and calculated by expression (1.4.10-13). 𝜀1,𝑘 is decided by expression
(2.4.2-12).
~ 254 ~
𝑖,𝑞
Then, 𝑵𝑝,𝑘 is yielded as follow:
𝑵𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑝,𝑘 = −𝑵ℎ𝑝 = 𝐴𝑝,𝑘 𝒊 + 𝐵𝑝,𝑘 𝒋 + 𝐶𝑝,𝑘 𝒌 = −(𝐴ℎ𝑝 𝒊ℎ,𝑘 + 𝐵ℎ𝑝 𝒋ℎ,𝑘 + 𝐶ℎ𝑝 𝒌ℎ,𝑘 ) (2.4.2-14)
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are expression (2.3.2-35) and,

𝑝,𝑘 = −𝐴ℎ𝑝 𝑁𝑜𝑝𝑥,𝑘 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑦,𝑘 ,
𝑖,𝑞
= −𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝐵𝑝,𝑘 𝑝,𝑘 𝑁𝑜𝑝𝑦,𝑘 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑥,𝑘 ,
𝑖,𝑞
𝐶𝑝,𝑘 = −𝐵ℎ𝑝 sin 𝛼 − 𝐶ℎ𝑝 cos 𝛼 . }
Due to unit normal 𝑵𝑖,𝑞

𝑝,𝑘 to tooth profile at conjugate contact point being pass through
corresponding pitch point, then, conjugate cutting point 𝑹𝑖,𝑞

𝑝,𝑘 of 𝑞th tooth at 𝑖th cycle and 𝑘th
step of rotating angle of hob is derived as follow:
𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑝,𝑘 = 𝑹𝑜𝑝,𝑘 + 𝜎ℎ 𝒌 + 𝑠𝑛,𝑘 𝑵𝑝,𝑘 = 𝑥𝑝,𝑘 𝒊 + 𝑦𝑝,𝑘 𝒋 + 𝑧𝑝,𝑘 𝒌 (2.4.2-15)
Where: 𝑠𝑛,𝑘 is decided by expression (2.4.2-7). 𝑹𝑖,𝑞 𝑖,𝑞

𝑜𝑝,𝑘 is pitch point at 𝜀1,𝑘 and calculated by
expression (1.4.10-5), then
𝑖,𝑞 𝑖,𝑞
𝑥𝑝,𝑘 = 𝑥𝑜𝑝,𝑘 + 𝑠𝑛,𝑘 𝐴𝑖,𝑞
𝑝,𝑘 ,
𝑦𝑝,𝑘 = 𝑦𝑜𝑝,𝑘 + 𝑠𝑛,𝑘 𝐵𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞
𝑧𝑝,𝑘 = ±𝑖𝛿 + 𝑠𝑛,𝑘 𝐶𝑝,𝑘 .}
B. Tooth Profile of Right-Flank of Tooth Space of Driving Gear
Similarly, solving equation (2.3.5-13) yields surface parameters of left-flank helicoid of hob 𝐶 at
conjugate cutting point corresponding to 𝑘th step of rotating angle of hob, that is,
𝑟𝑏 𝑏𝑎 𝑟𝑏 𝑏𝑎 𝑏 𝑟2 𝑟2
𝑏
𝑠𝑛,𝑘 = − ∆𝜀ℎ = − 𝑘𝛿𝜀ℎ , 𝜃𝑘 = − 𝑟 2+𝑏 2 ∆𝜀ℎ = − 𝑟 2 +𝑏 2 𝑘𝛿𝜀ℎ
√𝑟𝑏2 +𝑏𝑎2 √𝑟𝑏2 +𝑏𝑎2 𝑏 𝑎 𝑏 𝑎
(2.4.2-16)
𝑏𝑎2 𝑏𝑎2
Γ𝑘 = 𝛼0 + 𝑟 2+𝑏2 ∆𝜀ℎ = 𝛼0 + 𝑟 2+𝑏2 𝑘𝛿𝜀ℎ
𝑏 𝑎 𝑏 𝑎 }
~ 255 ~
𝑖,𝑞
2) Calculation of Unit Normal 𝑵𝑝,𝑘 to Tooth Profile at Conjugate Cutting Position
Let 𝑵𝑖,𝑞
𝑝,𝑘 be unit normal to tooth profile of workpiece 1 at instant conjugate cutting point
corresponding to 𝑞th tooth at 𝑖th cycle and 𝑘th step of rotating angle of hob 𝐶. and 𝑵ℎ𝑝 be unit
normal to helicoid of hob 𝐶 corresponding to conjugate cutting point 𝑃.
Method 1:
With help of expression (2.4.2-6), unit normal 𝑵ℎ𝑝 to helicoid of hob 𝐶 corresponding to cutting
point is as follow:
𝑵ℎ𝑝 = 𝐴ℎ𝑝 𝒊ℎ + 𝐵ℎ𝑝 𝒋ℎ + 𝐶ℎ𝑝 𝒌ℎ = 𝐴ℎ𝑝 𝒊 + 𝐵ℎ𝑝 𝒋 + 𝐶ℎ𝑝 𝒌
𝑖,𝑞 𝑖,𝑞
[𝐴ℎ𝑝 𝑁𝑜𝑝𝑥,0 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑦,0 ]𝒊 (2.4.2-17)
={ 𝑖,𝑞 𝑖,𝑞
}
+[𝐴ℎ𝑝 𝑁𝑜𝑝𝑦,0 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑥,0 ]𝒋 + (𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼)𝒌
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are (2.3.2-49), and

ℎ𝑝 = 𝐴ℎ𝑝 𝑁𝑜𝑝𝑥,0 − (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑦,0 ,
𝐵ℎ𝑝 = 𝐴ℎ𝑝 𝑁𝑜𝑝𝑦,0 + (𝐵ℎ𝑝 cos 𝛼 − 𝐶ℎ𝑝 sin 𝛼)𝑁𝑜𝑝𝑥,0 (2.4.2-18)
𝑖,𝑞
𝐶ℎ𝑝 = 𝐵ℎ𝑝 sin 𝛼 + 𝐶ℎ𝑝 cos 𝛼 . }
𝑖,𝑞
𝑵𝑝,𝑘 is derived by rotating (−𝑵ℎ𝑝 ) from initial reference position to conjugate cutting position
𝑖,𝑞
through an angle (−∆𝜑𝑝,𝑘 ) about 𝒌 as an axis, that is,

𝑝,𝑘 = 𝐴𝑝,𝑘 𝒊 + 𝐵𝑝,𝑘 𝒋 + 𝐶𝑝,𝑘 𝒌 = (−∆𝜑𝑝,𝑘 𝒌)⨂(−𝑵ℎ𝑝 )
𝑖,𝑞
(2.4.2-19)
= −(−∆𝜑𝑝,𝑘 ℎ𝑝 𝒊 + 𝐵ℎ𝑝 𝒋 + 𝐶ℎ𝑝 𝒌)
Where:
𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑝,𝑘 = −𝐴ℎ𝑝 cos(∆𝜑𝑝,𝑘 ) − 𝐵ℎ𝑝 sin(∆𝜑𝑝,𝑘 ) ,
𝑖,𝑞
𝐵𝑝,𝑘 ℎ𝑝 sin(∆𝜑𝑝,𝑘 ) − 𝐵ℎ𝑝 cos(∆𝜑𝑝,𝑘 ) ,
𝑖,𝑞 𝑖,𝑞
𝐶𝑝,𝑘 = −𝐶ℎ𝑝 . }
𝑖,𝑞
∆𝜑𝑝,𝑘 is calculated in the way similar to expression (2.4.2-11).
Method 2:
~ 256 ~
𝑖,𝑞
Similar to expression (2.4.2-13), 𝑵𝑝,𝑘 is yielded as follow:
𝑵𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑝,𝑘 = −𝑵ℎ𝑝 = 𝐴𝑝,𝑘 𝒊 + 𝐵𝑝,𝑘 𝒋 + 𝐶𝑝,𝑘 𝒌 = −(𝐴ℎ𝑝 𝒊ℎ,𝑘 + 𝐵ℎ𝑝 𝒋ℎ,𝑘 + 𝐶ℎ𝑝 𝒌ℎ,𝑘 ) (2.4.2-20)
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are expression (2.3.2-35) and,

𝑖,𝑞
𝑖,𝑞
𝐶𝑝,𝑘 = −𝐵ℎ𝑝 sin 𝛼 − 𝐶ℎ𝑝 cos 𝛼 . }
Where: 𝐴ℎ𝑝 , 𝐵ℎ𝑝 and 𝐶ℎ𝑝 are (2.3.2-49).
Due to unit normal 𝑵𝑖,𝑞

𝑝,𝑘 to tooth profile at conjugate contact point being pass through
corresponding pitch point, then, conjugate cutting point 𝑹𝑖,𝑞

𝑝,𝑘 of 𝑞th tooth at 𝑖th cycle and 𝑘th
step of rotating angle of hob is derived as follow:
𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑝,𝑘 = 𝑹𝑜𝑝,𝑘 + 𝜎ℎ 𝒌 + 𝑠𝑛,𝑘 𝑵𝑝,𝑘 = 𝑥𝑝,𝑘 𝒊 + 𝑦𝑝,𝑘 𝒋 + 𝑧𝑝,𝑘 𝒌 (2.4.2-21)
Where: 𝑠𝑛,𝑘 is decided by expression (2.4.2-16). 𝑹𝑖,𝑞 𝑖,𝑞

𝑜𝑝,𝑘 is pitch point at 𝜀1,𝑘 and calculated by
𝑖,𝑞
expression (1.4.10-5), 𝜀1,𝑘 is calculated by expression (2.4.2-12), then
𝑖,𝑞 𝑖,𝑞
𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞

𝑖,𝑞
Point 𝑹1,𝑘 on 𝑞th tooth of driving gear corresponding to 𝑖th cycle and 𝑘th step is derived
through rotating instantaneous contact point 𝑹𝑖,𝑞 𝑖,𝑞
𝑝,𝑘 by an angle (−𝜀1,𝑘 ) about 𝒌, that is,
𝑖,𝑞 𝑖,𝑞
𝒌)⨂𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑹1,𝑘 = (−𝜀1,𝑘 𝑝,𝑘 = (−𝜀1,𝑘 𝒌)⨂(𝑥𝑝,𝑘 𝒊 + 𝑦𝑝,𝑘 𝒋 + 𝑧𝑝,𝑘 𝒌)
(2.4.2-22)
= 𝑥1,𝑘 𝒊 + 𝑦1,𝑘 𝒋 + 𝑧1,𝑘 𝒌
Where:
~ 257~
𝑥1,𝑘 = 𝑥𝑝,𝑘 cos 𝜀1,𝑘 + 𝑦𝑝,𝑘 sin 𝜀1,𝑘 ,
𝑦1,𝑘 = −𝑥𝑝,𝑘 sin 𝜀1,𝑘 + 𝑦𝑝,𝑘 cos 𝜀1,𝑘
𝑖,𝑞 𝑖,𝑞
𝑧1,𝑘 = 𝑧𝑝,𝑘 . }
𝑖,𝑞
Unit normal 𝑵1,𝑘 to tooth profile 𝐴 of workpiece 1 at corresponding point 𝑵𝑖,𝑞
𝑝,𝑘 is
𝑖,𝑞 𝑖,𝑞
𝒌)⨂𝑵𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑵1,𝑘 = (−𝜀1,𝑘 𝑝,𝑘 = (−𝜀1,𝑘 𝒌)⨂(𝐴𝑝,𝑘 𝒊 + 𝐵𝑝,𝑘 𝒋 + 𝐶𝑝,𝑘 𝒌)
(2.4.2-23)
= 𝐴1,𝑘 𝒊 + 𝐵1,𝑘 𝒋 + 𝐶1,𝑘 𝒌
Where:
𝑖,𝑞
𝐴1,𝑘 𝑝,𝑘 cos 𝜀1,𝑘 + 𝐵𝑝,𝑘 sin 𝜀1,𝑘 ,
𝑖,𝑞
= −𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝐵1,𝑘 𝑝,𝑘 sin 𝜀1,𝑘 , + 𝐵𝑝,𝑘 cos 𝜀1,𝑘 ,
𝑖,𝑞 𝑖,𝑞
𝐶1,𝑘 = 𝐶𝑝,𝑘 . }
Point 𝑹𝑖,𝑞
2,𝑘 on 𝑞th tooth of driven gear corresponding to 𝑖th cycle and 𝑘th step is derived
through rotating instantaneous contact point 𝑹𝑖,𝑞 𝑖,𝑞
𝑝,𝑘 by an angle 𝜀2,𝑘 about 𝒌, that is,
𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

𝑹2,𝑘 = 𝑥2,𝑘 𝒊 + 𝑦2,𝑘 𝒋 + 𝑧2,𝑘 𝒌 = (𝜀2,𝑘 𝒌)⨂ [𝑹𝑝,𝑘 − (𝑙𝒑)|𝜀𝑖,𝑞 ]
1,𝑘 (2.4.2-24)
𝑖,𝑞 𝑖,𝑞
𝑓𝑘𝑖,𝑞 )𝒊 𝑖,𝑞
ℎ𝑘𝑖,𝑞 )𝒋 𝑖,𝑞
= (𝜀2,𝑘 𝒌)⨂[(𝑥𝑝,𝑘 − + (𝑦𝑝,𝑘 − + 𝑧𝑝,𝑘 𝒌]
Where: 𝑓𝑘𝑖,𝑞 and ℎ𝑘𝑖,𝑞 are decided by prescribed motion requirement and evaluated at angle 𝜀1,𝑘
𝑖,𝑞
which is calculated by application of expression (2.4.2-12), that is,

𝑖,𝑞 𝑖,𝑞
− 𝑓𝑘𝑖,𝑞 ) cos 𝜀2,𝑘
𝑖,𝑞 𝑖,𝑞
− ℎ𝑘𝑖,𝑞 ) sin 𝜀2,𝑘
𝑖,𝑞
𝑥2,𝑘 = (𝑥𝑝,𝑘 − (𝑦𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞
− 𝑓𝑘𝑖,𝑞 ) sin 𝜀2,𝑘
𝑖,𝑞 𝑖,𝑞
− ℎ𝑘𝑖,𝑞 ) cos 𝜀2,𝑘
𝑖,𝑞
𝑦2,𝑘 = (𝑥𝑝,𝑘 + (𝑦𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞
𝑧2,𝑘 = 𝑧𝑝,𝑘 . }
𝑖,𝑞 𝑖,𝑞 𝑑𝜀
𝜀2,𝑘 = 𝜀2,𝑘−1 + 𝑀|𝜀𝑖,𝑞 ( 𝑑𝑠1 ) | 𝑏𝑎 cos(𝛾0 − 𝜓 ) 𝛿𝜀ℎ (2.4.2-25)
1,𝑘−1 0 𝜏0 𝜀 𝑖,𝑞
1,𝑘−1
~ 258 ~
Where: 𝑀|𝜀𝑖,𝑞 is transmission ratio between workpiece 1 and 2 at instant rotating angle
1,𝑘−1
𝑖,𝑞 𝑑𝜀 𝑖,𝑞
𝜀1,𝑘−1 . ( 𝑑𝑠1 ) | is decided by expression (1.4.10-16) and evaluated at 𝜀1,𝑘−1 .
0 𝜏0 𝜀 𝑖,𝑞
1,𝑘−1
Unit normal 𝑵𝑖,𝑞

2,𝑘 to 𝑞th tooth of driven gear corresponding to 𝑖th cycle and 𝑘th step is as
follow:
𝑵𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

2,𝑘 = 𝐴2,𝑘 𝒊 + 𝐵2,𝑘 𝒋 + 𝐶2,𝑘 𝒌 = −(𝜀2,𝑘 𝒌)⨂(𝑵𝑝,𝑘 )
𝑖,𝑞
(2.4.2-26)
= −(𝜀2,𝑘 𝑝,𝑘 𝒊 + 𝐵𝑝,𝑘 𝒋 + 𝐶𝑝,𝑘 𝒌)
Where:
𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞

2,𝑘 = −𝐴𝑝,𝑘 cos 𝜀2,𝑘 + 𝐵𝑝,𝑘 sin 𝜀2,𝑘 ,
𝑖,𝑞
= −𝐴𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝐵2,𝑘 𝑝,𝑘 sin 𝜀2,𝑘 − 𝐵𝑝,𝑘 cos 𝜀2,𝑘 ,
𝑖,𝑞 𝑖,𝑞
𝐶2,𝑘 = −𝐶𝑝,𝑘 . }

A. Machine Setting Parameters for Workpiece 1 (as shown in figure 2.4.2-2)
With respect to machine coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ), corresponding to point on 𝑞th

tooth of 𝑖th cycle and 𝑘th step, rotating angle of driving gear should be adjusted by a
𝑖,𝑞
compensate angle ∆𝜀𝑚,𝑘 as shown in figure 2.4.2-1, that is,
𝑖,𝑞
𝑖,𝑞 𝑁𝑜𝑝𝑦,𝑘
−1
∆𝜀𝑚,𝑘 = tan ( 𝑖,𝑞 ) (2.4.2-27)
𝑁𝑜𝑝𝑥,𝑘
Where: 𝑵𝑖,𝑞 𝑖,𝑞

𝑜𝑝,𝑘 is unit normal to pitch curve at 𝜀1,𝑘 and calculated by expression (1.4.10-13).
𝑖,𝑞
Then, actual rotating angle ∆𝜀1𝑚,𝑘 of driving gear with respect to machine coordinate system
(𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ) is
∆𝜀1𝑚,𝑘 = 𝜀1,𝑘 − ∆𝜀𝑚,𝑘 (2.4.2-28)
As shown in figure 2.4.2-1, due to,

𝑖,𝑞
𝑓1𝑚,𝑘 𝑜𝑝,𝑘 = 𝑹𝑜𝑝,𝑘 + 𝑟0 𝑵𝑜𝑝,𝑘 + 𝑑𝑠1𝑚,𝑘 𝒌 × 𝑵𝑜𝑝,𝑘
~ 259 ~
𝑹𝑖,𝑞
𝑜𝑝,𝑘 rotating axis of hob 2 𝒌 × 𝑵𝑖,𝑞
𝑜𝑝,𝑘
𝑖,𝑞
𝑂 ∆𝜀𝑚,𝑘 𝒋
(𝑙𝒑)𝑖,𝑞
ℎ′ ,𝑘
𝑖,𝑞
𝑓1𝑚,𝑘
𝑖,𝑞
𝑑𝑠2𝑚,𝑘 rotating axis of hob 1
𝑂ℎ′
𝑃0 (𝑙𝒑)𝑖,𝑞
ℎ,𝑘
(𝑙𝒑)𝑖,𝑞
𝑘 𝑂ℎ 𝑖,𝑞
𝑑𝑠1𝑚,𝑘
𝑖,𝑞
𝒌ℎ 𝑓2𝑚,𝑘 𝑂′ 𝒋′
𝑵𝑖,𝑞
𝑜𝑝,𝑘
𝒊 𝒌ℎ
Pitch curve of workpiece 1 𝒊′ Pitch curve of workpiece 2
Figure 2.4.2-1 Machine Setting Parameters for point on 𝑞th tooth of 𝑖th cycle and 𝑘th step
Dot product of equation above with 𝑵𝑖,𝑞 𝑖,𝑞

𝑜𝑝,𝑘 and 𝒌 × 𝑵𝑜𝑝,𝑘 respectively gives
𝑖,𝑞
= 𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑓1𝑚,𝑘 𝑜𝑝,𝑘 ∙ 𝑵𝑜𝑝,𝑘 + 𝑟0 = 𝑥𝑜𝑝,𝑘 𝑁𝑜𝑝𝑥,𝑘 + 𝑦𝑜𝑝,𝑘 𝑁𝑜𝑝𝑦,𝑘 + 𝑟0 ,
𝑖,𝑞
} (2.4.2-29)
= −𝑹𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑑𝑠1𝑚,𝑘 𝑜𝑝,𝑘 ∙ (𝒌 × 𝑵𝑜𝑝,𝑘 ) = 𝑥𝑜𝑝,𝑘 𝑁𝑜𝑝𝑦,𝑘 − 𝑦𝑜𝑝,𝑘 𝑁𝑜𝑝𝑥,𝑘 .

𝑜𝑝,𝑘 is pitch point at 𝜀1,𝑘 and calculated by expression (1.4.10-5). 𝑵𝑜𝑝,𝑘 is unit normal
𝑖,𝑞 𝑖,𝑞
to pitch curve at 𝜀1,𝑘 and calculated by expression (1.4.10-13). 𝜀1,𝑘 is calculated by expression
(2.4.2-12).
~ 260 ~
𝑂𝑚 𝑱𝑚
𝑖,𝑞
𝑓1𝑚,𝑘
𝑃0
𝒌ℎ 𝒌 × 𝑵𝑖,𝑞
𝑜𝑝,𝑘
𝑖,𝑞
𝑂ℎ 𝑑𝑠1𝑚,𝑘
𝑰𝑚
B. Machine Setting Parameters for Workpiece 2 (as shown in figure 2.4.2-3)
With respect to machine coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ), corresponding to point on 𝑞th

tooth of 𝑖th cycle and 𝑘th step, actual rotating angle of driven gear about 𝝎′ = −𝑲𝑚 is
𝑖,𝑞
𝑵𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑓2𝑚,𝑘 𝑜𝑝,𝑘 = (𝑙𝒑)𝑘 − 𝑹𝑜𝑝,𝑘 + 𝑟0 𝑵𝑜𝑝,𝑘 + 𝑑𝑠2𝑚,𝑘 𝒌 × 𝑵𝑜𝑝,𝑘
Dot product of equation above with 𝑵𝑖,𝑞 𝑖,𝑞

𝑜𝑝,𝑘 and 𝒌 × 𝑵𝑜𝑝,𝑘 respectively gives
𝑖,𝑞
= [(𝑙𝒑)𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑓2𝑚,𝑘 𝑘 − 𝑹𝑜𝑝,𝑘 ] ∙ 𝑵𝑜𝑝,𝑘 + 𝑟0
𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
= (𝑓𝑘 − 𝑥𝑜𝑝,𝑘 )𝑁𝑜𝑝𝑥,𝑘 + (ℎ𝑘 − 𝑦𝑜𝑝,𝑘 )𝑁𝑜𝑝𝑦,𝑘 + 𝑟0 ,
𝑖,𝑞
(2.4.2-30)
= −[(𝑙𝒑)𝑖,𝑞 𝑖,𝑞 𝑖,𝑞
𝑑𝑠2𝑚,𝑘 𝑘 − 𝑹𝑜𝑝,𝑘 ] ∙ (𝒌 × 𝑵𝑜𝑝,𝑘 )
= (𝑓𝑘𝑖,𝑞 − 𝑥𝑜𝑝,𝑘
𝑖,𝑞 𝑖,𝑞
− (ℎ𝑘𝑖,𝑞 − 𝑦𝑜𝑝,𝑘
𝑖,𝑞 𝑖,𝑞
)𝑁𝑜𝑝𝑦,𝑘 )𝑁𝑜𝑝𝑥,𝑘 . }
Where: 𝑓𝑘𝑖,𝑞 and ℎ𝑘𝑖,𝑞 are decided by prescribed motion requirement.
~261 ~
𝑖,𝑞
𝑑𝑠2𝑚,𝑘
𝒌ℎ 𝑂ℎ′ 𝒌 × 𝑵𝑖,𝑞
𝑜𝑝,𝑘
𝑃0
𝑖,𝑞
𝑓2𝑚,𝑘
𝑂𝑚 𝑱𝑚
𝑰𝑚

Let point 𝑃(𝑹1𝑝 ) be conjugate contact point on tooth profile 𝐴 of workpiece 1 at instant
𝑖,𝑞
rotating angle 𝜀1,𝑘 , 𝑵𝑝 be unit normal to tooth profile 𝐴 of workpiece 1 at corresponding point
𝑃(𝑹1𝑝 ) and 𝝉 be unit tangent to tooth profile 𝐴 at corresponding point 𝑃(𝑹1𝑝 ) as shown in
𝑵𝑝 ×𝒌
𝝉 = |𝑵 (2.4.3-1)
𝑝 ×𝒌|
𝑑𝑵𝑝
A. Curvature ( ) of Tooth Profile 𝐴 of Workpiece 1 in Direction 𝝉
𝑑𝑠 𝝉
Point 𝑃0 is a pitch point on pitch surface 𝐴0 of tooth profile 𝐴 corresponding to point 𝑃(𝑹1𝑝 )
and 𝑵0𝑝 is unit normal to pitch surface 𝐴0 of tooth profile 𝐴. 𝒕0 is unit tangent to pitch surface
𝐴0 of tooth profile 𝐴 corresponding to 𝑵0𝑝 , that is,
~ 262 ~
𝒕0 = 𝑵0𝑝 × 𝒌 (2.4.3-2)
𝝉0 is another unit tangent to pitch surface 𝐴0 at pitch point 𝑃0 corresponding to unit tangent 𝝉.
𝝉0 = (𝜆0 𝑵0𝑝 ) ⊗ 𝒕0 = cos 𝜆0 𝒕0 + sin 𝜆0 𝑵0𝑝 × 𝒕0 = cos 𝜆0 𝒕0 − sin 𝜆0 𝒌 (2.4.3-3)
Relationship between arc-length 𝑑𝑠0 in tangent direction 𝝉0 and arc-length 𝑑𝑠𝑡 in tangent
direction 𝒕0 is
𝑑𝑠𝑡 = 𝑑𝑠0 cos 𝜆0 (2.4.3-4)
Pitch surface 𝐴0 of tooth profile 𝐴
𝑂 𝒋
𝑹0𝑝 + 𝜎ℎ 𝒌
𝑑𝑠𝑡 𝑃0
𝑠𝑛
𝒕0 𝜆0 𝑑𝑠0
𝝉0 𝑹1𝑝 𝑵0𝑝
𝑑𝑠𝑛 + 𝑠𝑛 𝑃
tooth profile 𝐴
𝒊 𝝉 𝑃′ 𝑑𝑠𝜏 𝑵𝑝
𝑑𝑵𝑝
𝑵𝑝 + ( ) 𝑑𝑠𝜏
𝑑𝑠 𝝉
Figure 2.4.3-1 Curvature of Tooth Profile 𝐴 at Conjugate Contact Point 𝑃 in Direction 𝝉
~ 263 ~
𝑑𝑵𝑝
𝑵𝑝′ = 𝑵𝑝 + ( ) 𝑑𝑠𝜏 (2.4.3-5)
𝑑𝑠 𝝉
With aid of expression (1.2.1-10), expression (2.4.3-5) is updated as follow:

𝑑𝑵𝑝
𝑵𝑝′ = 𝑵𝑝 + ( ) 𝑑𝑠𝜏 = 𝑵𝑝 + (𝛀𝜏 × 𝑵𝑝 )𝑑𝑠𝜏 (2.4.3-6)
𝑑𝑠 𝝉
Where: 𝛀𝜏 = 𝐾𝜏 (𝑵𝑝 × 𝝉) − 𝐺𝜏 𝝉.
By neglecting second or higher order infinitesimal, unit normal to tooth profile 𝐴 at point 𝑃′ in
conjugate contact position is as follow:
𝑝
𝑵𝑝′ = (𝑑𝜀1 𝒌) ⊗ 𝑵𝑝′ = 𝑵𝑝′ + 𝑑𝜀1 𝒌 × 𝑵𝑝′
(2.4.3-7)
= 𝑵𝑝 + (𝛀𝜏 × 𝑵𝑝 )𝑑𝑠𝜏 + 𝑑𝜀1 𝒌 × 𝑵𝑝
Corresponding to point 𝑃 on tooth profile 𝐴, point 𝑃 is also a point on involute helicoid of hob
𝐶. Point 𝑃′′ on involute helicoid of Hob 𝐶 adjacent to point 𝑃 is a conjugate point to point 𝑃′ on
tooth profile 𝐴 as shown in figure 2. 4.3-2. Unit normal 𝑵ℎ𝑝′′ to involute helicoid of hob 𝐶 at
point 𝑃′′ in conjugate cutting position is expressed in formular (2.3.6-13), that is,
𝑝
𝑵ℎ𝑝′′ = 𝑵ℎ𝑝 + (𝛀𝜏′ 𝑑𝑠𝜏′ + 𝑑𝜀ℎ 𝒌ℎ − 𝑑𝜑𝒌) × 𝑵ℎ𝑝
Tangent plane to involute helicoid of hob 𝐶 at point 𝑃 𝑵ℎ𝑝 𝑵ℎ𝑝 × 𝜻𝑝 𝑵ℎ𝑝′′
𝑑𝑠𝜏′ 𝝉′
𝑃 𝜆 𝑃′′
𝒌ℎ 𝜻𝑝
−𝑠𝑛 𝑵ℎ𝑝
𝑂ℎ 𝑟0 𝒋ℎ
𝒊ℎ
Figure 2.4.3-2 Tangent Plane to Involute Helicoid of Hob 𝐶 at Point 𝑃
~ 264 ~
𝑝 𝑝
Due to 𝑵𝑝′ = −𝑵ℎ𝑝′′ , then, application of expressions (2.4.3-7), (2.3.6-12) and expression
above gives
𝑑𝑠 𝑑𝜀 𝑑𝜑
(𝛀𝜏 × 𝑵𝑝 ) (𝑑𝑠𝜏 ) = − [( 𝑑𝑠1 ) + (𝑑𝑠 ) ] 𝒌 × 𝑵𝑝 (2.4.3-8)
0 𝜏0 0 𝜏0 0 𝜏0
Application of expression (2.4.3-4) yields

𝑑𝜀 𝑑𝜀 𝑑𝑠 𝑑𝜀
( 𝑑𝑠1) = ( 𝑑𝑠1 ) (𝑑𝑠𝑡 ) = ( 𝑑𝑠1) cos 𝜆0 ,
0 𝜏0 𝑡 𝑡 0 𝜏0 𝑡 𝑡
𝑑𝜑 𝑑𝜑 𝑑𝑠𝑡 𝑑𝜑
} (2.4.3-9)
(𝑑𝑠 ) = (𝑑𝑠 ) (𝑑𝑠 ) = (𝑑𝑠 ) cos 𝜆0 .
0 𝜏0 𝑡 𝑡 0 𝜏0 𝑡 𝑡
𝑑𝑠 𝑑𝜀 𝑑𝜑
(𝛀𝜏 × 𝑵𝑝 ) (𝑑𝑠𝜏 ) = |𝒌 × 𝑵𝑝 | [( 𝑑𝑠1) + (𝑑𝑠 ) ] cos 𝜆0 𝝉
0 𝜏0 𝑡 𝑡 𝑡 𝑡
𝑑𝜀 𝑑𝜀 𝑑𝜀 𝑑𝜑
With consideration 𝐾2𝑔0 = 0 , (𝑑𝑠1) = ( 𝑑𝑠1 ) and ( 𝑑𝑠2 ) = (𝑑𝑠 ) in expression (1.4.10-24),
0 𝜏0 𝑡 𝑡 0 𝜏0 𝑡 𝑡
expression above is modified as follow:

𝑑𝑠
(𝛀𝜏 × 𝑵𝑝 ) (𝑑𝑠𝜏 ) = 𝐾1𝑔0 |𝒌 × 𝑵𝑝 | cos 𝜆0 𝝉 (2.4.3-10)
0 𝜏0
Dot product on both sides of expression (2.4.3-10) with 𝝉 and 𝑵𝑝 × 𝝉 respectively results in
𝑑𝑠
𝐾𝜏 (𝑑𝑠𝜏 ) = 𝐾1𝑔0 |𝒌 × 𝑵𝑝 | cos 𝜆0 ,
0 𝜏0 } (2.4.3-11)
𝐺𝜏 = 0.
Due to relationship as shown in figure 2.4.3-1, that is,

𝑑𝑵𝑝
𝝉0 𝑑𝑠0 + (𝑑𝑠𝑛 + 𝑠𝑛 ) [𝑵𝑝 + ( ) 𝑑𝑠𝜏 ] = 𝑠𝑛 𝑵𝑝 + 𝑑𝑠𝜏 𝝉
𝑑𝑠 𝝉
Then, neglecting second or higher order infinitesimal gives

𝑑𝑵𝑝
𝝉0 𝑑𝑠0 + 𝑑𝑠𝑛 𝑵𝑝 + 𝑠𝑛 ( ) 𝑑𝑠𝜏 = 𝑑𝑠𝜏 𝝉
𝑑𝑠 𝝉
Dot product on both sides of expression above with 𝝉, 𝑵𝑝 and 𝑵𝑝 × 𝝉 respectively yields
~ 265 ~
𝑑𝑠 𝝉0 ∙𝝉
(𝑑𝑠𝜏 ) = 𝑑𝑵𝑝 ,
0 𝜏0 1−𝑠𝑛 ( ) ∙𝝉
𝑑𝑠 𝝉
𝑑𝑠
(𝑑𝑠𝑛) = −𝝉0 ∙ 𝑵𝑝 , (2.4.3-12)
0 𝜏0
𝝉0 ∙ (𝑵𝑝 × 𝝉) = 0. }
With help of expressions (2.4.3-1), (2.4.3-3) and (2.4.3-11), solving equation (2.4.3-12) gives
1 (𝑵𝑝 ∙𝑵0𝑝 )
= 2 + 𝑠𝑛 ,
𝐾𝜏 𝐾1𝑔0 |𝒌×𝑵𝑝 |
𝐺𝜏 = 0,
𝑑𝑠 (𝑵𝑝 ∙𝑵0𝑝 ) cos 𝜆0
(𝑑𝑠𝜏 ) = |𝑵 ,
0 𝜏0 𝑝 ×𝒌|(1−𝑠𝑛 𝐾𝜏 ) (2.4.3-13)
𝑑𝑠
( 𝑑𝑠𝑛) = −(cos 𝜆0 𝒕0 − sin 𝜆0 𝒌) ∙ 𝑵𝑝 ,
0 𝜏0
(𝒕0 ∙𝑵𝑝 )(𝑵𝑝 ∙𝒌)
tan 𝜆0 = − 2 .
1−(𝑵𝑝 ∙𝒌) }
Where: 𝒕0 = 𝑵0𝑝 × 𝒌 . 𝑠𝑛 is calculated by expression (2.4.2-6) or (2.4.2-15). 𝑵0𝑝 is determined

by expression (1.4.10-13). 𝐾1𝑔0 is determined by expression (1.4.10-26).
𝑑𝑵𝑝
B. Curvature ( ) of Tooth Profile 𝐴 of Workpiece 1 in Direction 𝒒 = 𝑵𝑝 × 𝝉
𝑑𝑠 𝒒
Unit tangent 𝒒 to tooth profile 𝐴 is defined as follow:
𝒒 = 𝑵𝑝 × 𝝉 (2.4.3-14)
Where: 𝝉 is decided by expression (2.4.3-1).
𝒒0 is an unit tangent to pitch surface 𝐴0 at pitch point 𝑃0 corresponding to unit tangent 𝒒 as

𝒒0 = (𝜆𝑞 𝑵0𝑝 ) ⊗ 𝒕0 = cos 𝜆𝑞 𝒕0 + sin 𝜆𝑞 𝑵0𝑝 × 𝒕0 = cos 𝜆𝑞 𝒕0 − sin 𝜆𝑞 𝒌 (2.4.3-15)
Relationship between arc-length 𝑑𝑠0 in tangent direction 𝒒0 and arc-length 𝑑𝑠𝑡 in tangent
direction 𝒕0 is
𝑑𝑠𝑡 = 𝑑𝑠0 cos 𝜆𝑞 (2.4.3-16)
~ 266 ~
𝒌
Pitch surface 𝐴0 of tooth profile 𝐴
𝑂 𝒋
𝑹0𝑝 + 𝜎ℎ 𝒌
𝑑𝑠𝑡 𝑃0
𝒕0 𝜆𝑞 𝑑𝑠0 𝑠𝑛
𝒒0 𝑹1𝑝
𝑑𝑠𝑛 + 𝑠𝑛 𝑵0𝑝
tooth profile 𝐴 𝑃
𝒊 𝑃′
𝒒 𝑑𝑠𝑞 𝑵𝑝
𝑑𝑵𝑝
𝑵𝑝 + ( ) 𝑑𝑠𝑞
𝑑𝑠 𝑞
Figure 2.4.3-3 Curvature of Tooth Profile 𝐴 at Contact Point 𝑃 in Direction 𝒒 = 𝑵𝑝 × 𝝉

𝑑𝑵𝑝
𝑵𝑝′ = 𝑵𝑝 + ( ) 𝑑𝑠𝑞 = 𝑵𝑝 + (𝛀𝑞 × 𝑵𝑝 )𝑑𝑠𝑞 (2.4.3-17)
𝑑𝑠 𝑞
Where: 𝛀𝑞 = 𝐾𝑞 (𝑵𝑝 × 𝒒) − 𝐺𝑞 𝒒.
By neglecting second or higher order infinitesimal, unit normal to tooth profile 𝐴 at point 𝑃′ in
conjugate contact position is as follow:
𝑝
𝑵𝑝′ = (𝑑𝜀1 𝒌) ⊗ 𝑵𝑝′ = 𝑵𝑝′ + 𝑑𝜀1 𝒌 × 𝑵𝑝′
(2.4.3-18)
= 𝑵𝑝 + (𝛀𝑞 × 𝑵𝑝 )𝑑𝑠𝑞 + 𝑑𝜀1 𝒌 × 𝑵𝑝
Similar to expression (2.4.3-8), it follows
~ 267 ~
𝑑𝑠𝑞 𝑑𝜀 𝑑𝜑
(𝛀𝑞 × 𝑵𝑝 ) (𝑑𝑠 ) = [( 𝑑𝑠1 ) + (𝑑𝑠 ) ]|𝑵𝑝 × 𝒌|𝝉 (2.4.3-19)
0 𝑞0 0 𝑞0 0 𝑞0

𝑑𝜀 𝑑𝜀 𝑑𝑠 𝑑𝜀
( 𝑑𝑠1) = ( 𝑑𝑠1) (𝑑𝑠𝑡 ) = ( 𝑑𝑠1) cos 𝜆𝑞 ,
0 𝑞0 𝑡 𝑡 0 𝑞0 𝑡 𝑡
𝑑𝜑 𝑑𝜑 𝑑𝑠𝑡 𝑑𝜑
} (2.4.3-20)
(𝑑𝑠 ) = (𝑑𝑠 ) (𝑑𝑠 ) = (𝑑𝑠 ) cos 𝜆𝑞 .
0 𝑞0 𝑡 𝑡 0 𝑞0 𝑡 𝑡
𝑑𝑠𝑞 𝑑𝜀 𝑑𝜑
(𝛀𝑞 × 𝑵𝑝 ) (𝑑𝑠 ) = [( 𝑑𝑠1) + (𝑑𝑠 ) ]|𝑵𝑝 × 𝒌| cos 𝜆𝑞 𝝉 (2.4.3-21)
0 𝑞0 𝑡 𝑡 𝑡 𝑡
𝑑𝜀 𝑑𝜑 𝑑𝜀
With consideration of 𝐾1𝑔0 = 𝐾1𝜏0 , 𝐾2𝜏0 = 0, substitution of ( 𝑑𝑠1) and (𝑑𝑠 ) into`( 𝑑𝑠1) and
𝑡 𝑡 𝑡 𝑡 0 𝜏0
𝑑𝜀
( 𝑑𝑠2) in expression (1.4.10-24) respectively yields
0 𝜏0
𝑑𝜀 𝑑𝜑
( 𝑑𝑠1) + (𝑑𝑠 ) = 𝐾1𝑔0 (2.4.3-22)
𝑡 𝑡 𝑡 𝑡

𝑑𝑠𝑞
(𝛀𝑞 × 𝑵𝑝 ) (𝑑𝑠 ) = 𝐾1𝑔0 |𝑵𝑝 × 𝒌| cos 𝜆𝑞 𝝉 (2.4.3-23)
0 𝑞0
Due to 𝒒 ⊥ 𝝉 , then 𝐺𝑞 = −𝐺𝜏 = 0 and 𝛀𝑞 × 𝑵𝑝 = 𝐾𝑞 𝒒 + 𝐺𝑞 𝑵𝑝 × 𝒒 = 𝐾𝑞 𝒒,
cos 𝜆𝑞 = 0,
} (2.4.3-24)
𝐾𝑞 = 0, 𝐺𝑞 = −𝐺𝜏 = 0.
𝑑𝑵𝑝
C. Curvature ( ) of Tooth Profile 𝐴 of Workpiece 1 in any Tangent Direction 𝒕
𝑑𝑠 𝒕
With help of expressions (2.4.3-13) and (2.4.3-24), curvature of tooth profile 𝐴 of Workpiece 1
at point 𝑃 in any tangent direction 𝒕 is calculated by expression (1.2.1-23) as shown in figure
2.4.3-4, that is,
𝐾𝑡 = 𝐾𝜏 cos2 𝜃𝜏𝑡 + 𝐾𝑞 sin2 𝜃𝜏𝑡 + 2𝐺𝜏 sin 𝜃𝜏𝑡 cos 𝜃𝜏𝑡 = 𝐾𝜏 cos2 𝜃𝜏𝑡 ,
} (2.4.3-25)
𝐺𝑡 = −(𝐾𝜏 − 𝐾𝑞 ) sin 𝜃𝜏𝑡 cos 𝜃𝜏𝑡 + 𝐺𝜏 (cos 2 𝜃𝜏𝑡 − sin2 𝜃𝜏𝑡 ) = −𝐾𝜏 sin 𝜃𝜏𝑡 cos 𝜃𝜏𝑡 .
~ 268 ~
𝒒 = 𝑵𝑝 × 𝝉
𝜃𝜏𝑡
𝑃 𝝉
Figure 2.4.3-4 Tangent Plane to Tooth Profile 𝐴 of Workpiece 1 at Point 𝑃

𝑑𝑵2𝑝 𝒗𝒑 𝟏𝟐
A. Curvature ( ) of Tooth Profile 𝐴̅ of Workpiece 2 in Direction |𝒗𝟏𝟐 |
𝑑𝑠 𝝉 𝒑
With help of expressions (2.4.1-18), )2.4.1-19), (2.4.1-20) and (2.4.1-25), relative velocity 𝒗12
𝑝 of
workpiece 1 with respect to workpiece 2 is derived as follow:
𝑑𝜀
𝒗12 ′ 2
𝑝 = 𝒗𝑝 − 𝒗𝑝 = 𝒌 × ∆𝑝 + 𝑑𝜀 𝒌 × ∆𝑝 = 𝑠𝑛 (1 + 𝑀)𝒌 × 𝑵𝑝 (2.4.3-26)
1
Where: 𝑠𝑛 is calculated by expression (2.4.2-6) or (2.4.2-15).
𝒗𝟏𝟐
𝒑
Comparing expressions (2.4.3-26) with (2.4.3-1) gives 𝝉 ∥ |𝒗𝟏𝟐 |.
𝒑
Application of expression (1.5.4-4) generates curvature of tooth profile 𝐴̅ of workpiece 2 in

direction 𝝉 as follow:
𝐷𝑝2
𝐾2𝜏 = 𝐷 12 − 𝐾𝜏 ,
𝐷𝑝 𝐸𝑝 𝐷𝑝 𝐸𝑝
} (2.4.3-27)
𝐺2𝜏 = 𝐺𝜏 − 𝐷 12 = −𝐷 12 .
𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝 𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝
Here: 𝐾𝜏 and 𝐺𝜏 are decided by expression (2.4.3-13). 𝑱𝑝 is calculated by formular (1.5.2-7), that
is,
~ 269 ~
𝑱𝑝 = 𝐽𝑝𝑥 𝒊 + 𝐽𝑝𝑦 𝒋
𝑑𝑀 𝑑2 (𝑙𝒑) 𝑑(𝑙𝒑)
𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + + 𝑀𝝎2 × [𝒗𝑝 − ]
={ 𝑑(𝑙𝒑)
}
−𝝎1 × [𝑀𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + ] (2.4.3-28)
𝑑𝜀1
𝑑ℎ 𝑑ℎ 𝑑2 𝑓 𝑑𝑀
𝐽𝑝𝑥 = 𝑀 (𝑓 − 𝑑𝜀 ) + 𝑑𝜀 + 𝑑𝜀2 + 𝑑𝜀 (𝑦𝑝 − ℎ),
1 1 1 1
𝑑𝑓 𝑑𝑀 𝑑𝑓 𝑑2 ℎ
𝐽𝑝𝑦 = 𝑀 (ℎ + 𝑑𝜀 ) − 𝑑𝜀 (𝑥𝑝 − 𝑓) − 𝑑𝜀 + 𝑑𝜀2 . }
1 1 1 1
With help of expression (2.4.3-13), 𝐷𝑝 and 𝐸𝑝 are calculated by formular (1.5.2-11)
𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑
𝐷𝑝 = 𝐾𝜏 |𝒗12 12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵𝑝 ] ∙ |𝒗𝟏𝟐 | = 𝐾𝜏 |𝒗𝑝 | − (1 + 𝑀)(𝒌 × 𝑵𝑝 ) ∙ |𝒗𝟏𝟐 | ,
𝒑 𝒑 } (2.4.3-29)
𝐸𝑝 = |𝒗12
𝑝 |𝐺𝜏 + (𝝎1 − 𝑀𝝎2 ) ∙ 𝝉 = 0.
Then, expression (2.4.3-27) is updated as follow:
𝐷𝑝2
𝐾2𝜏 = 𝐷 12 − 𝐾𝜏 ,
𝑝 |𝒗𝒑 |+𝑱𝑝 ∙𝑵1𝑝 } (2.4.3-30)
𝐺2𝜏 = 0.
𝑑𝑵2𝑝 𝒗𝒑 𝟏𝟐
B. Curvature ( ) of Tooth Profile 𝐴̅ of Workpiece 2 in Direction 𝒆 = 𝑵𝑝 × |𝒗𝟏𝟐 |
𝑑𝑠 𝝉 𝒑
𝒑 𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐
𝒆 = (𝜃𝜏𝑒 𝑵𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐| cos 𝜃𝜏𝑒 + (𝑵𝑝 × |𝒗𝟏𝟐 |) sin 𝜃𝜏𝑒 (2.4.3-31)
𝒑 𝒑 𝒑
Where:
𝐷𝑝
sin 𝜃𝜏𝑒 = − ,
𝐸𝑝
cos 𝜃𝜏𝑒 = = 0.
}
𝒗𝟏𝟐
𝒑
That is, 𝒆 = 𝑵2𝑝 × |𝒗𝟏𝟐 |
𝒑
𝐾2𝑒 = −𝐾𝑒 = 𝐾𝑞 = 0,
} (2.4.3-32)
𝐺2𝑒 = 0.
~ 270 ~
𝑑𝑵2𝑝
C. Curvature ( ) of Tooth Profile 𝐴̅ of Workpiece 2 in any Tangent Direction 𝒕
𝑑𝑠 𝒕
With help of expressions (2.4.3-30) and (2.4.3-32), curvature of tooth profile 𝐴 of Workpiece 1
at point 𝑃 in any tangent direction 𝒕 is calculated by expression (1.2.1-23) as shown in figure
2.4.3-5, that is,
𝐾2𝑡 = 𝐾2𝜏 cos2 𝜃𝜏𝑡 + 𝐾2𝑒 sin2 𝜃𝜏𝑡 + 2𝐺2𝜏 sin 𝜃𝜏𝑡 cos 𝜃𝜏𝑡 = 𝐾2𝜏 cos2 𝜃𝜏𝑡 ,
𝐺2𝑡 = −(𝐾2𝜏 − 𝐾2𝑒 ) sin 𝜃𝜏𝑡 cos 𝜃𝜏𝑡 + 𝐺2𝜏 (cos 2 𝜃𝜏𝑡 − sin2 𝜃𝜏𝑡 ) } (2.4.3-33)
= −𝐾2𝜏 sin 𝜃𝜏𝑡 cos 𝜃𝜏𝑡
𝒗𝟏𝟐
𝒑
𝒆 = 𝑵2𝑝 × |𝒗𝟏𝟐|
𝒑
𝜃𝜏𝑡
𝒗𝟏𝟐
𝒑
𝑃 |𝒗𝟏𝟐
𝒑 |
Figure 2.4.3-5 Tangent Plane to Tooth Profile 𝐴̅ of Workpiece 2 at Point 𝑃
2.4.4 Limit Tooth Profile Angle of Hob

In order to generate tooth profile on both sides of pitch curve, it is necessary for tooth profile
to intersect with pitch curve as shown in figure 2.4.4-1.
Let 𝑵𝑝 be unit normal to tooth profile 𝐴 at point 𝑃 as shown in figure 2.4.4-1 and 𝑵ℎ𝑝 be unit
normal to involute helicoid of hob 𝐶, that is, 𝑵𝑝 = −𝑵ℎ𝑝 .
𝒕0 is unit tangent to pitch curve at pitch point 𝑃0 corresponding to point 𝑃 on tooth profile 𝐴
and is calculated as follow:
𝒕0 = [−(𝛾0 − 𝜓)𝒊ℎ ] ⊗ 𝒌ℎ = sin(𝛾0 − 𝜓) 𝒋ℎ + cos(𝛾0 − 𝜓) 𝒌ℎ (2.4.4-1)

𝑏𝑎
With help of tan 𝛾0 = and expression (2.3.2-35) or (2.3.2-49), distance between 𝑃0 and 𝐷 is
𝑟0
calculated as shown in figure 2.4.4-1, that is,
~ 271 ~
̅̅̅̅̅
𝑃0 𝐷 = |𝑠𝑛 𝑵𝑝 ∙ 𝒕0 | = |𝑠𝑛 𝑵ℎ𝑝 ∙ 𝒕0 | = |𝑠𝑛 [𝐵ℎ𝑝 sin(𝛾0 − 𝜓) + 𝐶ℎ𝑝 cos(𝛾0 − 𝜓)]|
𝑠𝑛 𝑠𝑛 (2.4.4-2)
=| cos(𝛾0 − 𝜓) (𝑏𝑎 cos 𝛼0 tan(𝛾0 − 𝜓) + 𝑟𝑏 )| = | 𝑟0 cos 𝛼0 cos 𝜓|
tooth profile 𝐴
𝑃
𝑠𝑛 𝑵𝑝 Σ
𝜌0
𝐷
𝑃0
𝒕0
Figure 2.4.4-1 Limit Tooth Profile Angle
And
1
̅̅̅̅̅
Σ = 2𝜌 (𝑃 0 𝐷)
2
(2.4.4-3)
0
Where: 𝜌0 is curvature radius of pitch curve 𝐴0 .
Distance between 𝑃 and 𝐷 is as follow:
1 1
̅̅̅̅ = |𝑠𝑛 𝑵𝑝 ∙ 𝒊ℎ | = |𝑠𝑛 𝐴ℎ𝑝 | = |
𝑃𝐷 𝑠𝑛 𝑏𝑎 sin 𝛼0 | = | 𝑠𝑛 𝑟0 tan 𝛾0 sin 𝛼0 | (2.4.4-4)
Limit condition is as follow:
̅̅̅̅
𝑃𝐷 ≥ Σ
That is,
~ 272 ~
2
1 1 𝑠𝑛
| 𝑠𝑛 𝑟0 tan 𝛾0 sin 𝛼0 | − 2𝜌 ( 𝑟0 cos 𝛼0 cos 𝜓) ≥ 0
√𝑟𝑏2 +𝑏𝑎2 0 cos 𝛾0 √𝑟𝑏2 +𝑏𝑎2
Then
1
tan 𝛾0 sin 𝛼0 ≥ |𝑠𝑛 |𝑟0 cos2 𝛼0 cos 2 𝜓
2𝜌0 cos2 𝛾0 √𝑟𝑏2 +𝑏𝑎2
Substitution of expression (2.4.2-6) or (2.4.2-15) into expression above gives

1 cos 𝛾0
tan3 𝛼0 + sin2 𝛾 tan 𝛼0 − 2𝜌 3𝛾
𝑏𝑎 |∆𝜀ℎ | cos2 𝜓 ≥ 0 (2.4.4-5)
0 0 sin 0
1 cos 𝛾0
Let 𝐹 = sin2 𝛾 and 𝐺 = − 2𝜌 3𝛾 𝑏𝑎 |∆𝜀ℎ | cos 2 𝜓
0 0 sin 0
Then
𝟑 2 3 𝟑 2 3
𝐺 𝐺 𝐹 𝐺 𝐺 𝐹 (2.4.4-6)
tan 𝛼0𝑚𝑖𝑛 = √− 2 + √( 2 ) + (3) + √− 2 − √( 2 ) + (3)
Example 2. 4.1 continue Example 1.4.1.
Given Condition:
Parameters of Hob
Then, let pitch of workpiece is equally divided by 𝑚 = 40 segments. Helical angle of workpiece
is 𝜓 = 12(𝑑𝑒𝑔)
In sum:
1 𝑏
𝑃𝑑 = 0.4, 𝑏𝑎 = 2𝑃 = 1.25, 𝑟0 = 35.0 𝑚 = 40, 𝛾0 = tan−1 ( 𝑟𝑎) = 2.04(𝑑𝑒𝑔. ),
𝑑 0
𝜋 𝑝 }
𝑝 = 𝑃 cos(𝛾0 − 𝜓) = 6.7556, 𝛿𝑠0 = 𝑚, 𝑠0 = 123.438, 𝛼0 = 85° , 𝑁 = 15.
𝑑
~273 ~
𝑑𝜀 𝜀
1 1
0,0 0,0
𝜀1,0 = 0, 𝜀2,0 = 0.
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑖 = 0; 𝑖 ≤ 𝑢𝑛𝑡𝑖𝑙𝑒 𝑤ℎ𝑜𝑙𝑒 𝑡𝑜𝑜𝑡ℎ ℎ𝑒𝑖𝑔ℎ𝑡; 𝑖 + +)
𝑖,0 𝑖−1,0 𝑑𝜀
𝜀1,0 = 𝜀1,0 + ( 𝑑𝑠1 ) | 𝛿 tan 𝜓, Expression (2.4.2-1)
0 𝜏0 𝑖−1,0
𝜀1,0
𝑖,0 𝑖−1,0 𝑑𝜀
𝜀2,0 = 𝜀2,0 + 𝑀|𝜀𝑖−1,0 (𝑑𝑠1 ) | 𝛿 tan 𝜓,
1,0 0 𝜏0 𝑖−1,0
𝜀1,0
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 ≤ 𝑁; 𝑞 + +)
{
𝑖,𝑞 𝑖,𝑞−1 𝑖,𝑞 𝑖,𝑞−1
𝜀1,0 = 𝜀1,𝑛 , 𝜀2,𝑞 = 𝜀2,𝑛 ,
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑘 = 1; 𝑘 ≤ 𝑢𝑛𝑡𝑖𝑙 𝑐𝑜𝑣𝑒𝑟𝑖𝑛𝑔 𝑒𝑛𝑡𝑖𝑟𝑒 𝑡𝑜𝑜𝑡ℎ 𝑝𝑟𝑜𝑓𝑖𝑙𝑒; 𝑘 + +)
𝜀1,𝑘 = 𝜀1,𝑘−1 + (𝑑𝑠1 ) | 𝑏𝑎 𝛿𝜀ℎ cos(𝛾0 − 𝜓 ) expression (2.4.2-12)
0 𝜏0 𝑖,𝑞
𝜀1,𝑘−1
𝜀2,𝑘 = 𝜀2,𝑘−1 + 𝑀|𝜀𝑖,𝑞 (𝑑𝑠1 ) | 𝑏𝑎 𝛿𝜀ℎ cos(𝛾0 − 𝜓 )
1,𝑘−1 0 𝜏0 𝑖,𝑞
𝜀1,𝑘−1
Step 2. Calculation for Contact Point and Unit Normal to Tooth Profile in Cutting Position, i.e.,
expressions (2.4.2-13) or (2.4.2-19) and (2.4.2-14) or (2.4.2-20)
~ 274 ~
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 ≤ 𝑁; 𝑞 + +)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑘 = 1; 𝑘 ≤ 𝑢𝑛𝑡𝑖𝑙 𝑐𝑜𝑣𝑒𝑟𝑖𝑛𝑔 𝑒𝑛𝑡𝑖𝑟𝑒 𝑡𝑜𝑜𝑡ℎ 𝑝𝑟𝑜𝑓𝑖𝑙𝑒; 𝑘 + +)

𝑖,𝑞
𝑖,𝑞
𝐶𝑝,𝑘 = −𝐵ℎ𝑝 sin 𝛼 − 𝐶ℎ𝑝 cos 𝛼 , }
𝑖,𝑞 𝑖,𝑞
𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞
Step 3. Calculation for Tooth Profile of Workpiece 1 & 2, that is, expressions (2.4.2-21) and
(2.4.2-23)
𝑓𝑜𝑟(𝑖𝑛𝑡 𝑞 = 0; 𝑞 ≤ 𝑁; 𝑞 + +)
~275 ~
𝑥1,𝑘 = 𝑥𝑝,𝑘 cos 𝜀1,𝑘 + 𝑦𝑝,𝑘 sin 𝜀1,𝑘 ,
𝑦1,𝑘 = −𝑥𝑝,𝑘 sin 𝜀1,𝑘 + 𝑦𝑝,𝑘 cos 𝜀1,𝑘
𝑖,𝑞 𝑖,𝑞
𝑧1,𝑘 = 𝑧𝑝,𝑘 . }
𝑖,𝑞 𝑖,𝑞
− 𝑓𝑘𝑖,𝑞 ) cos 𝜀2,𝑘
𝑖,𝑞 𝑖,𝑞
− ℎ𝑘𝑖,𝑞 ) sin 𝜀2,𝑘
𝑖,𝑞
𝑥2,𝑘 = (𝑥𝑝,𝑘 − (𝑦𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞
− 𝑓𝑘𝑖,𝑞 ) sin 𝜀2,𝑘
𝑖,𝑞 𝑖,𝑞
− ℎ𝑘𝑖,𝑞 ) cos 𝜀2,𝑘
𝑖,𝑞
𝑦2,𝑘 = (𝑥𝑝,𝑘 + (𝑦𝑝,𝑘 ,
𝑖,𝑞 𝑖,𝑞
𝑧2,𝑘 = 𝑧𝑝,𝑘 . }
~276~
Example 2.4.1-a A Pair of Gear Sets
Example 2.4.1-b Manufacturing Process of Driving Gear
~ 277 ~
Example 2.4.1-c Manufacturing Process of Driven Gear
~278~
Part III
Gear Transmission with Varied Transmission Ratio
between Two Intersecting Rotating Axes
This chapter discusses and invents an innovative tooth profile. Conjugate motion of cutter with
respect to workpiece requires special machine which doesn’t exist in current industry.
Mathematic formulas developed in this part can provide theoretical foundation to design and
develop new machine specially for this type of tooth profile.
~279~
Chapter 1
Pitch Curves of Workpiece 1 & 2
3.1.1 Coordinate System and Relative Velocity

1 Coordinate System
Workpiece 1 rotates by an angle 𝜀1 about 𝒌 = 𝝎1 as an axis, and workpiece 2 rotates by an
angle 𝜀2 about 𝝎2 as an axis as shown in figure 3.1.1-1.
𝒌 = 𝝎1
𝑹0𝑝
𝛾𝑞 𝒌′ = −𝝎2
𝑂 𝒋
𝝎2
𝒊 = 𝒊′ 𝒋′
Figure 3.1.1-1 Coordinate System
Relationship between coordinate systems 𝑂 − 𝒊, 𝒋, 𝒌 and 𝑂 − 𝒊′ , 𝒋′ , 𝒌′ is as follow:
𝒊 = 𝒊′ ,
𝒌′ = −𝝎2 = (− 𝛼𝒊) ⊗ 𝒌 = sin 𝛼 𝒋 + cos 𝛼 𝒌,
𝒋′ = 𝒌′ × 𝒊′ = − sin 𝛼 𝒌 + cos 𝛼 𝒋, (3.1.1-1)
𝒋 = cos 𝛼 𝒋′ + sin 𝛼 𝒌′ ,
𝒌 = − sin 𝛼 𝒋′ + cos 𝛼 𝒌′ . }
2 Index Curve
In order to conduct conjugate motion with periodic transmission ratio 𝑀, tooth profiles
~ 280 ~
of workpieces are distributed on closed curves which are defined as index curves. In the case of
𝑑𝑓 𝑑ℎ 𝑑𝜎1 𝑑𝜎2
two fixed intersecting rotating axes, that is, 𝑓 = ℎ = 𝜎1 = 𝜎2 = 𝑑𝜀 = 𝑑𝜀 = = = 0,
1 1 𝑑𝜀1 𝑑𝜀1
existent condition of pitch surfaces, that is, expression (1.4.2-1), is satisfied, and corresponding
pitch curve of workpiece 1 is generated by application of expression (1.4.3-1) as follow:
𝑹0 = 𝑥0 𝒊 + 𝑦0 𝒋 + 𝑧0 𝒌,
𝑀𝑧0 sin 𝛼 sin 𝜀1
𝑥0 = , (3.1.1-2)
1+𝑀 cos 𝛼
𝑀𝑧0 sin 𝛼 cos 𝜀1
𝑦0 = . }
1+𝑀 cos 𝛼
Where: 𝜀1 is independent parameter and 𝑧0 is a prescribed function of transmission ratio 𝑀.

Due to 𝑀 being a periodic function, pitch curve of workpiece 1 defined in expression (3.1.1-2) is
closed curve.
Likewise, pitch curve of workpiece 2 is generated by application of expression (1.4.3-3) as

follow:
𝑹′0 = 𝑥0′ 𝒊′ + 𝑦0′ 𝒋′ + 𝑧0′ 𝒌′ ,

−𝑀𝑧0 sin 𝛼 cos 𝛼 sin 𝜀2
𝑥0′ = + 𝑧0 sin 𝛼 sin 𝜀2 ,
1+𝑀 cos 𝛼
𝑀𝑧0 sin 𝛼 cos 𝛼 cos 𝜀2 (3.1.1-3)
𝑦0′ = − 𝑧0 sin 𝛼 cos 𝜀2 ,
1+𝑀 cos 𝛼
𝑀𝑧0 sin 𝛼
𝑧0′ = 1+𝑀 cos 𝛼 sin 𝛼 + 𝑧0 cos 𝛼 . }
3 Relative Velocity
As an option, let pitch curve 𝐴0 of workpiece 1 lie on sphere with radius 𝑅0 . Vector 𝑹0𝑝 of pitch
point (𝑃) in conjugate contact position is
𝑹0𝑝 = 𝑅0 (cos 𝜃 𝒋 + sin 𝜃 𝒌) (3.1.1-4)
Velocity 𝒗0 of pitch point (𝑃) on workpiece 1 is
𝒗0 = 𝒌 × 𝑹0𝑝 = −𝑅0 cos 𝜃 𝒊 (3.1.1-5)
Velocity 𝒗′0 of pitch point (𝑃) on workpiece 2 is

𝑑𝜀
𝒗′0 = 𝑑𝜀2 𝝎2 × 𝑹0𝑝 = −𝑅0 𝑀12 (sin 𝛼 𝒋 + cos 𝛼 𝒌) × (cos 𝜃 𝒋 + sin 𝜃 𝒌)
1 (3.1.16)
= 𝑅0 𝑀12 cos(𝜃 + 𝛼) 𝒊
𝑑𝜀
Where: 𝑀12 = 𝑑𝜀2.
1
~ 281 ~
Due to 𝑹0𝑝 being pitch point, that is,
𝒗0 − 𝒗′0 = −𝑅0 cos 𝜃 𝒊 − 𝑅0 𝑀12 cos(𝜃 + 𝛼) 𝒊 = 𝟎
Thus,
𝑀12 cos 𝛼+1 1
tan 𝜃 = = cot 𝛼 + 𝑀 (3.1.1-7)
𝑀12 sin 𝛼 12 sin 𝛼
3.1.2 Pitch Curves of Workpiece 1 & 2

1 First Pitch Curve
Application of expression (1.4.3-1) gives the pitch curve 𝐴0 of workpiece 1, that is,
𝑹0 = 𝑥0 𝒊 + 𝑦0 𝒋 + 𝑧0 𝒌 (3.1.2-1)
Where: 𝜀1 is independent parameters and
𝑧0 = 𝑅0 sin 𝜃 ,
𝑀12 𝑧0 sin 𝛼 sin 𝜀1 𝑀12 𝑧0 sin 𝛼 cos 𝜀1
𝑥0 = = 𝑅0 cos 𝜃 sin 𝜀1 , 𝑦0 = 1+𝑀12 cos 𝛼
= 𝑅0 cos 𝜃 cos 𝜀1 ,
1+𝑀12 cos 𝛼
𝑑𝑧0 𝑑𝜃 𝑑𝜃 sin 𝛼 𝑑𝑀12
= 𝑑𝜀 𝑅0 cos 𝜃 , = − 1+2𝑀 2 ,
𝑑𝜀1 1 𝑑𝜀1 12 cos 𝛼+𝑀12 𝑑𝜀1
𝑑𝑥0 𝑑𝜃 𝑑𝑦0 𝑑𝜃
= 𝑅0 (− 𝑑𝜀 sin 𝜃 sin 𝜀1 + cos 𝜃 cos 𝜀1 ) , = −𝑅0 (cos 𝜃 sin 𝜀1 + 𝑑𝜀 sin 𝜃 cos 𝜀1 ) .}
𝑑𝜀1 1 𝑑𝜀1 1
2 Second Pitch Curve

Application of expression (1.4.3-3) gives the pitch curve 𝐴̅0 of workpiece 2, that is,
𝑹′0 = 𝑥0′ 𝒊′ + 𝑦0′ 𝒋′ + 𝑧0′ 𝒌′ (3.1.2-2)
Where:
−𝑀12 𝑧0 sin 𝛼 cos 𝛼 sin 𝜀2 1
𝑥0′ = + 𝑧0 sin 𝛼 sin 𝜀2 = − sin 𝜃 𝑧0 cos(𝜃 + 𝛼) sin 𝜀2 ,
1+𝑀12 cos 𝛼
𝑀12 𝑧0 sin 𝛼cos 𝛼 cos 𝜀2 1
𝑦0′ = − 𝑧0 sin 𝛼 cos 𝜀2 = sin 𝜃 𝑧0 cos(𝜃 + 𝛼) cos 𝜀2 ,
1+𝑀12 cos 𝛼
𝑧0 𝑀12 sin 𝛼 1
𝑧0′ = 1+𝑀 sin 𝛼 + 𝑧0 cos 𝛼 = sin 𝜃 𝑧0 sin(𝜃 + 𝛼) . }
cos 𝛼
12
3 Arc-Length of Pitch Curve
Arc-length of pitch curve is as follow:
~282 ~
𝑑𝑥 2 𝑑𝑦 2 𝑑𝑧 2 𝑑𝜃 2
𝑑𝑠0 = √(𝑑𝜀 0) + ( 𝑑𝜀 0 ) + (𝑑𝜀0) 𝑑𝜀1 = 𝑅0 √cos 2 𝜃 + (𝑑𝜀 ) 𝑑𝜀1 (3.1.2-3)
1 1 1 1
4 Calculation of Parameter 𝑅0
Let 𝑝 be pitch of workpiece and 𝑍1 be tooth number of workpiece 1, then, circumference 𝑠0 of
pitch curve 𝐴0 of workpiece 1 is as follow:
2𝜋 𝑑𝜃 2
𝑠0 = 𝑅0 ∫0 √cos2 𝜃 + (𝑑𝜀 ) 𝑑𝜀1 = 𝑝𝑍1 (3.1.2-4)
1
Therefore
𝑝𝑍1
𝑅0 = (3.1.2-5)
2𝜋 𝑑𝜃 2
∫0 √cos2 𝜃+(𝑑𝜀 ) 𝑑𝜀1
1
~ 283 ~
Chapter 2
Cutter Surfaces
For practical convenience, conical surface is used as cutter surface to generate tooth profile of
workpiece 1 & 2. Relative motion of workpiece with respect to cutter is decided by application
of chapter 7 in part one.
3.2.1 General Equation of Conical Surface

Machine coordinate system is 𝑂𝑚 − 𝒊𝑚 , 𝒋0 , 𝒌𝑚 as shown in figure 3.2.1-1
𝒌𝑚 is rotating axis of cradle and 𝒌𝑐 is axis of conical surface.
Relationship of coordinate systems 𝑂𝑐 − 𝒊𝑐 , 𝒋𝑐 , 𝒌𝑐 with respect to 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 is as follow:
𝒊𝑐 = (Θ𝒌𝑚 ) ⊗ 𝒊𝑚 = cos Θ 𝒊𝑚 + sin Θ 𝒋𝑚 ,

𝒌𝑐 = (ζ𝒊𝑐 ) ⊗ 𝒌𝑚 = sin ζ (sin Θ 𝒊𝑚 − cos Θ 𝒋𝑚 ) + cos ζ 𝒌𝑚 ,
(3.2.1-1)
𝒋𝑐 = 𝒌𝑐 × 𝒊𝑐 = cos ζ (− sin Θ 𝒊𝑚 + cos Θ 𝒋𝑚 ) + sin ζ 𝒌𝑚 ,
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 = 𝑥𝑐 𝒊𝑚 + 𝑦𝑐 𝒋𝑚 + 𝑧𝑐 𝒌𝑚 . }
𝒌𝑐
𝒌𝑚 𝒋𝑐 𝒕𝑐
ζ 𝑠𝑐
𝑂𝑐 𝑟𝑐
Θ 𝒊𝑐
𝑂𝑚 𝒋𝑚
𝒊𝑚
Figure 3.2.1-1 Coordinate System and Conical Surface
𝒕𝑐 is unit tangent to cutting edge, that is,
𝒕𝑐 = sin ∅𝑐 𝒊𝑐 + cos ∅𝑐 𝒌𝑐 (3.2.1-2)

~ 284~
With help of expression (3.2.1-1), conical surface 𝑹 is as follow:
𝑹 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 + (𝜇𝒌𝑐 ) ⊗ (𝑟𝑐 𝒊𝑐 + 𝑠𝑐 𝒕𝑐 )
= ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 𝒊𝑐 + sin 𝜇 𝒋𝑐 ) + 𝑠𝑐 cos ∅𝑐 𝒌𝑐
[𝑥𝑐 + 𝑠𝑐 cos ∅𝑐 sin ζ sin Θ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 cos Θ − sin 𝜇 cos ζ sin Θ)]𝒊𝑚 (3.2.1-3)
= {+[𝑦𝑐 − 𝑠𝑐 cos ∅𝑐 sin ζ cos Θ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 sin Θ + sin 𝜇 cos ζ cos Θ)]𝒋𝑚 }
+[𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 cos ζ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ]𝒌𝑚
Where: Θ is swivel angle and ζ is tilt angle.
In the case of no tilt device, that is, Θ = ζ = 0, then, expression (3.2.1-3) is simplified as follow:
[𝑥𝑐 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos 𝜇]𝒊𝑚 + [𝑦𝑐 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇]𝒋𝑚
𝑹={ } (3.2.1-4)
+(𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 )𝒌𝑚
3.2.2 Cutter Surface for Workpiece 1

Cutter surface for workpiece 1 is generated by cutting edge of cutter head. Unit tangent to
cutting edge is as follow:
𝒕𝑐 = sin ∅𝑐 𝒊𝑐 + cos ∅𝑐 𝒌𝑐 (3.2.2-1)

𝜋
Where: for inner blade: ∅𝑐 is equal to blade angle ∅𝑐𝑖 of inner cutter head, thus, 0 < ∅𝑐𝑖 < ,
2
𝒕𝑐 = 𝒕𝑐𝑖 = sin ∅𝑐𝑖 𝒊𝑐 + cos ∅𝑐𝑖 𝒌𝑐 and for outer blade: ∅𝑐 is equal to blade angle ∅𝑐𝑜 of outer
𝜋
cutter head, thus, < ∅𝑐𝑜 < 𝜋 and 𝒕𝑐 = 𝒕𝑐𝑜 = sin ∅𝑐𝑜 𝒊𝑐 + cos ∅𝑐𝑜 𝒌𝑐 as shown in figure
2
3.2.2-1.
Therefore, with respect to coordinate system 𝑂𝑐 − 𝒊𝑐 , 𝒋𝑐 , 𝒌𝑐 as shown in figure 3.2.2-1, cutter

surface 𝑹𝑐 is obtained by rotating cutting edge 𝑠𝑐 𝒕𝑐 about 𝒌𝑐 as axis, that is,
𝑹𝑐 = (𝜇𝒌𝑐 ) ⊗ (𝑟𝑐 𝒊𝑐 + 𝑠𝑐 𝒕𝑐 ) = (𝜇𝒌𝑐 ) ⊗ [(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )𝒊𝑐 + 𝑠𝑐 cos ∅𝑐 𝒌𝑐 ]

(3.2.2-2)
= (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 𝒊𝑐 + sin 𝜇 𝒋𝑐 ) + 𝑠𝑐 cos ∅𝑐 𝒌𝑐
Where: 𝑟𝑐 is nominal radius of cutter head, for inner cutter head: 𝑟𝑐 = 𝑟𝑐𝑖 and for outer cutter
head: 𝑟𝑐 = 𝑟𝑐𝑜 .
Substitution of expressions (3.2.2-2) into (3.2.1-3) gives equation of cutter surface with respect
to coordinate system 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 as follow:
𝑹𝑐 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂0𝑚 𝑂𝑐 + (𝜇𝒌𝑐 ) ⊗ (𝑟𝑐 𝒊𝑐 + 𝑠𝑐 𝒕𝑐 ) = 𝑥𝒊𝑚 + 𝑦𝒋𝑚 + 𝑧𝒌𝑚 (3.2.2-3)
Where: for inner blade: Θ = Θ𝑖 , ζ = ζ𝑖 , 𝜇 = 𝜇𝑖 and 𝑠𝑐 = 𝑠𝑐𝑖 ; for outer blade: Θ = Θ𝑜 , ζ = ζ𝑜 ,

~ 285 ~
𝜇 = 𝜇𝑜 and 𝑠𝑐 = 𝑠𝑐𝑜 , and
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 = 𝑥𝑐 𝒊𝑚 + 𝑦𝑐 𝒋𝑚 + 𝑧𝑐 𝒌𝑚 ,
𝑥 = 𝑥𝑐 + 𝑠𝑐 cos ∅𝑐 sin ζ sin Θ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 cos Θ − sin 𝜇 cos ζ sin Θ),
𝑦 = 𝑦𝑐 − 𝑠𝑐 cos ∅𝑐 sin ζ cos Θ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 sin Θ + sin 𝜇 cos ζ cos Θ),
𝑧 = 𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 cos ζ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ . }
𝒌𝑐 𝒕𝑐𝑖
∅𝑐𝑖
𝑟𝑐𝑖 𝑵𝑐𝑖 𝑠𝑐𝑖
𝑂𝑐 ∅𝑐𝑜 𝒊𝑐
𝑟𝑐𝑜 𝑠𝑐𝑜 𝑵𝑐𝑜
𝒕𝑐𝑜
Figure 3.2.2-1 Cutting Edge of Cutter for Workpiece 1
In case of no tilt device, that is, Θ = ζ = 0, then, expression above is updated as follow:
𝑹𝑐 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 + (𝜇𝒌𝑐 ) ⊗ (𝑟𝑐 𝒊𝑐 + 𝑠𝑐 𝒕𝑐 ) = 𝑥𝒊𝑚 + 𝑦𝒋𝑚 + 𝑧𝒌𝑚 (3.2.2-4)
Where:
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 = 𝑥𝑐 𝒊𝑚 + 𝑦𝑐 𝒋𝑚 + 𝑧𝑐 𝒌𝑚 ,
𝑥 = 𝑥𝑐 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos 𝜇 ,
𝑦 = 𝑦𝑐 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 ,
𝑧 = 𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 . }
Unit normal 𝑵𝑐 to cutter surface is
𝑵𝑐 = (𝜇𝒌𝑐 ) ⊗ (sin ∅𝑐 𝒌𝑐 − cos ∅𝑐 𝒊𝑐 ) = − cos ∅𝑐 (cos 𝜇 𝒊𝑐 + sin 𝜇 𝒋𝑐 ) + sin ∅𝑐 𝒌𝑐 (3.2.2-5)
~286 ~
𝑵𝑐 = 𝐴𝑚 𝒊𝑚 + 𝐵𝑚 𝒋𝑚 + 𝐶𝑚 𝒌𝑚 (3.2.2-6)
Where:
𝐴𝑚 = sin ∅𝑐 sin ζ sin Θ − cos ∅𝑐 (cos 𝜇 cos Θ − sin 𝜇 cos ζ sin Θ),
𝐵𝑚 = − sin ∅𝑐 sin ζ cos Θ − cos ∅𝑐 (cos 𝜇 sin Θ + sin 𝜇 cos ζ cos Θ),}
𝐶𝑚 = sin ∅𝑐 cos ζ − cos ∅𝑐 sin 𝜇 sin ζ .
In case of no tilt device, that is, Θ = ζ = 0, then, expression above is updated as follow:
𝑵𝑐 = 𝐴𝑚 𝒊𝑚 + 𝐵𝑚 𝒋𝑚 + 𝐶𝑚 𝒌𝑚 (3.2.2-7)
Where:
𝐴𝑚 = − cos ∅𝑐 cos 𝜇 ,
𝐵𝑚 = − cos ∅𝑐 sin 𝜇 , }
𝐶𝑚 = sin ∅𝑐 .
3.2.3 Cutter Surface for Workpiece 2

Cutter surface of inner cutter head for convex flank of workpiece 2 is identical to cutter surface
of outer cutter head for workpiece 1 but opposite direction from entity to void as shown in
figure 3.2.3-1.
𝒌𝑐
𝑟𝑐𝑜 ∅𝑐𝑜
𝒊𝑐
𝑂𝑐 𝑠𝑐𝑜
𝒕𝑐𝑜
Figure 3.2.3-1 Cutting Edge of Inner Blade of Cutter Head for Workpiece 2
Likewise, cutter surface of outer cutter head for concave flank of workpiece 2 is identical to
cutter surface of inner cutter head for workpiece 1 but opposite direction from entity to void as
shown in figure 3.2.3-2
~ 287 ~
𝒌𝑐 𝒕𝑐𝑖
∅𝑐𝑖
𝑟𝑐𝑖
𝑠𝑐𝑖
𝑂𝑐 𝒊𝑐
Figure 3.2.3-2 Cutting Edge for Concave Flank of Workpiece 2
~288 ~
Chapter 3
3.3.1 Coordinate System

1 Machine Coordinate System
Motion of Machining
Milling process of 𝑞𝑡ℎ tooth profile is composed of three basic motions with respect to machine
coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ) as shown in figure 3.3.1-1, that is,
A. Rotation of cradle by an angle 𝜀0 about axis 𝒌𝑚 of cradle.

B. Rotation of workpiece 1 or 2 by an angle 𝜀1 or 𝜀2 about 𝝎1 or 𝝎2 as rotating axis of
workpiece 1 or 2.
C. Index cradle and workpiece to next tooth profile when 𝑞𝑡ℎ tooth profile is completed.
𝒌𝑚 is rotating axis of cradle and 𝒊𝑚 is vertical down.
𝑂𝑚
𝒋𝑚
𝒌𝑚
𝒊𝑚
Figure 3.3.1-1 Machine Coordinate System (𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 )
2 Integration of Machine Coordinate System with Coordinate Systems of

Workpiece 1 and 2
Let motion 𝜑1 of workpiece 1 be designated as motion 𝜑𝑟 and motion 𝜑2 of workpiece 2 be
designated as motion 𝜑𝑠 in expression (1.7.3-3), then, relationship of machine coordinate
~ 289 ~
system (𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 ) with coordinate systems (𝑂 − 𝒊, 𝒋, 𝒌) of workpiece 1 and
(𝑂 − 𝒊′ , 𝒋′ , 𝒌′ ) of workpiece 2 are generated as shown in figure 3.3.1-2, that is,
𝛼1 = 𝛼𝑚 + 𝜋,
𝛼2 = 𝛼𝑚 + 𝛼, } (3.3.1-1)
𝛼2 − 𝛼1 = 𝛼 − 𝜋.
Where: 𝛼𝑚 is intersecting angle between axis 𝒌𝑚 of cradle and axis 𝒌 = 𝝎1 of workpiece 1

corresponding to 𝑞𝑡ℎ tooth profile.
Relationship of machine coordinate system (𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 ) with coordinate system

(𝑂 − 𝒊, 𝒋, 𝒌) of workpiece 1 is as
𝒊 = 𝒊𝑚 ,
𝒌 = (−𝛼𝑚 𝒊𝑚 ) ⊗ 𝒌𝑚 = sin 𝛼𝑚 𝒋𝑚 + cos 𝛼𝑚 𝒌𝑚 ,} (3.3.1-2)
𝒋 = 𝒌 × 𝒊 = cos 𝛼𝑚 𝒋𝑚 − sin 𝛼𝑚 𝒌𝑚 .
Relationship of machine coordinate system (𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 ) with coordinate system

(𝑂 − 𝒊′ , 𝒋′ , 𝒌′ ) of workpiece 2 is as
𝒊′ = 𝒊𝑚 ,
𝒌′ = −𝝎2 = (−𝛼2 𝒊𝑚 ) ⊗ 𝒌𝑚 = sin 𝛼2 𝒋𝑚 + cos 𝛼2 𝒌𝑚
(3.3.1-3)
= sin(𝛼𝑚 + 𝛼) 𝒋𝑚 + cos(𝛼𝑚 + 𝛼) 𝒌𝑚 ,
𝒋 = 𝒌′ × 𝒊′ = cos(𝛼𝑚 + 𝛼) 𝒋𝑚 −sin(𝛼𝑚 + 𝛼) 𝒌𝑚 . }
′
𝛼1 𝒌′ (= −𝝎2 )
𝑂𝑚 𝒋𝑚
𝛼 𝛼2
𝝎2
𝒌𝑚 𝛼𝑚 𝒌(= 𝝎1 )
Figure 3.3.1-2 Relationship of Coordinate Systems
~ 290 ~
3.3.2 Ratio of Roll
1 Ratio of Roll for Workpiece 1
Application of the first formula of expression (1.7.3-3) results in ratio of roll for workpiece 1,
that is,
𝑑𝜀 sin 𝛼1 −𝑀12 sin 𝛼2 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑀1 = 𝑑𝜀1 = = (3.3.2-1)
0 𝑀12 sin(𝛼2 −𝛼1 ) 𝑀12 sin 𝛼
𝑑𝜀
Where: 𝑀12 = 𝑑𝜀2 is given motion requirement.
1
2 Ratio of Roll for Workpiece 2

Application of the second formula of expression (1.7.3-3) results in ratio of roll for workpiece 2,
that is,
sin 𝛼1 −𝑀12 sin 𝛼2 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑀2 = 𝑀12 𝑀1 = = (3.3.2-2)
sin(𝛼2 −𝛼1 ) sin 𝛼
3.3.3 Calculation for Machine Setting Parameters

1 Design Reference Point
Let pitch point 𝑃0𝑞 on 𝑞𝑡ℎ tooth profile of workpiece 1 be design reference point on 𝑞𝑡ℎ tooth.
𝜋 𝜋
Helical angle at design reference point 𝑃0𝑞 is 𝜓𝑔 which is 0 < 𝜓𝑔 < 2 for right-hand and 2 <
𝜓𝑔 < 𝜋 for left-hand. Pressure angle at design reference point 𝑃0𝑞 is ∅𝑔 which is equal to ∅𝑔𝑖
for convex flank and ∅𝑔𝑜 for concave flank. Pitch angle 𝛾 𝑞 at design reference point 𝑃0𝑞 of 𝑞𝑡ℎ
𝜋 𝜋 𝜋
tooth is 𝛾 𝑞 = ( 2 − 𝜃 𝑞 ) which is equal to 𝛾 𝑞 = ( 2 − 𝜃𝑖𝑞 ) for convex flank and 𝛾 𝑞 = (2 − 𝜃𝑜𝑞 )
for concave flank as shown in figure 3.1.1-1 and both 𝜃𝑖𝑞 and 𝜃𝑜𝑞 are decided by application of
With help of expression (3.3.1-2), application of expression (3.1.1-2) results in conjugate

contact position of pitch point 𝑃0𝑞 on 𝑞th tooth profile of workpiece 1, that is,
𝑹𝑞0𝑝 = 𝑅0 (cos 𝜃 𝑞 𝒋 + sin 𝜃 𝑞 𝒌) = 𝑅0 [cos(𝜃 𝑞 − 𝛼𝑚

𝑞 𝑞
) 𝒋𝑚 + sin(𝜃 𝑞 − 𝛼𝑚 ) 𝒌𝑚 ] (3.3.3-1)
Where: 𝜃 𝑞 is calculated by expressions (3.1.1-7) and 𝑝 is pitch, that is,
~291 ~
𝑓𝑜𝑟 𝑐𝑜𝑛𝑣𝑒𝑥 𝑓𝑙𝑎𝑛𝑘 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒 1
𝑀12 |𝜀1 =𝜀1,𝑞 cos 𝛼+1 𝑠 =𝑞𝑝 1
tan 𝜃 𝑞 = tan 𝜃𝑖𝑞 = , 𝜀1,𝑞 = ∫𝑠 0=0 𝑑𝑠0 ,
𝑀12 |𝜀1 =𝜀1,𝑞 sin 𝛼 0 2
𝑑𝜃
𝑅0 √cos2 𝜃+( )
𝑑𝜀1
𝑓𝑜𝑟 𝑐𝑜𝑛𝑐𝑎𝑣𝑒 𝑓𝑙𝑎𝑛𝑘 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒 1 (3.3.3-2)

𝑀12 |𝜀1 =𝜀1,𝑞 cos 𝛼+1 1
𝑠0 =(𝑞+ )𝑝 1
tan 𝜃 𝑞 = tan 𝜃𝑜𝑞 = , 𝜀1,𝑞 = ∫𝑠0=0 2 𝑑𝑠0 ,
𝑀12 |𝜀1 =𝜀1,𝑞 sin 𝛼
𝑑𝜃 2
𝑅0 √cos2 𝜃+( )
𝑑𝜀1
𝑞 = 0, 1, 2, 3, ⋯ (𝑍1 − 1) . }
Unit normal 𝑵𝑞0𝑝 to 𝑞th tooth profile of workpiece 1 at pitch point 𝑃0 in conjugate contact
position is prescribed as follow:
𝑵0𝑝 = (−𝛾 𝑞 𝒊) ⊗ {(−𝜓𝑔 𝒋) ⊗ [(∅𝑔 𝒌) ⊗ 𝒊]}

cos ∅𝑔 cos 𝜓𝑔 𝒊 + (cos ∅𝑔 sin 𝜓𝑔 cos 𝜃 𝑞 + sin ∅𝑔 sin 𝜃 𝑞 )𝒋
={ }
+(cos ∅𝑔 sin 𝜓𝑔 sin 𝜃 𝑞 − sin ∅𝑔 cos 𝜃 𝑞 )𝒌 (3.3.3-3)
𝑞 𝑞
cos ∅𝑔 cos 𝜓𝑔 𝒊𝑚 + [sin ∅𝑔 sin(𝜃 − 𝛼𝑚 ) + cos ∅𝑔 sin 𝜓𝑔 cos(𝜃 − 𝛼𝑚 )]𝒋𝑚
={ }
+[− sin ∅𝑔 cos(𝜃 𝑞 − 𝛼𝑚 ) + cos ∅𝑔 sin 𝜓𝑔 sin(𝜃 𝑞 − 𝛼𝑚 )]𝒌𝑚
Corresponding to conjugate cutting position of design reference point 𝑃0𝑞 on 𝑞𝑡ℎ tooth profile of
workpiece, the relative position and motion of cutter with respect to workpieces 1 & 2 are
machine setting parameters as follow:
A. position of cutter with respect to machine coordinate system 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 , that is,

• Coordinate of center of cutter head for 𝑞𝑡ℎ tooth profile of workpiece, 𝑥𝑐𝑞 , 𝑦𝑐𝑞
and 𝑧𝑐𝑞 .
• Tilt angle ζ𝑞 and swivel angle Θ𝑞 of cutter head for 𝑞𝑡ℎ tooth profile of
workpiece.
B. Position of workpiece 1 & 2 with respect to machine coordinate system 𝑂𝑚 −
𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 , that is,
𝑞
• Shaft angle 𝛼𝑚 of rotating axis 𝒌(= 𝝎1 ) of workpiece 1 with respect to rotating
axis 𝒌𝑚 of machine corresponding to 𝑞𝑡ℎ tooth profile of workpiece.
𝑞
• Shaft angle 𝛼𝑚 + 𝛼 of rotating axis 𝒌′ (= −𝝎2 ) of workpiece 2 with respect to
rotating axis 𝒌𝑚 of machine corresponding to 𝑞𝑡ℎ tooth profile of workpiece.
C. Relative motion of cutter head with respect to workpiece 1 & 2, that is,
𝑑𝜀
• Ratio of roll for 𝑞𝑡ℎ tooth profile of workpiece 1, 𝑀1𝑞 = 𝑑𝜀1.
0
~ 292 ~
𝑑𝜀
0
3 Calculation for Machine Setting Parameters

Due to requirement of conjugate contact, that is,
𝑹𝑞𝑐 = 𝑹𝑞0𝑝 ,
} (3.3.3-4)
𝑵𝑞𝑐 = −𝑵𝑞0𝑝
Substitution of expressions (3.2.2-3), (3.2.2-6), (3.3.3-1) and (3.3.3-3) into expression (3.3.3-4)
yields
𝑥𝑐𝑞 + 𝑠𝑐𝑞 cos ∅𝑐 sin ζ𝑞 sin Θ𝑞

{ } = 0,
+(𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 )(cos 𝜇 𝑞 cos Θ𝑞 − sin 𝜇 𝑞 cos ζ𝑞 sin Θ𝑞 )
𝑦𝑐𝑞 − 𝑠𝑐𝑞 cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 + (𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 )(cos 𝜇 𝑞 sin Θ𝑞 + sin 𝜇 𝑞 cos ζ𝑞 cos Θ𝑞 )
𝑞
= 𝑅0 cos(𝜃 𝑞 − 𝛼𝑚 ),
𝑧𝑐𝑞 + 𝑠𝑐𝑞 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 ) sin 𝜇 𝑞 sin ζ𝑞 = 𝑅0 sin(𝜃 𝑞 − 𝛼𝑚
𝑞 (3.3.3-5)
),
𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
sin ∅𝑐 sin ζ sin Θ − cos ∅𝑐 (cos 𝜇 cos Θ − sin 𝜇 cos ζ sin Θ )
= − cos ∅𝑔 cos 𝜓𝑔 ,
sin ∅𝑐 cos ζ𝑞 − cos ∅𝑐 sin 𝜇 𝑞 sin ζ𝑞
𝑞 𝑞
= sin ∅𝑔 cos(𝜃 𝑞 − 𝛼𝑚 ) − cos ∅𝑔 sin 𝜓𝑔 sin(𝜃 𝑞 − 𝛼𝑚 ). }
where:
𝑓𝑜𝑟 𝑐𝑜𝑛𝑣𝑒𝑥 𝑓𝑙𝑎𝑛𝑘 𝑜𝑓 𝑞𝑡ℎ 𝑡𝑜𝑜𝑡ℎ 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒 1

𝑞 𝑞 𝑞 𝑞
𝑧𝑐𝑞 = 𝑧𝑐𝑖
𝑞
, Θ𝑞 = Θ𝑞𝑖 , ζ𝑞 = ζ𝑖 , 𝛼𝑚𝑞 𝑞
𝑥𝑐𝑞 𝑞
= 𝑥𝑐𝑖 , = 𝑦𝑐𝑞 𝑦𝑐𝑖𝑞 , = 𝛼𝑚𝑖 , 𝜇 𝑞 = 𝜇𝑖 , 𝑠𝑐 = 𝑠𝑐𝑖 ,
𝑓𝑜𝑟 𝑐𝑜𝑛𝑐𝑎𝑣𝑒 𝑓𝑙𝑎𝑛𝑘 𝑜𝑓 𝑞𝑡ℎ 𝑡𝑜𝑜𝑡ℎ 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒 1
𝑞 𝑞
𝑥𝑐 = 𝑥𝑐𝑜 , 𝑦𝑐 = 𝑦𝑐𝑜 , 𝑧𝑐𝑞 = 𝑧𝑐𝑜
𝑞 𝑞 𝑞
, Θ𝑞 = Θ𝑞𝑜 , ζ𝑞 = ζ𝑞𝑜 , 𝛼𝑚
𝑞 𝑞
= 𝛼𝑚𝑜 , 𝜇 𝑞 = 𝜇𝑜𝑞 , 𝑠𝑐𝑞 = 𝑠𝑐𝑜
𝑞
.}
and
𝑠𝑐𝑞 = 0. Thus, simultaneous equation (3.3.3-5) is updated as follow:
𝑥𝑐𝑞 − 𝑟𝑐 (cos 𝜇 𝑞 sin 𝜓𝑔 + sin 𝜇 𝑞 cos ζ𝑞 cos 𝜓𝑔 ) = 0,

𝑦𝑐𝑞 + 𝑟𝑐 (cos 𝜇 𝑞 cos 𝜓𝑔 − sin 𝜇 𝑞 cos ζ𝑞 sin 𝜓𝑔 ) = 𝑅0 ,
𝑧𝑐𝑞 + 𝑟𝑐 sin 𝜇 𝑞 sin ζ𝑞 = 0,
(3.3.3-6)
sin ∅𝑐 sin ζ𝑞 cos 𝜓𝑔 + cos ∅𝑐 (cos 𝜇 𝑞 sin 𝜓𝑔 + sin 𝜇 𝑞 cos ζ𝑞 cos 𝜓𝑔 )
= − cos ∅𝑔 cos 𝜓𝑔 ,
sin ∅𝑐 cos ζ − cos ∅𝑐 sin 𝜇 𝑞 sin ζ𝑞 = sin ∅𝑔 .
𝑞
}
~293 ~
Solving equation above leads
𝜋
𝜇𝑞 = − 2 , ζ𝑞 = ∅𝑔 − ∅𝑐 ,
𝑥𝑐𝑞 = −𝑟𝑐 cos(∅𝑔 − ∅𝑐 ) cos 𝜓𝑔 , 𝑦𝑐𝑞 = 𝑅0 − 𝑟𝑐 cos(∅𝑔 − ∅𝑐 ) sin 𝜓𝑔 ,} (3.3.3-7)
𝑧𝑐𝑞 = 𝑟𝑐 sin(∅𝑔 − ∅𝑐 ) .
Combination of expressions (3.3.1-1), (3.3.2-1), (3.3.2-2), (3.3.3-2) and (3.3.3-7) generates

machine setting parameters for 𝑞th tooth of workpieces 1 & 2 as shown in figure 3.3.3-1, that
is,
𝑞
𝛼𝑚 = 𝜃 𝑞 , 𝛼1𝑞 = 𝛼𝑚
𝑞
+ 𝜋, 𝛼2𝑞 = 𝛼𝑚
𝑞
+ 𝛼, ζ𝑞 = ∅𝑔 − ∅𝑐 , Θ𝑞 = 𝜋 + 𝜓𝑔
2
𝑞 𝑞 𝑞 𝑞
𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼) 𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑀1𝑞 = 𝑑𝜀1 = 𝑞
𝑀12 sin 𝛼
, 𝑀2𝑞 = 𝑑𝜀2 = sin 𝛼
,
0 0
𝑥𝑐𝑞 = −𝑟𝑐 cos(∅𝑔 − ∅𝑐 ) cos 𝜓𝑔 , 𝑦𝑐𝑞 = 𝑅0 − 𝑟𝑐 cos(∅𝑔 − ∅𝑐 ) sin 𝜓𝑔 ,

𝑧𝑐𝑞 = 𝑟𝑐 sin(∅𝑔 − ∅𝑐 ) , (3.3.3-8)
1
𝑠 =𝑞𝑝 1 𝑠 =(𝑞+ )𝑝 1
𝜀1,𝑞 = ∫𝑠 0=0 𝑑𝑠0 ( 𝑜𝑟 𝜀1,𝑞 = ∫𝑠 0=0 2 𝑑𝑠0 ),
0 2 0 2
𝑑𝜃 𝑑𝜃
𝑅0 √cos2 𝜃+( ) 𝑅0 √cos2 𝜃+( )
𝑑𝜀1 𝑑𝜀1
𝜀 𝜋
𝜀2,𝑞 = ∫𝜀 1,𝑞 𝑀 𝑑 𝜀1 , 𝜇 𝑞 = − 2 .
=0 12 }
1
Where: 𝜀1,𝑞 and 𝜀2,𝑞 are index angles of workpiece 1 and 2 respectively. 𝑞 = 0, 1, 2, ⋯ , 𝑁 − 1.
Without tilt device, ζ𝑞 = Θ𝑞 = 0, simultaneous equation (3.3.3-5) is reduced to
𝑥𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 ) cos 𝜇 𝑞 = 0,

𝑦𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 ) sin 𝜇 𝑞 = 𝑅0 cos(𝜃 𝑞 − 𝛼𝑚
𝑞
),
𝑧𝑐𝑞 + 𝑠𝑐𝑞 cos ∅𝑐 = 𝑅0 sin(𝜃 𝑞 − 𝛼𝑚
𝑞
), (3.3.3-9)
𝑞
cos ∅𝑐 cos 𝜇 = cos ∅𝑔 cos 𝜓𝑔 ,
𝑞 𝑞
sin ∅𝑐 = sin ∅𝑔 cos(𝜃 𝑞 − 𝛼𝑚 ) − cos ∅𝑔 sin 𝜓𝑔 sin(𝜃 𝑞 − 𝛼𝑚 ) .}
There are five equations in simultaneous equation (3.3.3-9) and six variables, i.e., 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 ,
𝑞
𝛼𝑚 , 𝜇 𝑞 and 𝑠𝑐𝑞 . Therefore, one variable can be prescribed. Let 𝑠𝑐𝑞 = 0, then, simultaneous
(3.3.3-9) is updated as
𝑥𝑐𝑞 + 𝑟𝑐 cos 𝜇 𝑞 = 0,
𝑦𝑐𝑞 + 𝑟𝑐 sin 𝜇 𝑞 = 𝑅0 cos(𝜃 𝑞 − 𝛼𝑚 𝑞
) , 𝑧𝑐𝑞 = 𝑅0 sin(𝜃 𝑞 − 𝛼𝑚
𝑞
)
𝑞 (3.3.3-10)
cos ∅𝑐 cos 𝜇 = cos ∅𝑔 cos 𝜓𝑔 ,
𝑞 𝑞
sin ∅𝑐 = sin ∅𝑔 cos(𝜃 𝑞 − 𝛼𝑚 ) − cos ∅𝑔 sin 𝜓𝑔 sin(𝜃 𝑞 − 𝛼𝑚 ) .}
~294 ~
Solving equation (3.3.3-10) leads
cos ∅𝑔 cos 𝜓𝑔 𝑞 𝑊
𝜇 𝑞 = cos−1 ( ), 𝛼𝑚 = sin−1 (√𝑈 2 ) + 𝜃 𝑞 − 𝛿,
cos ∅𝑐 +𝑉 2 } (3.3.3-11)
𝑥𝑐𝑞 = −𝑟𝑐 cos 𝜇 𝑞 , 𝑦𝑐𝑞 = 𝑅0 cos(𝜃 𝑞 − 𝛼𝑚
𝑞
𝑧𝑐𝑞 𝑞
) − 𝑟𝑐 sin 𝜇 , = 𝑅0 sin(𝜃 𝑞 − 𝛼𝑚 ).
Where: 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1,
𝑈= cos ∅𝑔 sin 𝜓𝑔 , 𝑉 = sin ∅𝑔 ,

𝑉 } (3.3.3-12)
𝑊 = sin ∅𝑐 , tan 𝛿 = 𝑈 .
Cutter Surface 𝒊𝑐
𝒋𝑐
𝑂𝑐
Θ𝑞
ζ𝑞
𝒌𝑐 𝒋𝑚
𝑂𝑚
𝒌 = 𝝎1
𝑞
𝛼𝑚
𝒌𝑚
Workpiece 1
𝒊𝑚
Figure 3.3.3-1 Machine Setting Parameters
Combination of expressions (3.3.2-1), (3.3.2-2) and (3.3.3-11) yields machine setting parameters
for 𝑞th tooth of workpieces 1 & 2, that is,
~ 295 ~
cos ∅𝑔 cos 𝜓𝑔 𝑞 𝑊
𝜇 𝑞 = cos −1 ( ), 𝛼𝑚 = sin−1 (√𝑈 2 ) + 𝜃 𝑞 − 𝛿,
cos ∅𝑐 +𝑉 2
𝑉
𝑈 = cos ∅𝑔 sin 𝜓𝑔 , 𝑉 = sin ∅𝑔 , 𝑊 = sin ∅𝑐 , tan 𝛿 = 𝑈 ,
𝑥𝑐𝑞 = −𝑟𝑐 cos 𝜇 𝑞 , 𝑦𝑐𝑞 = 𝑅0 cos(𝜃 𝑞 − 𝛼𝑚
𝑞
) − 𝑟𝑐 sin 𝜇 𝑞 , 𝑧𝑐𝑞 = 𝑅0 sin(𝜃 𝑞 − 𝛼𝑚
𝑞
),
𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
𝑀1𝑞 = 𝑑𝜀1 = 𝑞 , 𝑀2𝑞 = 𝑑𝜀2 = , (3.3.3-13)
0 𝑀12 sin 𝛼 0 sin 𝛼
1
𝑠 =𝑞𝑝 1 𝑠 =(𝑞+ )𝑝 1
𝜀1,𝑞 = ∫𝑠 0=0 𝑑𝑠0 ( 𝑜𝑟 𝜀1,𝑞 = ∫𝑠 0=0 2 𝑑𝑠0 ),
0 2 0 2
𝑑𝜃 𝑑𝜃
𝑅0 √cos2 𝜃+( ) 𝑅0 √cos2 𝜃+( )
𝑑𝜀1 𝑑𝜀1
𝜀
𝜀2,𝑞 = ∫𝜀 1,𝑞 𝑀 𝑑 𝜀1 .
=0 12 }
1
Where: 𝜀1,𝑞 and 𝜀2,𝑞 are index angles of workpiece 1 and 2 respectively. 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 −
1.
~ 296 ~
Chapter 4
Calculation of Tooth Profile
3.4.1 Instantaneous Contact Point and Instantaneous Contact Line

1 Instantaneous Contact Point and Instantaneous Contact Line in the Case of Tilt
Device
A. Instantaneous Contact Point
Point 𝑃 is any point in coordinate plane 𝑂 − 𝒋, 𝒌 within the region corresponding to tooth
profile of 𝑞th tooth of workpiece 1 as shown figure 3.4.1-1, and is prescribed by two
parameters of 𝑙ℎ and 𝑙𝑤 as follow:
𝑷𝑞0 = (𝑅0 + 𝑙𝑤 )𝜻𝑞 + 𝑙ℎ 𝜼𝑞 = 𝐴𝒋 + 𝐵𝒌 (3.4.1-1)
Where:
𝐴 = (𝑅0 + 𝑙𝑤 ) cos 𝜃 𝑞 + 𝑙ℎ sin 𝜃 𝑞 , 𝐵 = (𝑅0 + 𝑙𝑤 ) sin 𝜃 𝑞 − 𝑙ℎ cos 𝜃 𝑞 ,

} (3.4.1-2)
𝜻𝑞 = cos 𝜃 𝑞 𝒋 + sin 𝜃 𝑞 𝒌, 𝜼𝑞 = 𝜻𝑞 × 𝒊 = sin 𝜃 𝑞 𝒋 − cos 𝜃 𝑞 𝒌.
𝜻𝑞
𝑅0 𝑙ℎ
𝜃 𝑞 𝜼𝑞 𝑙𝑤
𝑂 𝒋
Figure 3.4.1-1 Coordinate of Point 𝑃
Point 𝑃(𝑷𝑞0 ) becomes point 𝑹1𝑝

𝑞
on tooth profile of 𝑞th tooth of workpiece 1 as follow:
𝑞
= (𝜉𝑝 𝒌) ⊗ 𝑷𝑞0 = (𝜉𝑝 𝒌) ⊗ (𝐴𝒋 + 𝐵𝒌) = 𝑥1𝑝
𝑞 𝑞 𝑞
𝑹1𝑝 𝒊 + 𝑦1𝑝 𝒋 + 𝑧1𝑝 𝒌 (3.4.1-3)
𝑞 𝑞 𝑞
Where: 𝑥1𝑝 = −𝐴 sin 𝜉𝑝 , 𝑦1𝑝 = 𝐴 cos 𝜉𝑝 and 𝑧1𝑝 = 𝐵.
~297 ~
𝑞 𝑞
Point 𝑹1𝑝 on tooth profile of 𝑞th tooth of workpiece 1 reaches conjugate cutting position 𝑹𝑝
after rotating by an angle ∆𝜀1,𝑞 about 𝒌 as an axis, that is,
𝑹𝑞𝑝 = (∆𝜀1,𝑞 𝒌) ⊗ 𝑹1𝑝

𝑞
= 𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌
(3.4.1-4)
= 𝑥𝑝𝑞 𝒊𝑚 + (𝑦𝑝𝑞 cos 𝛼𝑚
𝑞
+ 𝑧𝑝𝑞 sin 𝛼𝑚
𝑞
)𝒋𝑚 + (−𝑦𝑝𝑞 sin 𝛼𝑚
𝑞
+ 𝑧𝑝𝑞 cos 𝛼𝑚
𝑞
)𝒌𝑚
Where: 𝑥𝑝𝑞 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , 𝑦𝑝𝑞 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) and 𝑧𝑝𝑞 = 𝐵.
On the other hand, point 𝑹𝑞𝑐 on cutter surface corresponding to point 𝑃 on tooth profile is
defined by expression (3.2.2-3), that is,
𝑹𝑞𝑐 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂0 𝑂𝑐 + (𝜇𝒌𝑞𝑐 ) ⊗ (𝑟𝑐 𝒊𝑞𝑐 + 𝑠𝑐 𝒕𝑞𝑐 ) = 𝑥 𝑞 𝒊𝑚 + 𝑦 𝑞 𝒋𝑚 + 𝑧 𝑞 𝒌𝑚
(3.4.1-5)
= 𝑥𝑐𝑞 𝒊𝑚 + 𝑦𝑐𝑞 𝒋𝑚 + 𝑧𝑐𝑞 𝒌𝑚 + (𝜇𝒌𝑞𝑐 ) ⊗ (𝑟𝑐 𝒊𝑞𝑐 + 𝑠𝑐 𝒕𝑞𝑐 )
Where: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 and Θ𝑞 are calculated by expression (3.3.3-8),
𝑥𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin Θ𝑞

𝑥𝑞 = { },
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 )
𝑦𝑐𝑞 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 (3.4.1-6)
𝑦𝑞 = { },
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 )
𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 . }
Unit normal 𝑵𝑞𝑐 to cutter surface at point 𝑃 is calculated by expression (3.2.2-6), that is,
𝑵𝑞𝑐 = 𝐴𝑞 𝒊𝑚 + 𝐵 𝑞 𝒋𝑚 + 𝐶 𝑞 𝒌𝑚 (3.4.1-7)
Where:
𝐴𝑞 = sin ∅𝑐 sin ζ𝑞 sin Θ𝑞 − cos ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ),

𝐵 𝑞 = − sin ∅𝑐 sin ζ𝑞 cos Θ𝑞 − cos ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ),}
𝐶 𝑞 = sin ∅𝑐 cos ζ𝑞 − cos ∅𝑐 sin 𝜇 sin ζ𝑞 .
After rotating by an angle ∆𝜀0𝑞 about 𝒌0 as an axis, point 𝑹𝑞𝑐 reaches conjugate cutting position
as follow:
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ (𝑥 𝑞 𝒊𝑚 + 𝑦 𝑞 𝒋𝑚 + 𝑧 𝑞 𝒌𝑚 )

𝑞 𝑞 𝑞
= 𝑥𝑝𝑚 𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 ,
(3.4.1-8)
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ (𝐴𝑞 𝒊𝑚 + 𝐵 𝑞 𝒋𝑚 + 𝐶 𝑞 𝒌𝑚 ) = 𝐴𝑞𝑝 𝒊 + 𝐵𝑝𝑞 𝒋 + 𝐶𝑝𝑞 𝒌
= 𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 , }
~ 298 ~
Where:
𝑞
𝑥𝑝𝑚 = 𝑥 𝑞 cos ∆𝜀0𝑞 − 𝑦 𝑞 sin ∆𝜀0𝑞
𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )
={ },
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )[cos 𝜇 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜇 cos ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞
𝑦𝑝𝑚 = 𝑥 𝑞 sin ∆𝜀0𝑞 + 𝑦 𝑞 cos ∆𝜀0𝑞
𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
={ },
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )[cos 𝜇 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜇 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 ,
𝐴𝑞𝑝𝑚 = 𝐴𝑞 cos ∆𝜀0𝑞 − 𝐵 𝑞 sin ∆𝜀0𝑞 (3.4.1-9)
𝑞 𝑞
sin ∅𝑐 sin ζ sin(Θ + ∆𝜀0𝑞 )
={ },
− cos ∅𝑐 [cos 𝜇 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜇 cos ζ sin(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞
𝑞
𝐵𝑝𝑚 = 𝐴𝑞 sin ∆𝜀0𝑞 + 𝐵 𝑞 cos ∆𝜀0𝑞
− sin ∅𝑐 sin ζ𝑞 cos(Θ + ∆𝜀0𝑞 )
={ },
− cos ∅𝑐 [cos 𝜇 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜇 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞
𝐶𝑝𝑚 = sin ∅𝑐 cos ζ𝑞 − cos ∅𝑐 sin 𝜇 sin ζ𝑞 ,
𝐶𝑝𝑞 = 𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
𝐴𝑞𝑝 = 𝐴𝑞𝑝𝑚 , 𝐵𝑝 = 𝐵𝑝𝑚 cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 , sin 𝛼𝑚 + 𝐶𝑝𝑚 cos 𝛼𝑚 .}

𝑞 𝑞 𝑞
𝑹𝑝 = (∆𝜀0 𝒌𝑚 ) ⊗ 𝑹𝑐
{ }
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑥𝑐𝑞 sin ∆𝜀0𝑞
+ cos ∆𝜀0𝑞 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
𝑦𝑐𝑞
{ } (3.4.1-10)
𝑞 𝑞
= 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) cos 𝛼𝑚 + 𝐵 sin 𝛼𝑚 ,
𝑞
𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 cos ζ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞
𝑞
𝑞 𝑞
= −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 }
𝑞
Where: 𝛼𝑚 , 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 and Θ𝑞 are calculated by expression (3.3.3-8). 𝐴 and 𝐵 are decided
by expression (3.4.1-2). ∆𝜀0𝑞 is calculated by expression (3.3.2-1), that is,
~ 299 ~
𝜀 +∆𝜀1,𝑞 1 𝜀 +∆𝜀1,𝑞 𝑀12 sin 𝛼
∆𝜀0𝑞 = ∫𝜀 1,𝑞 𝑞 𝑑𝜀1 = ∫𝜀 1,𝑞 𝑞 𝑞 𝑑𝜀1 (3.4.1-11)
1,𝑞 𝑀1 1,𝑞 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
Let 𝜀0 be visualized as virtual time parameter, velocity of point 𝑃(𝑹𝑞𝑝 ) on workpiece 1 is as

follow:
𝑑𝜀
𝒗𝑞𝑝 = 𝑑𝜀1 𝝎1 × 𝑹𝑞𝑝 (3.4.1-12)
0
With help of expression (3.4.1-4), velocity of point 𝑃(𝑹𝑞𝑝 ) on cutter surface is as follow:
𝒗𝑐 = 𝒌𝑚 × 𝑹𝑞𝑝 (3.4.1-13)
Relative velocity of cutter with respect to workpiece 1 at point 𝑃 is resulted from expressions
(3.4.1-12) and (3.4.1-13) as follow:
𝑑𝜀
𝒗𝑐 − 𝒗𝑞𝑝 = (𝒌𝑚 − 𝑑𝜀1 𝝎1 ) × 𝑹𝑞𝑝
0
𝑞 𝑞 𝑞 𝑞 (3.4.1-14)
−[𝑦𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑀1 𝑧𝑝𝑚 sin 𝛼𝑚 ]𝒊𝑚
={ 𝑞 𝑞 𝑞 𝑞 }
+𝑥𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 )𝒋𝑚 + 𝑀1 𝑥𝑝𝑚 sin 𝛼𝑚 𝒌𝑚
(𝒗𝑐 − 𝒗𝑞𝑝 ) ∙ [(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 ] = 0 (3.4.1-15)

𝑞 𝑞 𝑞
𝐴𝑞𝑝𝑚 ) + 𝑀1 sin 𝛼𝑚 (𝑥𝑝𝑚
𝑞 𝑞 𝑞
(1 − 𝑀1 cos 𝛼𝑚 )(𝑥𝑝𝑚 𝐵𝑝𝑚 − 𝑦𝑝𝑚 𝐶𝑝𝑚 − 𝑧𝑝𝑚 𝐴𝑞𝑝𝑚 ) = 0 (3.4.1-16)
𝑞 𝑞 𝑞
, 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚
𝑞 𝑞
Where: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 , 𝑧𝑝𝑚 and 𝐶𝑝𝑚 are calculated by expression (3.4.1-9).
Combination of expressions (3.4.1-10) and (3.4.1-16) gives simultaneous equation as follow:
{ }
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑥𝑐 sin ∆𝜀0 + 𝑦𝑐 cos ∆𝜀0 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0 )
{ }
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )[cos 𝜇 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜇 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )] (3.4.1-17)
𝑞 𝑞
𝑞
𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞
𝑞 𝑞
= −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 ,
𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
(1 − 𝑀1 cos 𝛼𝑚 )(𝑥𝑝𝑚 𝐵𝑝𝑚 − 𝑦𝑝𝑚 𝐴𝑝𝑚 ) + 𝑀1 sin 𝛼𝑚 (𝑥𝑝𝑚 𝐶𝑝𝑚 − 𝑧𝑝𝑚 𝐴𝑞𝑝𝑚 ) = 0.}
~ 300 ~
𝑞
Where: ∆𝜀0 is calculated by expression (3.4.1-11).
There are four equations in simultaneous (3.4.1-17) and four variables, i.e., 𝑠𝑐 , 𝜇, ∆𝜀1,𝑞 and 𝜉𝑝 .
Instantaneous contact point 𝑹𝑞𝑝 at instant rotating angle 𝜀1,𝑞 + ∆𝜀1,𝑞 is as follow:
𝑹𝑞𝑝 = 𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌 (3.4.1-18)
Where: 𝜉𝑝 and ∆𝜀1,𝑞 are resulted from simultaneous equation (3.4.1-17). 𝐴 and 𝐵 are
calculated by expression (3.4.1-2),
𝑥𝑝𝑞 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,

𝑦𝑝𝑞 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) , }
𝑧𝑝𝑞 = 𝐵.
Unit normal 𝑵𝑞𝑝 to cutter surface at instantaneous conjugate cutting position is generated by
𝑵𝑞𝑝 = 𝐴𝑞𝑝 𝒊 + 𝐵𝑝𝑞 𝒋 + 𝐶𝑝𝑞 𝒌 (3.4.1-19)
Where:
sin ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )

𝐴𝑞𝑝 = 𝐴𝑞𝑝𝑚 ={ },
− cos ∅𝑐 [cos 𝜇 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜇 cos ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )]
− sin ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 ) 𝑞
{ 𝑞 } cos 𝛼𝑚
𝐵𝑝𝑞 = { − cos ∅𝑐 [cos 𝜇 sin(Θ + 𝑞
∆𝜀0𝑞 ) + 𝑞
sin 𝜇 cos ζ cos(Θ + ∆𝜀0 )] 𝑞 },
𝑞 𝑞) 𝑞
−(sin ∅𝑐 cos ζ − cos ∅𝑐 sin 𝜇 sin ζ sin 𝛼𝑚
− sin ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 ) 𝑞
{ 𝑞 } sin 𝛼𝑚
𝐶𝑝𝑞 = 𝑞 𝑞 𝑞 𝑞
{ − cos ∅𝑐 [cos 𝜇 sin(Θ + ∆𝜀0 ) + sin 𝜇 cos ζ cos(Θ + ∆𝜀0 )] }.
𝑞 𝑞) 𝑞
+(sin ∅𝑐 cos ζ − cos ∅𝑐 sin 𝜇 sin ζ cos 𝛼𝑚 }
B. Instantaneous Contact Line

𝑞
Given ∆𝜀0 , Simultaneous equation (3.4.1-17) becomes
~ 301 ~
𝑥𝑐 cos ∆𝜀0 − 𝑦𝑐 sin ∆𝜀0 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0 )
{ }
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑥𝑐𝑞 sin ∆𝜀0𝑞
+ cos ∆𝜀0𝑞 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
𝑦𝑐𝑞
{ }
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )[cos 𝜇 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜇 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )] (3.4.1-20)
𝑞 𝑞
𝑞
𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 cos ζ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞
𝑞
𝑞 𝑞
𝑞 𝑞 𝑞 𝑞
𝐴𝑞𝑝𝑚 ) + 𝑀1 sin 𝛼𝑚
𝑞 𝑞 𝑞 𝑞
(1 − 𝑀1 cos 𝛼𝑚 )(𝑥𝑝𝑚 𝐵𝑝𝑚 − 𝑦𝑝𝑚 (𝑥𝑝𝑚 𝐶𝑝𝑚 − 𝑧𝑝𝑚 𝐴𝑞𝑝𝑚 ) = 0.}
Where: 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚

𝑞 𝑞
and 𝐶𝑝𝑚 are calculated by expression (3.4.1-9). 𝐴 and 𝐵 are defined by
𝐴 = (𝜌𝑎 + 𝑙𝑤 ) sin 𝜃 𝑞 + 𝑙ℎ cos 𝜃 𝑞 , 𝐵 = (𝜌𝑎 + 𝑙𝑤 ) cos 𝜃 𝑞 − 𝑙ℎ sin 𝜃 𝑞 ,

}
𝜻𝑞 = sin 𝜃 𝑞 𝒋 + cos 𝜃 𝑞 𝒌, 𝜼𝑞 = 𝜻𝑞 × 𝒊 = cos 𝜃 𝑞 𝒋 − sin 𝜃 𝑞 𝒌.
There are four equations in simultaneous equation (4.3.1-18) and five unknown variables, i.e.,
𝑠𝑐 , 𝜇, 𝜉𝑝 , 𝑙𝑤 and 𝑙ℎ . Let 𝑙ℎ be prescribed, 𝑠𝑐 , 𝜇, 𝜉𝑝 and 𝑙𝑤 can be solved which are parameters of
point on instantaneous contact line corresponding to instant rotating angle ∆𝜀0𝑞 of cradle. ∆𝜀1,𝑞
is calculated by ratio of roll 𝑀1𝑞 for workpiece 1.
When 𝑙ℎ changes through entire tooth profile, the entire instantaneous contact line
corresponding to ∆𝜀0𝑞 is generated in machine coordinate system 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 as follow:
𝑹𝑞𝑝 = 𝑥𝑝𝑚
𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 (3.4.1-21)
Where:
𝑞 𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )
𝑥𝑝𝑚 ={ },
𝑞 𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
𝑦𝑝𝑚 ={ },
𝑞
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 . }
2 Instantaneous Contact Point and Instantaneous Contact Line in the Case of No
Tilt Device
~ 302 ~
𝑞 𝑞 𝑞
Without tilt device, 𝑥𝑐 , 𝑦𝑐 and 𝑧𝑐 are calculated by expression (3.3.3-13), and then, expression
(3.4.1-6) is simplified as follow:
𝑥 𝑞 = 𝑥𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos 𝜇 ,

𝑦 𝑞 = 𝑦𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 , } (3.4.1-22)
𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 .
Expression (3.4.1-7) is simplified as follow:
Where: 𝐴𝑞 = − cos ∅𝑐 cos 𝜇, 𝐵 𝑞 = − cos ∅𝑐 sin 𝜇 and 𝐶 𝑞 = sin ∅𝑐 .
Expression (3.4.1-9) is modified as follow:

𝑞
𝑥𝑝𝑚 = 𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos(𝜇 + ∆𝜀0𝑞 ) ,
𝑞
𝑦𝑝𝑚 = 𝑥𝑐 sin ∆𝜀0𝑞 + 𝑦𝑐 cos ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin(𝜇 + ∆𝜀0𝑞 ) ,
𝑞
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 ,
𝐴𝑞𝑝𝑚 = − cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ), 𝐵𝑝𝑚
𝑞
= − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) , 𝑞
𝐶𝑝𝑚 = sin ∅𝑐 . (3.4.1-24)
𝐴𝑞𝑝 = 𝐴𝑞𝑝𝑚 = − cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) ,
𝐵𝑝𝑞 = − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) cos 𝛼𝑚
𝑞 𝑞
− sin ∅𝑐 sin 𝛼𝑚 ,
𝐶𝑝𝑞 = − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) sin 𝛼𝑚
𝑞 𝑞
+ sin ∅𝑐 cos 𝛼𝑚 . }
Expression (3.4.1-10) becomes as follow:
𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos(𝜇 + ∆𝜀0𝑞 )
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑥𝑐 sin ∆𝜀0 + 𝑦𝑐 cos ∆𝜀0 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin(𝜇 + ∆𝜀0 ) (3.4.1-25)
𝑞 𝑞
𝑧𝑐𝑞 𝑞 𝑞
+ 𝑠𝑐 cos ∅𝑐 = −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 .}
𝑞
Where: 𝛼𝑚 , 𝑥𝑐𝑞 , 𝑦𝑐𝑞 and 𝑧𝑐𝑞 are calculated by expression (3.3.3-13).
𝑞 𝑞 𝑞
, 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚
𝑞 𝑞
𝑥𝑝𝑚 , 𝑦𝑝𝑚 , 𝑧𝑝𝑚 and 𝐶𝑝𝑚 are calculated by expression (3.4.1-24), and thus, expression
(3.4.1-16) becomes as follow:
(1 − 𝑀1 cos 𝛼𝑚 )(−𝑥𝑐 cos ∅𝑐 sin𝜇 + 𝑦𝑐 cos ∅𝑐 cos 𝜇)

{ (𝑥𝑐 cos ∆𝜀0𝑞 − 𝑦𝑐 sin ∆𝜀0𝑞 ) sin ∅𝑐 + 𝑟𝑐 sin ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) } = 0 (3.4.1-26)
+𝑀1 sin 𝛼𝑚 [ ]
+𝑧𝑐𝑞 cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) + 𝑠𝑐 cos(𝜇 + ∆𝜀0𝑞 )
~ 303~
Combination of expressions (3.4.1-25) and (3.4.1-26) gives simultaneous equation for the case
of no tilt device as follow:
𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos(𝜇 + ∆𝜀0𝑞 ) = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin(𝜇 + ∆𝜀0𝑞 )
𝑞 𝑞
𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 = −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 𝑞 𝑞
+ 𝐵 cos 𝛼𝑚 , (3.4.1-27)
{ (𝑥𝑐 cos ∆𝜀0𝑞 − 𝑦𝑐 sin ∆𝜀0𝑞 ) sin ∅𝑐 + 𝑟𝑐 sin ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) } = 0
+𝑧𝑐 cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) + 𝑠𝑐 cos(𝜇 + ∆𝜀0𝑞 ) }
There are four equations in simultaneous (3.4.1-26) and four variables, i.e., 𝑠𝑐 , 𝜇, ∆𝜀1,𝑞 and 𝜉𝑝 .
Instantaneous contact point 𝑹𝑞𝑝 at instant rotating angle 𝜀1,𝑞 + ∆𝜀1,𝑞 is as follow:
𝑹𝑞𝑝 = 𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌 (3.4.1-28)
Where: 𝜉𝑝 and ∆𝜀1,𝑞 are resulted from simultaneous equation (3.4.1-27). 𝐴 and 𝐵 are
calculated by expression (3.4.1-2),

𝑞
𝑦𝑝 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) , }
Unit normal 𝑵𝑞𝑝 to cutter surface at instantaneous conjugate cutting position is generated by
𝑵𝑞𝑝 = 𝐴𝑞𝑝 𝒊 + 𝐵𝑝𝑞 𝒋 + 𝐶𝑝𝑞 𝒌 (3.4.1-29)
Where: 𝜇 is calculated by solution of equation (3.4.1-27) and ∆𝜀0𝑞 is decided by expression

(3.4.1-11) and
𝐴𝑞𝑝 = 𝐴𝑞𝑝𝑚 = − cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) ,

𝐵𝑝𝑞 = − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) cos 𝛼𝑚
𝑞 𝑞
− sin ∅𝑐 sin 𝛼𝑚 ,}
𝐶𝑝𝑞 = − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) sin 𝛼𝑚
𝑞 𝑞
+ sin ∅𝑐 cos 𝛼𝑚 .
Given ∆𝜀0𝑞 , simultaneous equation (3.4.1-27) becomes
~ 304 ~
𝑥𝑐 cos ∆𝜀0 − 𝑦𝑐 sin ∆𝜀0 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos(𝜇 + ∆𝜀0 ) = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑞 𝑞
𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 = −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 𝑞 𝑞
+ 𝐵 cos 𝛼𝑚 , (3.4.1-30)
{ (𝑥𝑐 cos ∆𝜀0𝑞 − 𝑦𝑐 sin ∆𝜀0𝑞 ) sin ∅𝑐 + 𝑟𝑐 sin ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) } = 0
+𝑧𝑐 cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) + 𝑠𝑐 cos(𝜇 + ∆𝜀0𝑞 ) }
Where: 𝐴 and 𝐵 are defined by expression (3.4.1-2), that is,

}
𝜻𝑞 = sin 𝜃 𝑞 𝒋 + cos 𝜃 𝑞 𝒌, 𝜼𝑞 = 𝜻𝑞 × 𝒊 = cos 𝜃 𝑞 𝒋 − sin 𝜃 𝑞 𝒌.
point on instantaneous contact line corresponding to instant rotating angle ∆𝜀0𝑞 of cradle. ∆𝜀1,𝑞
is calculated by ratio of roll 𝑀1𝑞 for workpiece 1.
𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 (3.4.1-31)
Where:
𝑞
𝑞
𝑦𝑝𝑚 = 𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin(𝜇 + ∆𝜀0𝑞 ) , }
𝑞
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 .
3.4.2 Tooth Profile

Tooth profile 𝑹1𝑞 of 𝑞 th tooth of workpiece 1 is obtained by rotating instantaneous contact

point 𝑹𝑞𝑝 by an angle −(𝜀1,𝑞 + ∆𝜀1,𝑞 ) about 𝒌 = 𝝎1 as an axis, that is,
𝑹1𝑞 = [−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ 𝑹𝑞𝑝 = 𝑥1𝑞 𝒊 + 𝑦1𝑞 𝒋 + 𝑧1𝑞 𝒌

= [−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ (𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌) (3.4.2-1)
= 𝑥1𝑞 𝒊 + 𝑦1𝑞 𝒋 + 𝑧1𝑞 𝒌
~ 305 ~
Where: ∆𝜀1,𝑞 is resulted from solution of simultaneous equation (3.4.1-17) for the case of tilt
device and (3.4.1-25) for the case of no-tilt device. 𝑥𝑝𝑞 , 𝑦𝑝𝑞 and 𝑧𝑝𝑞 are determined by expression
(3.4.1-18) for the case of tilt device and expression (3.4.1-26) for the case of no tilt device.
𝑥1𝑞 = 𝑥𝑝𝑞 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) + 𝑦𝑝𝑞 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) ,

𝑦1𝑞 = −𝑥𝑝𝑞 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) + 𝑦𝑝𝑞 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) ,}
𝑧1𝑞 = 𝑧𝑝𝑞 .
Unit normal 𝑵1𝑞 to tooth profile of 𝑞 th tooth of workpiece 1 is as follow:
𝑵1𝑞 = −[−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ (𝐴𝑞𝑝 𝒊 + 𝐵𝑝𝑞 𝒋 + 𝐶𝑝𝑞 𝒌) = 𝐴1𝑞 𝒊 + 𝐵1𝑞 𝒋 + 𝐶1𝑞 𝒌 (3.4.2-2)
Where: 𝐴𝑞𝑝 , 𝐵𝑝𝑞 and 𝐶𝑝𝑞 are calculated by expression (3.4.1-19) for the case of tilt device and
expression (3.4.1-22) for case of no tilt device.
𝐴1𝑞 = −𝐴𝑞𝑝 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) − 𝐵𝑝𝑞 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) ,

𝐵1𝑞 = 𝐴𝑞𝑝 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) − 𝐵𝑝𝑞 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) , }
𝐶1𝑞 = −𝐶𝑝𝑞 .
Tooth profile 𝑹𝑞2 of 𝑞 th tooth of workpiece 2 is obtained by rotating instantaneous contact

point 𝑹𝑞𝑝 by an angle (𝜀2,𝑞 + ∆𝜀2,𝑞 ) about 𝒌′ = −𝝎2 as an axis, that is,
𝑹𝑞2 = [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ 𝑹𝑞𝑝 = 𝑥2𝑞 𝒊′ + 𝑦2𝑞 𝒋′ + 𝑧2𝑞 𝒌′

= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ (𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌) (3.4.2-3)
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ [𝑥𝑝𝑞 𝒊′ + (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼)𝒋′ + (𝑦𝑝𝑞 sin 𝛼 + 𝑧𝑝𝑞 cos 𝛼)𝒌′ ]
Where: 𝑥𝑝𝑞 , 𝑦𝑝𝑞 and 𝑧𝑝𝑞 are determined by expression (3.4.1-18) for the case of tilt device and
𝑞 𝑞
𝜀 +∆𝜀1
expression (3.4.1-26) for the case of no tilt device. ∆𝜀2,𝑞 = ∫𝜀𝑞1 𝑀12 𝑑𝜀1 and
1
𝑥2𝑞 = 𝑥𝑝𝑞 cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) − (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼) sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,
𝑦2𝑞 = 𝑥𝑝𝑞 sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) + (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼) cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,}
𝑧2𝑞 = 𝑦𝑝𝑞 sin 𝛼 + 𝑧𝑝𝑞 cos 𝛼 .
With help of expression (3.1.1-1), unit normal 𝑵𝑞2 to tooth profile of 𝑞 th tooth of workpiece 2 is
as follow:
~ 306 ~
𝑵2 = [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ (𝐴𝑝 𝒊 + 𝐵𝑝 𝒋 + 𝐶𝑝 𝒌) = 𝐴2 𝒊′ + 𝐵2 𝒋′ + 𝐶2 𝒌′
(3.4.2-4)
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ [𝐴𝑞𝑝 𝒊′ + (𝐵𝑝𝑞 cos 𝛼 − 𝐶𝑝𝑞 sin 𝛼)𝒋′ + (𝐵𝑝𝑞 sin 𝛼 + 𝐶𝑝𝑞 cos 𝛼)𝒌′ ]
Where: 𝐴𝑞𝑝 , 𝐵𝑝𝑞 and 𝐶𝑝𝑞 are calculated by expression (3.4.1-19) for the case of tilt device and
expression (3.4.1-22) for case of no tilt device, then,
𝐴𝑞2 = 𝐴𝑞𝑝 cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) − (𝐵𝑝𝑞 cos 𝛼 − 𝐶𝑝𝑞 sin 𝛼) sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,
𝐵2𝑞 = 𝐴𝑞𝑝 sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) + (𝐵𝑝𝑞 cos 𝛼 − 𝐶𝑝𝑞 sin 𝛼) cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,}
𝐶2𝑞 = 𝐵𝑝𝑞 sin 𝛼 + 𝐶𝑝𝑞 cos 𝛼 .
~ 306 ~
Chapter 5
Calculation of Curvature
In manufacturing process of tooth profile, cutter surface is referred to the first conjugate
surface 𝐴 and workpiece is signified as the second conjugate surface 𝐴̅.
3.5.1 Curvature of Cutter Surface in Direction of Tangent to Cutting

Edge
For conical surface, the expression (1.6.2-2) is simplified as follow:
𝑑𝜎1 𝑑2 𝜎1
= 𝑏𝑎 = 0, = 0, 𝑏𝑟 = 0,
𝑑2 (𝑙𝒑) 𝑑𝑀 𝑑𝜎2 𝑑2 𝜎2
} (3.5.1-1)
𝑑(𝑙𝒑)
= 0, = 0, 𝑀 = 𝑑𝜀 = 0, = = 0.
𝑑𝜀1 𝑑𝜀12 1 𝑑𝜀1 𝑑𝜀12
𝜂 in expression (1.6.2-3) is as follow:
Then, 𝜂 and 𝒓0 in expression (1.6.2-3) is as follow:
𝜂 = 𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ,
} (3.5.1-2)
𝒓0 = cos 𝜇 𝒊𝑐 + sin 𝜇 𝒋𝑐 .
Where: 𝑟𝑐 is nominal radius of cutter head, for inner blade: 𝑟𝑐 = 𝑟𝑐𝑖 and for outer blade: 𝑟𝑐 =
𝑟𝑐𝑜 . ∅𝑐 is blade angle, for inner blade: ∅𝑐 = ∅𝑐𝑖 and for outer blade: ∅𝑐 = ∅𝑐𝑜 . 𝑠𝑐 and 𝜇 are
parameter of calculation point 𝑃 which is decided by solution of simultaneous equation (3.4.1-
17) for the case of tilt device or (3.4.1-27) for the case of no tilt device.
Let 𝜎 = 90° and 𝛽 = ∅𝑐 in expression (1.6.2-7), then, the unit tangent to cutting edge is
𝜻 = sin ∅𝑐 cos 𝜇 𝒊𝑐 + sin ∅𝑐 sin 𝜇 𝒋𝑐 + cos ∅𝑐 𝒌𝑐 (3.5.1-3)
Substitution of expressions (3.5.1-1) and (3.5.1-2) into (1.6.2-9) generates unit normal to conical
surface, i.e., cutter surface, as follow:
𝑵𝑐 = 𝐴𝑐 𝒊𝑐 + 𝐵𝑐 𝒋𝑐 + 𝐶𝑐 𝒌𝑐 = − cos ∅𝑐 cos 𝜇 𝒊𝑐 − cos ∅𝑐 sin 𝜇 𝒋𝑐 + sin ∅𝑐 𝒌𝑐 (3.5.1-4)
Due to 𝜅𝑐 = 0 in expression (1.6.2-10), normal curvature 𝐾𝜁 of cutter surface 𝐴 at point 𝑃 in

tangent direction 𝜻 of cutting edge is yielded as follow:
𝐾𝜁 = −𝜅𝑐 (𝑵1𝑝 ∙ 𝝃) = 0 (3.5.1-5)
~ 307~
And torsional curvature 𝐺1𝜁 of cutter surface 𝐴 at point 𝑃 in tangent direction 𝜻 of cutting edge
is generated by application (1.6.2-11) as follow:
𝐺𝜁 = 0 (3.5.1-6)
Normal curvature 𝐾𝑞 of cutter surface 𝐴 at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is resulted from

cos ∅𝑐
𝐾𝑞 = − 𝑟 +𝑠 (3.5.1-7)
𝑐 𝑐 sin ∅𝑐
Torsional curvature 𝐺𝑞 of the first conjugate surface 𝐴 at point 𝑃 in direction 𝒒 = 𝑵1𝑝 × 𝜻 is
𝐺𝑞 = −𝐺𝜁 = 0 (3.5.1-8)
3.5.2 Curvature of Tooth Profile of Workpiece 1

1 Curvature of Cutter Surface in Direction of Relative Velocity of Cutter Surface
with Respect to Workpiece 1
Parameters 𝑥𝑐𝑞 , 𝑦𝑐𝑞 and 𝑧𝑐𝑞 for initial position of cutter are decided by expression (3.3.3-8) or
(3.3.3-13). Point 𝑃 on cutter surface 𝐴 reaches conjugate cutting position from initial position
after rotating by an angle ∆𝜀0𝑞 about 𝒌𝑚 as an axis, that is,
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 = 𝑥𝑝𝑚

𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚
𝑞 𝑞 𝑞
Where: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are calculated by expression (3.4.1-9) for the case of tilt device and
expression (3.4.1-24) for the case of no tilt device. ∆𝜀0𝑞 , 𝑠𝑐 and 𝜇 are decided by simultaneous
equation (3.4.1-17) for the case of tilt device and (3.4.1-27) for the case of no tilt device.
Likewise, conjugate cutting position of unit tangent 𝜻 to cutting edge at point 𝑃 is as follow:
𝜻𝑝 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝜻 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ (sin ∅𝑐 cos 𝜇 𝒊𝑐 + sin ∅𝑐 sin 𝜇 𝒋𝑐 + cos ∅𝑐 𝒌𝑐 )
With help of expression (3.2.1-1), expression above gives unit tangent 𝜻𝑝 for the case of tilt device
as follow:
𝜻𝑝 = 𝜁𝑝𝑥 𝒊𝑚 + 𝜁𝑝𝑦 𝒋𝑚 + 𝜁𝑝𝑧 𝒌𝑚

[sin ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ) + cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 ]𝒊𝑚
sin ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ) (3.5.2-1)
= (∆𝜀0𝑞 𝒌𝑚 ) ⊗ +[ 𝑞 𝑞 ] 𝒋𝑚
− cos ∅𝑐 sin ζ cos Θ
[ +(sin ∅𝑐 sin 𝜇 sin ζ𝑞 + cos ∅𝑐 cos ζ𝑞 )𝒌𝑚 ]
~ 308 ~
𝑞
Where: ζ𝑞 and Θ𝑞 are decided by expression (3.3.3-8). ∆𝜀0 is calculated by expression (3.4.1-11).
𝜇 is resulted from solution of simultaneous equation (3.4.1-17), and
[sin ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ) + cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 ] cos ∆𝜀0𝑞
𝜁𝑝𝑥 = { },
−[sin ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ) − cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 ] sin ∆𝜀0𝑞
[sin ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ) + cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 ] sin ∆𝜀0𝑞
𝜁𝑝𝑦 = { },
+[sin ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ) − cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 ] cos ∆𝜀0𝑞
𝜁𝑝𝑧 = sin ∅𝑐 sin 𝜇 sin ζ𝑞 + cos ∅𝑐 cos ζ𝑞 . }
For the case of no tilt device, expressions (3.5.2-1) can be updated with consideration of ζ𝑞 =
Θ𝑞 = 0 as follow:
𝜻𝑝 = 𝜁𝑝𝑥 𝒊𝑚 + 𝜁𝑝𝑦 𝒋𝑚 + 𝜁𝑝𝑧 𝒌𝑚 (3.5.2-2)
Where: 𝜇 is calculated by simultaneous equation (3.4.1-27)
𝜁𝑝𝑥 = sin ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 ) ,

𝜁𝑝𝑦 = sin ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) , }
𝜁𝑝𝑧 = cos ∅𝑐 .
Unit normal 𝑵𝑝 to cutter surface 𝐴 with respect to machine coordinate system 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚

is as follow:
𝑵𝑝 = 𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 (3.5.2-3)

𝑞 𝑞
and 𝐶𝑝𝑚 are calculated by expression (3.4.1-9) for the case of tilt device and
expression (3.4.1-24) for the case of no tilt device.
Relative velocity 𝒗12

𝑝 of cutter surface 𝐴 with respect to workpiece 1 at point 𝑃 is resulted from
𝒗12 12 12 12
𝑝 = 𝑣𝑝𝑥 𝒊𝑚 + 𝑣𝑝𝑦 𝒋𝑚 + 𝑣𝑝𝑧 𝒌𝑚 (3.5.2-4)
𝑞 𝑞 𝑞
expression (3.4.1-24) for the case of no tilt device and
12 𝑞 𝑞 𝑞 𝑞
𝑣𝑝𝑥 = −[𝑦𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑀1 𝑧𝑝𝑚 sin 𝛼𝑚 ],
12 𝑞 𝑞 12 𝑞 𝑞
𝑣𝑝𝑦 = 𝑥𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 ), 𝑣𝑝𝑧 = 𝑀1 𝑥𝑝𝑚 sin 𝛼𝑚 ,
2 2 2
|𝒗12
𝑝 | = √(𝑣𝑝𝑥 ) + (𝑣𝑝𝑦 ) + (𝑣𝑝𝑧 ) .
12 12 12
}
~309 ~
𝒗12
𝑝
Also, unit relative velocity |𝒗12| = 𝝀 can be reached by rotating unit tangent 𝜻𝑝 to cutting edge
𝑝
by an angle 𝜃𝜁𝜆 about unit normal 𝑵𝑝 to cutter surface 𝐴, that is,
𝒗12
𝑝
|𝒗12
= 𝝀 = (𝜃𝜁𝜆 𝑵𝑝 ) ⊗ 𝜻𝑝 = cos 𝜃𝜁𝜆 𝜻𝑝 + sin 𝜃𝜁𝜆 𝑵𝑝 × 𝜻𝑝 (3.5.2-5)
𝑝 |
Where: 𝜻𝑝 is calculated by expression (3.5.2-1) for the case of tilt device and expression (3.5.2-
2) for the case of no tilt device.
Then, expression (3.5.2-5) gives
𝒗12
𝑝
sin 𝜃𝜁𝜆 = |𝒗12| ∙ (𝑵𝑝 × 𝜻𝑝 ),
𝑝
𝒗12
} (3.5.2-6)
𝑝
cos 𝜃𝜁𝜆 = |𝒗12 | ∙ 𝜻𝑝 .
𝑝
With help of expressions (3.5.1-5), (3.5.1-7) and (3.5.1-8), application of expression (1.2.1-23)
𝒗12
𝑝
gives curvature of cutter surface 𝐴 at point 𝑃 in direction of relative velocity |𝒗12 | = 𝝀, that is,
𝑝
cos ∅𝑐
𝐾𝜆 = 𝐾𝜁 cos2 𝜃𝜁𝜆 + 𝐾𝑞 sin2 𝜃𝜁𝜆 + 2𝐺𝜁 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 = − 𝑟 +𝑠 sin2 𝜃𝜁𝜆 ,
𝐺𝜆 = −(𝐾𝜁 − 𝐾𝑞 ) sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 + 𝐺𝜁 (cos 2 𝜃𝜁𝜆 − sin2 𝜃𝜁𝜆 ) (3.5.2-7)
cos ∅𝑐
=− sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .
𝑟𝑐 +𝑠𝑐 sin ∅𝑐 }
𝒗12
𝑝
Also, curvature of cutter surface 𝐴 at point 𝑃 in direction of ∆= 𝑵𝑝 × |𝒗12| is as follow,
𝑝
cos ∅𝑐 cos2 𝜃𝜁𝜆

𝐾∆ = − ,
𝑟𝑐 +𝑠𝑐 sin ∅𝑐
cos ∅𝑐
} (3.5.2-8)
𝐺∆ = 𝑟 +𝑠 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .
2 Calculation of Some Parameters

1) Calculation of 𝑱𝑝
In manufacturing process of tooth profile of workpiece 1, motion conditions are as follow;

𝑞 𝑞 𝑞
𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼) 𝑑𝑀 𝑑𝑀1 𝑑𝑀12 𝑀1 sin 𝛼𝑚
𝑀 = 𝑀1 = 𝑑𝜀1 = , = =− 𝑑𝜀1 𝑀122 sin 𝛼 ,
0 𝑀12 sin 𝛼 𝑑𝜀1 𝑑𝜀0
𝑑𝑓 𝑑ℎ 𝑑2 𝑓 𝑑2 ℎ 𝑑𝜎1 𝑑𝜎2 𝑑2 𝜎1 𝑑2 𝜎2 (3.5.2-9)
𝑓 = ℎ = 𝑑𝜀 = 𝑑𝜀 = = = 0, = = = = 0,
1 1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 𝑑𝜀1 𝑑𝜀1 2 𝑑𝜀12
𝑞 𝑞
𝝎1 = 𝒌0 = 𝒌𝑚 , 𝝎2 =𝒌 = sin 𝛼𝑚 𝒋𝑚 + cos 𝛼𝑚 𝒌𝑚 }
~ 310 ~
Substitution of expression (3.5.2-10) into expression (1.5.2-7) yields parameter 𝑱𝑝 with
𝑞 𝑞 𝑞 𝑞
consideration 𝑥𝑝 = 𝑥𝑝𝑚 , 𝑦𝑝 = 𝑦𝑝𝑚 , 𝑧𝑝 = 𝑧𝑝𝑚 and 𝛼 = 𝛼1 = 𝛼𝑚 + 180°
𝑱𝑝 = 𝐽𝑝1 𝒊𝑚 + 𝐽𝑝2 𝒋𝑚 + 𝐽𝑝3 𝒌𝑚 (3.5.2-10)
Where:
𝑞
𝑑𝑀12 𝑀1 sin 𝛼𝑚 𝑞 𝑞 𝑞 𝑞
𝐽𝑝1 = − 2 sin 𝛼 (−𝑦𝑝𝑚 cos 𝛼𝑚 + 𝑧𝑝𝑚 sin 𝛼𝑚 ),
𝑑𝜀1 𝑀12
𝑞
𝑞 𝑞 𝑑𝑀12 𝑀1 sin 𝛼𝑚 𝑞 𝑞
𝐽𝑝2 = −𝑀1 𝑧𝑝𝑚 sin 𝛼𝑚 − 2 sin 𝛼 𝑥𝑝𝑚 cos 𝛼𝑚 ,
𝑑𝜀1 𝑀12
𝑞
𝑞 𝑞 𝑑𝑀12 𝑀1 sin 𝛼𝑚 𝑞 𝑞
𝐽𝑝3 = 𝑀1 𝑦𝑝𝑚 sin 𝛼𝑚 + 2 𝑥𝑝𝑚 sin 𝛼𝑚 . }
𝑑𝜀1 𝑀12 sin 𝛼
𝑞 𝑞 𝑞
Here: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are calculated by expression (3.4.1-9) for the case of tilt device and
2) Calculation of 𝐷𝑝 and 𝐸𝑝
Application of expression (1.5.2-11) generates parameters 𝐷𝑝 and 𝐸𝑝 as follow:
𝒗12
𝑝
𝐷𝑝 = 𝐾1𝜆 |𝒗12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ |𝒗12 |
𝑝
𝑞 𝑞
12
[𝒌𝑚 − 𝑀1 (sin 𝛼𝑚 𝒋𝑚 + cos 𝛼𝑚 𝒌𝑚 )] 𝒗12 𝑝
= 𝐾𝜆 |𝒗𝑝 | − { 𝑞 𝑞 𝑞 } ∙ |𝒗12|
× (𝐴𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚 𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 ) 𝑝
12 1 −𝑣𝑝𝑥 [𝐶𝑝𝑚 𝑀1 sin 𝛼𝑚 + 𝐵𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 )] (3.5.2-11)
= 𝐾𝜆 |𝒗𝑝 | − |𝒗12| { 12 𝑞 12 𝑞 𝑞 },
𝑝 +𝑣𝑝𝑦 𝐴𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑣𝑝𝑧 𝐴𝑝𝑚 𝑀1 sin 𝛼𝑚
𝒗12
𝑝
𝐸𝑝 = |𝒗12
𝑝 |𝐺1𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12 |
𝑝
1 𝑞 𝑞
= |𝒗12
𝑝 |𝐺𝜆 + |𝒗12 |
12
[−𝑣𝑝𝑦 𝑀1 sin 𝛼𝑚 + (1 − 𝑀1 cos 𝛼𝑚 12
)𝑣𝑝𝑧 ].
𝑝 }

𝑞 𝑞
and 𝐶𝑝𝑚 are calculated by expression (3.4.1-9) for the case of tilt device and
12 12 12
expression (3.4.1-22) for the case of no tilt device. 𝑣𝑝𝑥 , 𝑣𝑝𝑦 and 𝑣𝑝𝑧 are calculated by (3.5.2-4).
𝐾𝜆 and 𝐺𝜆 are calculated by expression (3.5.2-7).
3) Direction of Instantaneous Contact Line 𝒆 between cutter and workpiece 1
Application of expression (1.5.2-17) gives direction of Instantaneous Contact Line 𝒆 between

cutter and workpiece 1 as follow:
~311 ~
𝒑 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐
𝒆 = (𝜃𝜆𝑒 𝑵𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑒 + (𝑵𝑝 × |𝒗𝟏𝟐 |) sin 𝜃𝜆𝑒 (3.5.2-12)
𝒑 𝒑 𝒑
Where: 𝐷𝑝 and 𝐸𝑝 are decided by expression (3.5.2-11)

𝐷𝑝
𝐸𝑝
cos 𝜃𝜆𝑒 = ,
𝒈 = 𝑵𝑝 × 𝒆. }
4) Curvatures of Cutter Surface at point 𝑃 in directions of 𝒆 and 𝒈
Then, curvatures of cutter surface at point 𝑃 in directions of 𝒆 and 𝒈 are given by application of
𝐾𝑒 = 𝐾𝜆 cos2 𝜃𝜆𝑒 + 𝐾∆ sin2 𝜃𝜆𝑒 + 2𝐺𝜆 sin 𝜃𝜆𝑒 cos 𝜃𝜆𝑒 ,

𝐺𝑒 = −(𝐾𝜆 − 𝐾∆ ) sin 𝜃𝜆𝑒 cos 𝜃𝜆𝑒 + 𝐺𝜆 (cos 2 𝜃𝜆𝑒 − sin2 𝜃𝜆𝑒 ),
(3.5.2-13)
𝐾𝑔 = 𝐾𝜆 sin2 𝜃𝜆𝑒 + 𝐾∆ cos 2 𝜃𝜆𝑒 − 2𝐺𝜆 cos 𝜃𝜆𝑒 sin 𝜃𝜆𝑒 ,
𝐺𝑔 = −𝐺𝑒 . }
Where: 𝐾𝜆 and 𝐺𝜆 are decided by expression (3.5.2-7) and 𝐾∆ is calculated by expression (3.5.2-
8).

𝝉 = (𝜃𝑒𝜏 𝑵𝑝 ) ⊗ 𝒆 = cos 𝜃𝑒𝜏 𝒆 + sin 𝜃𝑒𝜏 𝑵𝑝 × 𝒆 (3.5.2-14)
Thus, curvature of cutter surface 𝐴 at point 𝑃 in direction of 𝝉 is generated as follow:
𝐾𝜏 = 𝐾𝑒 cos 2 𝜃𝑒𝜏 + 𝐾𝑔 sin2 𝜃𝑒𝜏 + 2𝐺𝑒 sin 𝜃𝑒𝜏 cos 𝜃𝑒𝜏 ,

} (3.5.2-15)
𝐺𝜏 = −(𝐾𝑒 − 𝐾𝑔 ) sin 𝜃𝑒𝜏 cos 𝜃𝑒𝜏 + 𝐺𝑒 (cos2 𝜃𝑒𝜏 − sin2 𝜃𝑒𝜏 ).
Curvature of tooth profile of 𝑞𝑡ℎ tooth of workpiece 1 in any tangent direction 𝝉 is decided by

𝐾1𝜏 = − 𝐾𝜏 ,
𝐷𝑝 |𝒗12
𝒑 |+𝑱𝑝 ∙𝑵𝑝
} (3.5.2-16)
𝐺1𝜏 = 𝐺𝜏 − .
𝐷𝑝 |𝒗12
~312 ~
Where: 𝑵𝑝 is decided by expression (3.5.2-3). 𝒗12
𝒑 is determined by expression (3.5.2-4). 𝑱𝑝 is
expressed in formular (3.5.2-10). 𝐷𝑝 and 𝐸𝑝 are calculated in expression (3.5.2-11). 𝐾𝜏 and 𝐺𝜏

are decided in expression (3.5.2-15).

Tooth profile of 𝑞𝑡ℎ tooth of workpiece 2 is manufactured by cutter surface identical to that for
tooth profile of 𝑞𝑡ℎ tooth of workpiece 1 with opposite direction from void to entity. Therefore,
unit normal 𝑵′𝑝 to cutter surface 𝐴 for workpiece 2 is as follow:
𝑵′𝑝 = −𝑵𝑝 (3.5.3-1)
Where: 𝑵𝑝 is decided by expression (3.5.2-3).

Let 𝜀0 be visualized as virtual time parameters, velocity of point 𝑃(𝑹𝑞𝑝 ) on workpiece 2 is as

follow:
𝑑𝜀
𝒗𝑞𝑝 = 𝑑𝜀2 𝝎2 × 𝑹𝑞𝑝 (3.5.3-2)
0
𝑞
Where: 𝝎2 is decided by expression (3.3.1-3) and 𝑹𝑝 is expressed in expression (3.4.1-4) for
case of tilt device or (3.4.1-26) for case of no-tilt device.
With help of expression (3.4.1-13), Relative velocity 𝒗12

𝑝 of cutter surface 𝐴 with respect to
workpiece 2 at point 𝑃 is given as follow:
𝑞
𝒗12 12 12 12
𝑝 = 𝒗𝑐 − 𝒗𝑝 = 𝑣𝑝𝑥 𝒊𝑚 + 𝑣𝑝𝑦 𝒋𝑚 + 𝑣𝑝𝑧 𝒌𝑚
𝑑𝜀 (3.5.3-3)
= (𝒌𝑚 − 𝑑𝜀2 𝝎2 ) × 𝑹𝑞𝑝 = {𝑀2 sin(𝛼𝑚
𝑞 𝑞
+ 𝛼) 𝒋𝑚 + [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)]𝒌𝑚 } × 𝑹𝑞𝑝
0
𝑞 𝑞 𝑞
expression (3.4.1-22) for the case of no tilt device, that is,
𝑣𝑝𝑥 = 𝑧𝑝𝑚 𝑀2 sin(𝛼𝑚 + 𝛼) − 𝑦𝑝𝑚 [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)],
12 𝑞 𝑞
𝑣𝑝𝑦 = 𝑥𝑝𝑚 [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)], }
12 𝑞 𝑞
𝑣𝑝𝑧 = −𝑥𝑝𝑚 𝑀2 sin(𝛼𝑚 + 𝛼) .
~ 313 ~
𝒗12
𝑝
𝑝
′
by an angle 𝜃𝜁𝜆 about unit normal 𝑵′𝑝 to cutter surface 𝐴, that is,
𝒗12
𝑝
|𝒗12
= 𝝀 = (𝜃𝜁𝜆 𝑵′𝑝 ) ⊗ 𝜻𝑝 = cos 𝜃𝜁𝜆 𝜻𝑝 − sin 𝜃𝜁𝜆 𝑵𝑝 × 𝜻𝑝 (3.5.3-4)
𝑝 |
Where: 𝜻𝑝 is calculated by expression (3.5.2-1) for the case of tilt device and expression (3.5.2-
2) for the case of no tilt device. 𝑵𝑝 is calculated by expression (3.5.2-3) and 𝒗12
𝑝 is decided by
Then, expression (3.5.3-4) results in
𝒗12
𝑝
sin 𝜃𝜁𝜆 = − |𝒗12 | ∙ (𝑵𝑝 × 𝜻𝑝 ),
𝑝
𝒗12
} (3.5.3-5)
𝑝
cos 𝜃𝜁𝜆 = |𝒗12 | ∙ 𝜻𝑝
𝑝
With help of expressions (3.5.1-5), (3.5.1-7) and (3.5.1-8), application of expression (1.2.1-23)
𝒗12
𝑝
gives curvature of cutter surface 𝐴 at point 𝑃 in direction of relative velocity |𝒗12 | = 𝝀, that is,
𝑝
𝐾𝜆 = 𝐾𝜁 cos2 𝜃𝜁𝜆 + 𝐾𝑞 sin2 𝜃𝜁𝜆 + 2𝐺𝜁 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆

cos ∅𝑐
= − 𝑟 +𝑠 sin2 𝜃𝜁𝜆 ,
(3.5.3-6)
𝐺𝜆 = −(𝐾𝜁 − 𝐾𝑞 ) sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 + 𝐺𝜁 (cos 2 𝜃𝜁𝜆 − sin2 𝜃𝜁𝜆 )
cos ∅𝑐
= − 𝑟 +𝑠 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 . }
Where: sin 𝜃𝜁𝜆 and cos 𝜃𝜁𝜆 are decided by expression (3.5.3-5).
𝒗12
𝑝
Also, curvature of cutter surface 𝐴 at point 𝑃 in direction of ∆= 𝑵′𝑝 × |𝒗12| is as follow,
𝑝
cos ∅𝑐
𝐾∆ = 𝐾𝑞 cos 2 𝜃𝜁𝜆 = − 𝑟 +𝑠 cos 2 𝜃𝜁𝜆 ,
cos ∅𝑐
} (3.5.3-7)
𝐺∆ = −𝐾𝑞 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 = sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .

In manufacturing process of tooth profile of workpiece 2, motion conditions are as follow:
~ 314 ~
𝑞 𝑞 𝑞
𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼) 𝑑𝑀 𝑑𝑀2 𝑑𝑀12 𝑀1 sin(𝛼𝑚 +𝛼)
𝑀 = 𝑀2 = 𝑑𝜀2 = , = = 𝑑𝜀1 sin 𝛼
,
0 sin 𝛼 𝑑𝜀1 𝑑𝜀0
𝑑𝑓 𝑑ℎ 𝑑2 𝑓 𝑑2 ℎ 𝑑𝜎1 𝑑𝜎2 𝑑2 𝜎1 𝑑2 𝜎2 (3.5.3-9)
𝑓 = ℎ = 𝑑𝜀 = 𝑑𝜀 = = = 0, = = = ,
1 1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12
𝑞 𝑞
𝝎1 = 𝒌0 = 𝒌𝑚 , 𝝎2 = − sin(𝛼𝑚 + 𝛼) 𝒋𝑚 − cos(𝛼𝑚 + 𝛼) 𝒌𝑚 . }

𝑞 𝑞 𝑞
consideration 𝑥𝑝 = 𝑥𝑝𝑚 , 𝑦𝑝 = 𝑦𝑝𝑚 , 𝑧𝑝 = 𝑧𝑝𝑚 as follow:
𝑱𝑝 = 𝐽𝑝1 𝒊𝑚 + 𝐽𝑝2 𝒋𝑚 + 𝐽𝑝3 𝒌𝑚 (3.5.3-10)

𝑑𝑀2 𝑞 𝑞 𝑞 𝑞
𝐽𝑝1 = [𝑦𝑝𝑚 cos(𝛼𝑚 + 𝛼) − 𝑧𝑝𝑚 sin(𝛼𝑚 + 𝛼)],
𝑑𝜀0
𝑞 𝑞 𝑑𝑀 𝑞 𝑞
𝐽𝑝2 = 𝑧𝑝𝑚 𝑀2 sin(𝛼𝑚 + 𝛼) − 𝑑𝜀 2 𝑥𝑝𝑚 cos(𝛼𝑚 + 𝛼) ,
0
𝑞 𝑞 𝑑𝑀2 𝑞 𝑞
𝐽𝑝3 = −𝑀2 𝑦𝑝𝑚 sin(𝛼𝑚 + 𝛼) + 𝑥𝑝𝑚 sin(𝛼𝑚 + 𝛼) .}
𝑑𝜀0
𝑞 𝑞 𝑞
Here: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are calculated by expression (3.4.1-9) for the case of tilt device and
With help of 𝐾1𝜆 = 𝐾𝜆 , 𝐺1𝜆 = 𝐺𝜆 , 𝑵1𝑝 = −𝑵𝑝 and expression (3.5.3-6), application of
expression (1.5.2-11) generates parameters 𝐷𝑝 and 𝐸𝑝 as follow:
𝒗12
𝑝
𝐷𝑝 = 𝐾1𝜆 |𝒗12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ |𝒗12 |
𝑝
𝑞 𝑞
{𝑀2 sin(𝛼𝑚
+ 𝛼) 𝒋𝑚 + [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)]𝒌𝑚 } 𝒗12 𝑝
= 𝐾𝜆 |𝒗12
𝑝 | + { 𝑞 𝑞 𝑞 } ∙ |𝒗12|
12 1 𝑣𝑝𝑥 {𝐶𝑝𝑚 𝑀2 sin(𝛼𝑚 + 𝛼) − 𝐵𝑝𝑚 [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)]} (3.5.3-11)
= 𝐾𝜆 |𝒗𝑝 | + |𝒗12| { 12 𝑞 𝑞 12 𝑞 𝑞 },
𝑝 +𝑣𝑝𝑦 𝐴𝑝𝑚 [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)] − 𝑣𝑝𝑧 𝐴𝑝𝑚 𝑀2 sin(𝛼𝑚 + 𝛼)
𝒗12
𝑝
𝐸𝑝 = |𝒗12
𝑝 |𝐺 1𝜆 + (𝝎1 − 𝑀𝝎 2 ) ∙ |𝒗12 | 𝑝
1 𝑞 𝑞
= |𝒗12
𝑝 |𝐺𝜆 − {𝑣 12 𝑀 sin(𝛼𝑚
|𝒗12 | 𝑝𝑦 2
+ 𝛼) + 12
𝑣𝑝𝑧 [1 + 𝑀2 cos(𝛼𝑚 + 𝛼)]}.
𝑝 }
12 12 12
Where: 𝑣𝑝𝑥 , 𝑣𝑝𝑦 and 𝑣𝑝𝑧 are calculated by expression (3.5.3-3). 𝐾𝜆 and 𝐺𝜆 are decided by
formular (3.5.3-6).
~315 ~
𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑 𝒗𝟏𝟐
𝒑
𝒆 = (𝜃𝜆𝑒 𝑵′𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑒 + (𝑵′𝑝 × |𝒗𝟏𝟐 |) sin 𝜃𝜆𝑒 (3.5.3-12)
𝒑 𝒑 𝒑
Where:
𝐷𝑝
𝐸𝑝
cos 𝜃𝜆𝑒 = , (3.5.3-13)
𝒈 = 𝑵′𝑝 × 𝒆. }
Where: 𝐷𝑝 and 𝐸𝑝 are calculated by expression (3.5.3-11).
4) Curvatures of Cutter Surface at point 𝑃 in directions of 𝒆 and 𝒈

(3.5.3-14)
𝐾𝑔 = 𝐾𝜆 sin2 𝜃𝜆𝑒 + 𝐾∆ cos 2 𝜃𝜆𝑒 − 2𝐺𝜆 sin 𝜃𝜆𝑒 cos 𝜃𝜆𝑒 ,
𝐺𝑔 = −𝐺𝑒 . }
Where: 𝐾𝜆 and 𝐺𝜆 are decided by expression (3.5.3-6). 𝐾∆ is calculated by expression (3.5.3-7).
sin 𝜃𝜆𝑒 and cos 𝜃𝜆𝑒 are determined by expression (3.5.3-13).

𝝉 = (𝜃𝑒𝜏 𝑵′𝑝 ) ⊗ 𝒆 = cos 𝜃𝑒𝜏 𝒆 + sin 𝜃𝑒𝜏 𝑵′𝑝 × 𝒆 (3.5.3-15)

} (3.5.3-16)
Where: 𝐾𝑒 , 𝐾𝑒 and 𝐺𝑒 are calculated by expression (3.5.3-14).
Curvature of tooth profile of 𝑞𝑡ℎ tooth of workpiece 2 in any tangent direction 𝝉 is decided by
~ 316 ~

𝐾2𝜏 = − 𝐾𝜏 ,
𝐷𝑝 |𝒗12 ′
} (3.5.3-17)
𝐺2𝜏 = 𝐺𝜏 − .
𝐷𝑝 |𝒗12 ′
Where: 𝑵′𝑝 is expressed in formular (3.5.3-1). 𝑱𝑝 is expressed in formular (3.5.3-10). 𝐷𝑝 and 𝐸𝑝

are calculated in expression (3.5.3-11). 𝐾𝜏 and 𝐺𝜏 are decided in expression (3.5.3-16).
Example 3.1.1 Design a pair of non-circular gears between intersecting rotating axes with
Manufacturing Process without Tilt Device.
Given: Motion Requirement as Follow
𝑑𝜀 1−𝑒 2 𝑑𝑀12 2𝑒(1−𝑒 2 ) sin 𝜀1

𝛼 = 80°, 𝑒 = 0.2, 𝑀12 = 𝑑𝜀2 = 1+2𝑒 cos 𝜀 , = (1+2𝑒 cos 𝜀 .
1 1 +𝑒 2 𝑑𝜀1 1 +𝑒
2 )2
Parameters of Gear Set
𝑝 = 7.85, 𝑍1 = 25, 𝜓𝑔 = 30°, ∅𝑔𝑖 = 30°, ∅𝑔𝑜 = 150°.
Parameters of Cutter Head as Follow
𝑟𝑐𝑖 = 30.0, ∅𝑐𝑖 = 30°, 𝑟𝑐𝑜 = 30.0, ∅𝑐𝑜 = 150°, Θ = ζ = 0.
Gear set is as shown in figure Example 3.1.1.
(a) A Pair of Gear Set
~ 317 ~
Workpiece 2 Conical Rotating Surface of Cutter Workpiece 1
(b) Manufacturing Process
Figure Example 3.1.1
𝑑𝜀 1−𝑒 2 𝑑𝑀12 2𝑒(1−𝑒 2 ) sin 𝜀1

𝛼 = 80°, 𝑒 = 0.2, 𝑀12 = 𝑑𝜀2 = 1+2𝑒 cos 𝜀 , = (1+2𝑒 cos 𝜀 .
1 1 +𝑒 2 𝑑𝜀1 1 +𝑒
2 )2
𝑝 = 7.85, 𝑍1 = 25, 𝜓𝑔 = 30°, ∅𝑔𝑖 = 30°, ∅𝑔𝑜 = 150°.
Parameters of Cutter Head as Follow
𝑟𝑐𝑖 = 30.0, ∅𝑐𝑖 = 30°, 𝑟𝑐𝑜 = 30.0, ∅𝑐𝑜 = 150°, Θ = ζ = 0.
Gear set is as shown in figure Example 3.1.1.
Calculation:
Machine Setting Parameters as listed in table 3.1.1-1 and table 3.1.1-2
~ 318 ~
Machine Setting Parameters for Convex Flank of Workpiece 1 and Concave Flank of Workpiece
2 without Tilt Device (table. 3.1.1-1)
𝑞𝑡ℎ tooth 𝑥𝑐 𝑦𝑐 𝑧𝑐 𝜌𝑐 𝑄𝑐 (𝑑𝑒𝑔) 𝛼𝑚 (𝑑𝑒𝑔) 𝜀1,𝑞 (𝑑𝑒𝑔) 𝜀2,𝑞 (𝑑𝑒𝑔)
1 -25.9808 34.0829 0 42.856 127.318 59.5266 0 0
2 -25.9808 34.0829 0 42.856 127.318 59.2186 18.0033 12.0552
3 -25.9808 34.0829 0 42.856 127.318 58.3184 35.6206 24.1694
4 -25.9808 34.0829 0 42.856 127.318 56.8942 52.5472 36.4158
5 -25.9808 34.0829 0 42.856 127.318 55.0473 68.6133 48.8901
6 -25.9808 34.0829 0 42.856 127.318 52.8992 83.7821 61.7126
7 -25.9808 34.0829 0 42.856 127.318 50.5819 98.1168 75.0236
8 -25.9808 34.0829 0 42.856 127.318 48.2311 111.74 88.9719
9 -25.9808 34.0829 0 42.856 127.318 45.9833 124.797 103.169
10 -25.9808 34.0829 0 42.856 127.318 43.9723 137.435 119.294
11 -25.9808 34.0829 0 42.856 127.318 42.3258 149.787 135.786
12 -25.9808 34.0829 0 42.856 127.318 41.156 161.959 153.074
13 -25.9808 34.0829 0 42.856 127.318 40.5492 174.037 170.922
14 -25.9808 34.0829 0 42.856 127.318 40.5523 186.085 188.974
15 -25.9808 34.0829 0 42.856 127.318 41.1651 198.162 206.828
16 -25.9808 34.0829 0 42.856 127.318 42.3397 210.332 224.127
17 -25.9808 34.0829 0 42.856 127.318 43.9895 222.68 240.632
18 -25.9808 34.0829 0 42.856 127.318 46.0017 235.313 256.245
19 -25.9808 34.0829 0 42.856 127.318 48.2489 248.362 270.983
20 -25.9808 34.0829 0 42.856 127.318 50.5971 261.974 284.944
21 -25.9808 34.0829 0 42.856 127.318 52.9107 276.293 298.265
22 -25.9808 34.0829 0 42.856 127.318 55.0547 291.444 311.097
23 -25.9808 34.0829 0 42.856 127.318 56.898 307.49 323.577
24 -25.9808 34.0829 0 42.856 127.318 58.3197 324.398 335.828
25 -25.9808 34.0829 0 42.856 127.318 59.2187 324.008 347.944
~ 319 ~
Machine Setting Parameters for Concave Flank of Workpiece 1 and Convex Flank of Workpiece
2 without Tilt Device (table. 3.1.1-2)
𝑞𝑡ℎ tooth 𝑥𝑐 𝑦𝑐 𝑧𝑐 𝜌𝑐 𝑄𝑐 (𝑑𝑒𝑔) 𝛼𝑚 (𝑑𝑒𝑔) 𝜀1,𝑞 (𝑑𝑒𝑔) 𝜀2,𝑞 (𝑑𝑒𝑔)
1 -25.9808 34.0829 0 42.856 127.318 59.4492 9.02656 6.02411

2 -25.9808 34.0829 0 42.856 127.318 58.8392 26.8821 18.1008
3 -25.9808 34.0829 0 42.856 127.318 57.6661 44.1842 30.2707
4 -25.9808 34.0829 0 42.856 127.318 56.0163 60.6929 42.6175
5 -25.9808 34.0829 0 42.856 127.318 54.0028 76.3077 55.2494
6 -25.9808 34.0829 0 42.856 127.318 51.7532 91.047 68.2978
7 -25.9808 34.0829 0 42.856 127.318 49.4022 105.008 81.9089
8 -25.9808 34.0829 0 42.856 127.318 47.0859 118.33 96.2294
9 -25.9808 34.0829 0 42.856 127.318 44.94 131.16 111.382
10 -25.9808 34.0829 0 42.856 127.318 43.096 143.639 127.431
11 -25.9808 34.0829 0 42.856 127.318 41.6751 155.889 144.342
12 -25.9808 34.0829 0 42.856 127.318 40.7783 168.005 161.948
13 -25.9808 34.0829 0 42.856 127.318 40.4734 180.061 179.948
14 -25.9808 34.0829 0 42.856 127.318 40.7844 192.116 197.95
15 -25.9808 34.0829 0 42.856 127.318 41.6868 204.231 215.565
16 -25.9808 34.0829 0 42.856 127.318 43.1118 216.478 232.488
17 -25.9808 34.0829 0 42.856 127.318 44.9581 228.953 248.551
18 -25.9808 34.0829 0 42.856 127.318 47.1042 241.777 263.718
19 -25.9808 34.0829 0 42.856 127.318 49.4188 255.088 278.052
20 -25.9808 34.0829 0 42.856 127.318 51.7667 269.036 291.675
21 -25.9808 34.0829 0 42.856 127.318 54.0122 283.759 304.733
22 -25.9808 34.0829 0 42.856 127.318 56.0218 299.354 317.373
23 -25.9808 34.0829 0 42.856 127.318 57.6685 315.844 329.725
24 -25.9808 34.0829 0 42.856 127.318 58.8397 333.129 341.898
25 -25.9808 34.0829 0 42.856 127.318 59.4492 350.975 353.967
~ 320 ~
Part IV
Gear Transmission with Varied Transmission Ratio
between Two Crossed Rotating Axes
This chapter discusses and invents an innovative tooth profile. Conjugate motion of cutter with
respect to workpiece requires special machine which doesn’t exist in current industry.
Mathematic formulas developed in this part can provide theoretical foundation to design and
develop new machine specially for this type of tooth profile.
~ 321~
Chapter 1
Parameter Design of Tooth Profile of Workpiece 1 & 2
4.1.1 Index Curve

Let rotating axis of workpiece 1 be 𝒌 = 𝝎1 and rotating axis of workpiece 2 be 𝝎2 = −𝒌′ .
Rotating angle of workpiece 1 about 𝒌 = 𝝎1 is 𝜀1 and rotating angle of workpiece 2 about 𝝎2 is

𝑑𝜀
𝜀2 . 𝑀 = 𝑑𝜀2 is transmission ratio. Coordinate system 𝑂 − 𝒊, 𝒋, 𝒌 is for workpiece 1 and 𝑂′ −
1
′ ′ ′
𝒊 , 𝒋 , 𝒌 is for workpiece 2. Relative position is as shown in figure 4.1.1,
𝜃 𝑹𝑎
𝛼 𝑂 𝜌𝑎 𝒋
𝑓 𝒌′ 𝑧𝑎
𝑂′
𝝎2 (= −𝒌′ ) 𝒊(= 𝒊′ ) 𝒋′
Figure 4.1.1
𝒊′ = 𝒊, 𝒋′ = cos 𝛼 𝒋 − sin 𝛼 𝒌,
} (4.1.1-1)
𝒌′ = −𝝎2 = sin 𝛼 𝒋 + cos 𝛼 𝒌, ⃗⃗⃗⃗⃗⃗⃗
𝑂𝑂′ = 𝑓𝒊.
Conjugate motion for two fixed crossed rotating axes is as follow:
𝑓 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡, ℎ = 𝜎1 =𝜎2 = 0,
𝑑𝑓 𝑑ℎ 𝑑𝜎1 𝑑𝜎2 } (4.1.1-2)
= 𝑑𝜀 = = = 0.
𝑑𝜀1 1 𝑑𝜀1 𝑑𝜀1
Therefore, existent condition of pitch surfaces, i.e., expression (1.4.2-1), is not satisfied. There is
~ 322 ~
no pitch surface available.
However, corresponding to conjugate motion of expression (4.1.1-2), screw axis on workpiece 1 at

instant rotating angle 𝜀1 is decided in expression (1.4.11-2), that is,
𝑹𝑎𝑝 = 𝑥𝑎𝑝 𝒊 + 𝑦𝑎𝑝 𝒋 + 𝑧𝑎𝑝 𝒌 (4.1.1-3)
Where: 𝑥𝑎𝑝 and 𝑦𝑎𝑝 are linear function of 𝑧𝑎𝑝 at instant rotating angle 𝜀1 , and thus screw axis is
straight line, that is,
𝑀𝑓(𝑀+cos 𝛼)
𝑥𝑎𝑝 = 𝐸 = 1+2𝑀 cos 𝛼+𝑀2 ,
𝑀𝑧𝑎𝑝 sin 𝛼 } (4.1.1-4)
𝑦𝑎𝑝 = 𝐹 = .
1+𝑀 cos 𝛼
Surface of screw axis on workpiece 1 in initial position is derived by application of expression

(1.4.11-3), that is,
𝑹𝑎 = 𝑥𝑎 𝒊 + 𝑦𝑎 𝒋 + 𝑧𝑎 𝒌 = (−𝜀1 𝒌) ⊗ (𝑥𝑎𝑝 𝒊 + 𝑦𝑎𝑝 𝒋 + 𝑧𝑎𝑝 𝒌)

𝑥𝑎 = 𝐸 cos 𝜀1 + 𝐹 sin 𝜀1 ,
(4.1.1-5)
𝑦𝑎 = −𝐸 sin 𝜀1 + 𝐹 cos 𝜀1 ,
𝑧𝑎 = 𝑧𝑎𝑝 . }
Where: 𝜀1 is independent parameter.
Similarly, surface of screw axis on workpiece 2 in initial position is generated by application of

𝑹′𝑎 = 𝑥𝑎′ 𝒊′ + 𝑦𝑎′ 𝒋′ + 𝑧𝑎′ 𝒌′ (4.1.1-6)
Where:
𝑥𝑎′ = (𝐸 − 𝑓) cos 𝜀2 + (𝑧𝑎 sin 𝛼 − 𝐹 cos 𝛼) sin 𝜀2 ,

𝑦𝑎′ = (𝐸 − 𝑓) sin 𝜀2 − (𝑧𝑎 sin 𝛼 − 𝐹 cos 𝛼) cos 𝜀2 , }
𝑧𝑎′ = 𝐹 sin 𝛼 + 𝑧𝑎 cos 𝛼 .
If transmission ratio 𝑀 and 𝑧𝑎 are periodic functions of rotating angle 𝜀1 with cycle of 𝑇 as well
as 𝑘𝑇 = 2𝜋 (𝑘 is an integer) then, expressions (4.1.1-5) and (4.1.1-6) are a pair of closed curves
on workpieces 1 and 2 which are, therefore, used as index curves.
As an option, let point 𝑃𝑎 on screw axis in instant rotating angle 𝜀1 be confined on a sphere with
radius 𝜌𝑎 and used as design reference point. Application of expression (1.4.11-3) yields
~ 323 ~
𝜌𝑎 = √𝑥𝑝2 + 𝑦𝑝2 + 𝑧𝑝2 = √𝐸 2 + 𝐹 2 + 𝑧𝑎2 (4.1.1-7)
let
𝑧𝑎 = 𝜌𝑎 cos 𝜃 = ±√𝜌𝑎2 − 𝐸 2 − 𝐹 2 (4.1.1-8)
Where: 𝜃 is intersecting angle between 𝑹𝑎 and 𝒌 as shown in figure 4.1.1.
With help of expression (4.1.1-4), application of expression (4.1.1-8) gives
1+𝑀 cos 𝛼 2 −𝐸 2
𝜌𝑎 𝑑𝐸 𝑑𝑀 (2𝑀+cos 𝛼+𝑀2 cos 𝛼)
cos 𝜃 = ± √ , = 𝑓 𝑑𝜀 ,
𝜌𝑎 1+2𝑀 cos 𝛼+𝑀2 𝑑𝜀1 2 2
1 (1+2𝑀 cos 𝛼+𝑀 )
𝑑𝑀 𝜌2 −𝐸 2
cos 𝛼 √1+2𝑀 𝑎cos 𝛼+𝑀2
𝑑𝜀1
𝑑𝜃 1
− 𝑑𝜀 sin 𝜃 = ± 𝜌 (1+𝑀 cos 𝛼)[𝐸
𝑑𝐸
(1+2𝑀 cos 𝛼+𝑀2 )+
𝑑𝑀 2 −𝐸 2 )]
(cos 𝛼+𝑀)(𝜌𝑎 , (4.1.1-9)
1 𝑎 𝑑𝜀1 𝑑𝜀1
− 3
(1+2𝑀 cos 𝛼+𝑀2 )2 √𝜌𝑎2 −𝐸 2
{ }
𝑑𝑀 𝑑𝜃
𝑀𝜌𝑎 cos 𝜃 sin 𝛼 𝑑𝐹 cos 𝜃− 𝑀 sin 𝜃(1+𝑀 cos 𝛼)
𝑑𝜀1 𝑑𝜀1
𝐹= , = (1+𝑀 cos 𝛼)2
𝜌𝑎 sin 𝛼 . }
1+𝑀 cos 𝛼 𝑑𝜀1
Index curve of workpiece 1 is given by application of expression (4.1.1-5) as follow:
𝑹𝑎 = 𝑥𝑎 𝒊 + 𝑦𝑎 𝒋 + 𝑧𝑎 𝒌
𝑥𝑎 = 𝐸 cos 𝜀1 + 𝐹 sin 𝜀1 , 𝑦𝑎 = −𝐸 sin 𝜀1 + 𝐹 cos 𝜀1 , 𝑧𝑎 = 𝜌𝑎 cos 𝜃 ,
𝑑𝑥𝑎 𝑑𝐸 𝑑𝐹
= (𝑑𝜀 + 𝐹) cos 𝜀1 + (𝑑𝜀 − 𝐸) sin 𝜀1 ,
𝑑𝜀1 1 1 (4.1.1-10)
𝑑𝑦𝑎 𝑑𝐸 𝑑𝐹
= − (𝑑𝜀 + 𝐹) sin 𝜀1 + (𝑑𝜀 − 𝐸) cos 𝜀1 ,
𝑑𝜀1 1 1
𝑑𝑧𝑎 𝑑𝜃
= − 𝑑𝜀 𝜌𝑎 sin 𝜃 . }
𝑑𝜀1 1
𝑑𝐸 𝑑𝐹
Where: 𝐸 and 𝐹 are calculated by expression (4.1.1-4). 𝑑𝜀 and 𝑑𝜀 are determined by
1 1
Arc-length of index curve on workpiece 1 is as follow:
𝑑𝑥 2 𝑑𝑦 2 𝑑𝑧 2
𝑑𝑠𝑎 = √( 𝑑𝜀𝑎) + ( 𝑑𝜀𝑎) + (𝑑𝜀𝑎) 𝑑𝜀1 (4.1.1-11)
1 1 1
𝑑𝑥 𝑑𝑦 𝑑𝑧
Where: 𝑑𝜀𝑎 , 𝑑𝜀𝑎 and 𝑑𝜀𝑎 are calculated by expression (4.1.1-10).
1 1 1
Index curve of workpiece 2 is generated by application of expression (4.1.1-6) as follow:
~ 324 ~
𝑹′𝑎 = 𝑥𝑎′ 𝒊′ + 𝑦𝑎′ 𝒋′ + 𝑧𝑎′ 𝒌′ ,
𝑥𝑎′ = (𝐸 − 𝑓) cos 𝜀2 + (𝑧𝑎 sin 𝛼 − 𝐹 cos 𝛼) sin 𝜀2 ,
𝑦𝑎′ = (𝐸 − 𝑓) sin 𝜀2 − (𝑧𝑎 sin 𝛼 − 𝐹 cos 𝛼) cos 𝜀2 ,
𝑧𝑎′ = 𝐹 sin 𝛼 + 𝑧𝑎 cos 𝛼 ,
𝑑𝐸
′ [𝑑𝜀 + 𝑀(𝑧𝑎 sin 𝛼 − 𝐹 cos 𝛼)] cos 𝜀2
𝑑𝑥𝑎 1
={ 𝑑𝐹 𝑑𝑧
}
𝑑𝜀1
+ [𝑀(𝑓 − 𝐸) − 𝑑𝜀 cos 𝛼 + 𝑑𝜀𝑎 sin 𝛼] sin 𝜀2 (4.1.1-12)
1 1
𝑑𝐸
[𝑑𝜀 + 𝑀(𝑧𝑎 sin 𝛼 − 𝐹 cos 𝛼)] sin 𝜀2
𝑑𝑦𝑎′ 1
={ 𝑑𝐹 𝑑𝑧
},
𝑑𝜀1
− [𝑀(𝑓 − 𝐸) − 𝑑𝜀 cos 𝛼 + 𝑑𝜀𝑎 sin 𝛼] cos 𝜀2
1 1
𝑑𝑧𝑎′ 𝑑𝐹 𝑑𝑧𝑎
= sin 𝛼 + cos 𝛼 . }
Arc-length of curve of screw axis on workpiece 2 is as follow:
2 2 2
𝑑𝑥 ′ 𝑑𝑦 ′ 𝑑𝑧 ′
𝑑𝑠𝑎′ = √( 𝑑𝜀𝑎) + ( 𝑑𝜀𝑎) + (𝑑𝜀𝑎) 𝑑𝜀1 (4.1.1-13)
1 1 1
4.1.2 Pitch Angle, Spiral Angle and Pressure Angle

1 Pitch Angle
Let instantaneous rotating angle 𝜀1 be visualized as virtual time parameter, velocity of point
𝑹𝑝 = 𝑥𝑝 𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌 on index curve of workpiece 1 is as follow:
𝒗𝑝 = 𝒌 × 𝑹𝑝 = −𝑦𝑝 𝒊 + 𝑥𝑝 𝒋 (4.1.2-1)
With help of expression (4.1.1-1), velocity of point 𝑹′𝑝 = 𝑹𝑝 − 𝑓𝒊 on index curve of workpiece 2
is as follow:
𝑑𝜀
𝒗′𝑝 = 𝑑𝜀2 𝝎2 × 𝑹′𝑝 = −𝑀𝒌′ × [(𝑥𝑝 − 𝑓)𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌 ]
1
= −𝑀[−(𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼)𝒊′ + (𝑥𝑝 − 𝑓)𝒋′ ] (4.1.2-2)

= 𝑀[(𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼)𝒊 − (𝑥𝑝 − 𝑓)(cos 𝛼 𝒋 − sin 𝛼 𝒌)]
Relative velocity of workpiece 1 with respect to workpiece 2 at point 𝑹𝑝 = 𝑥𝑝 𝒊 + 𝑦𝑝 𝒋 + 𝑧𝑝 𝒌 is
As follow:
𝒗12 ′ 12 12 12
𝑝 = 𝒗𝑝 − 𝒗𝑝 = 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑦 𝒌 (4.1.2-3)
Where:
~ 325 ~
12
𝑣𝑝𝑥 = 𝑀𝑧𝑝 sin 𝛼 − 𝑦𝑝 (1 + 𝑀 cos 𝛼),
12
𝑣𝑝𝑦 = 𝑥𝑝 (1 + 𝑀 cos 𝛼) − 𝑀𝑓 cos 𝛼 ,
12
𝑣𝑝𝑧 = −𝑀(𝑥𝑝 − 𝑓) sin 𝛼 ,
2 2 2
|𝒗12
𝑝 | = √(𝑣𝑝𝑥 ) + (𝑣𝑝𝑦 ) + (𝑣𝑝𝑧 ) .}
12 12 12
Unit normal 𝑵1𝑏 to gear blank surface of workpiece 1 is calculated by application of expression
(1.5.5-11), that is,
𝒗𝑝 ×𝒗′𝑝
𝑵1𝑏 = ± |𝒗 ′ = 𝐴1𝑏 𝒊 + 𝐵1𝑏 𝒋 + 𝐶1𝑏 𝒌 (4.1.2-4)
𝑝 ×𝒗𝑝 |
1 1
𝐴1𝑏 = 𝑄 𝑥𝑝 (𝑥𝑝 − 𝑓) sin 𝛼 , 𝐵1𝑏 = 𝑄 𝑦𝑝 (𝑥𝑝 − 𝑓) sin 𝛼 ,
1𝑏 1𝑏
1
𝐶1𝑏 = 𝑄 (𝑥𝑝 𝑧𝑝 sin 𝛼 − 𝑓𝑦𝑝 cos 𝛼),
1𝑏
2 𝟐
𝑄1𝑏 = ±√(𝑥𝑝2 + 𝑦𝑝2 )(𝑥𝑝 − 𝑓) sin2 𝛼 + (𝑥𝑝 𝑧𝑝 sin 𝛼 − 𝑓𝑦𝑝 cos 𝛼) .}
Where: 𝑄1𝑏 > 0 for 𝑓 < 0 and 𝑄1𝑏 < 0 for 𝑓 > 0.
Unit tangent 𝑾 to intersecting curve between gear blank surface of workpiece 1 and its axial
plane through conjugate contact point 𝑹𝑎 is as follow:
𝑵 ×(𝒌×𝑹𝑝 )
𝑾 = |𝑵1𝑏 ×(𝒌×𝑹 = 𝑊1 𝒊 + 𝑊2 𝒋 + 𝑊3 𝒌 (4.1.2-5)
1𝑏 𝑝 )|
Where:
1
𝑊1 = − 𝑊 𝐶1𝑏 𝑥𝑝 ,
1
𝑊2 = − 𝑊 𝐶1𝑏 𝑦𝑝 ,
1
𝑊3 = 𝑊 (𝐴1𝑏 𝑥𝑝 + 𝐵1𝑏 𝑦𝑝 )
2 2
𝑊 = √(𝑥𝑝2 + 𝑦𝑝2 )𝐶1𝑏 + (𝐴1𝑏 𝑥𝑝 + 𝐵1𝑏 𝑦𝑝 ) .}
Similarly, unit tangent 𝑾′ to intersecting curve between gear blank surface of workpiece 2 and
its axial plane of workpiece 2 through conjugate contact point 𝑹2𝑝 is as follow:
𝑵 ×(𝒌′ ×𝑹′𝑝 )
𝑾′ = |𝑵2𝑏 ×(𝒌′ ×𝑹′ )| = 𝑊1′ 𝒊′ + 𝑊2′ 𝒋′ + 𝑊3′ 𝒌′
2𝑏 𝑝 (4.1.2-6)
= 𝑊1′ 𝒊 + (𝑊2′ cos 𝛼 + 𝑊3′ sin 𝛼)𝒋 + (𝑊3′ cos 𝛼 − 𝑊2′ sin 𝛼)𝒌
~ 326 ~
Where: 𝑵2𝑏 = −𝑵1𝑏
1
𝑊1′ = 𝑊 ′ (𝐵1𝑏 sin 𝛼 + 𝐶1𝑏 cos 𝛼)(𝑥𝑝 − 𝑓),
1
𝑊2′ = 𝑊 ′ (𝐵1𝑏 sin 𝛼 + 𝐶1𝑏 cos 𝛼)(𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼),
1
𝑊3′ = − 𝑊 ′ [𝐴1𝑏 (𝑥𝑝 − 𝑓) + (𝐵1𝑏 cos 𝛼 − 𝐶1𝑏 sin 𝛼)(𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼)],
2
(𝐵1𝑏 sin 𝛼 + 𝐶1𝑏 cos 𝛼)2 (𝑥𝑝 − 𝑓)
2
𝑊′ = √ +(𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼) (𝐵1𝑏 sin 𝛼 + 𝐶1𝑏 cos 𝛼)2 .
2
{+[𝐴1𝑏 (𝑥𝑝 − 𝑓) + (𝐵1𝑏 cos 𝛼 − 𝐶1𝑏 sin 𝛼)(𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼)] } }
Pitch angle 𝛾1 of workpiece 1 is equal to sharp intersecting angle between 𝒌 and 𝑾, that is,
𝛾1 = cos −1(|𝒌 ∙ 𝑾|) = cos −1 (|𝑊3 |) (4.1.2-7)

𝜋
Where: 𝑊3 is calculated by expression (4.1.2-5), and 0 ≤ 𝛾1 ≤ 2 .
Likewise, pitch angle 𝛾2 of workpiece 2 is equal to sharp intersecting angle between 𝒌′ and 𝑾′ ,
that is,
𝛾2 = cos−1 (|𝒌′ ∙ 𝑾′ |) = cos −1 (|𝑊3′ |) (4.1.2-8)
2 Spiral Angle
Due to 𝑵1𝑏 being perpendicular to both 𝑾 and 𝒗12
𝑝 , spiral angle 𝜓1 of workpiece 1 is referred
𝒗12
𝑝
to as rotating angle by which |𝒗12| is rotated about 𝑵1𝑏 to 𝑾, that is,
𝑝
𝒗12
𝑝 𝒗12
𝑝 𝒗12
𝑝
𝑾 = (𝜓1 𝑵1𝑏 ) ⊗ |𝒗12| = cos 𝜓1 |𝒗12| + sin 𝜓1 𝑵1𝑏 × |𝒗12|
𝑝 𝑝 𝑝
Then,
𝒗12
𝑝
𝜓1 = cos −1 (𝑾 ∙ |𝒗12|) (4.1.2-9)
𝑝
Convention:
When (𝒗12 12
𝑝 ∙ 𝑾)[𝒗𝑝 ∙ (𝑵1𝑏 × 𝑾)] < 0 , then spiral angle of workpiece 1 is right hand and 0 ≤
𝜋
𝜓1 ≤ 2 as shown in figure 4.1.2-1
~ 327 ~
𝒌
𝑂 𝒋
𝑂 𝒋
𝑓<0 𝒌′
𝑵1𝑏 × 𝑾
𝜓1
𝒕 𝑾
𝜋
Figure 4.1.2-1 Right Hand of Workpiece 1, 0 ≤ 𝜓1 ≤ 2
𝜋
when (𝒗12 12
𝑝 ∙ 𝑾)[𝒗𝑝 ∙ (𝑵1𝑏 × 𝑾)] > 0, then, spiral angle of workpiece 1 is left hand and 2 ≤
𝜓1 ≤ 𝜋 as shown in figure 4.1.2-2, that is,

𝜋
𝑖𝑓 (𝒗12 12
𝑝 ∙ 𝑾)[𝒗𝑝 ∙ (𝑵1𝑏 × 𝑾)] < 0 , 𝑡ℎ𝑒𝑛 0 ≤ 𝜓1 ≤ 𝑅𝑖𝑔ℎ𝑡 𝐻𝑎𝑛𝑑,
2
𝜋 } (4.1.2-10)
𝑖𝑓 (𝒗12 12
𝑝 ∙ 𝑾)[𝒗𝑝 ∙ (𝑵1𝑏 × 𝑾)] > 0, 𝑡ℎ𝑒𝑛 ≤ 𝜓1 ≤ 𝜋 𝐿𝑒𝑓𝑡 𝐻𝑎𝑛𝑑.
2
Let unit vector 𝒕 be defined as follow:
𝒕 = (−𝜓1 𝑵1𝑏 ) ⊗ 𝑾 = cos 𝜓1 𝑾 − sin 𝜓1 𝑵1𝑏 × 𝑾 = 𝑡1 𝒊 + 𝑡2 𝒋 + 𝑡3 𝒌

(4.1.2-11)
= 𝑡1 𝒊 + (𝑡2 cos 𝛼 − 𝑡3 sin 𝛼)𝒋′ + (𝑡2 sin 𝛼 + 𝑡3 cos 𝛼)𝒌′
Where:
𝑡1 = 𝑊1 cos 𝜓1 − (𝐵1𝑏 𝑊3 − 𝐶1𝑏 𝑊2 ) sin 𝜓1 ,

𝑡2 = 𝑊2 cos 𝜓1 + (𝐴1𝑏 𝑊3 − 𝐶1𝑏 𝑊1 ) sin 𝜓1 ,}
𝑡3 = 𝑊3 cos 𝜓1 − (𝐴1𝑏 𝑊2 − 𝐵1𝑏 𝑊1 ) sin 𝜓1 .
~328 ~
𝒌
𝑂 𝒋
𝒌′
𝒕 𝑂 𝑓>0 𝒋
𝜓1 𝑵1𝑏 × 𝑾
𝑾
𝜋
Figure 4.1.2-2 Left Hand of Workpiece 1, 2 ≤ 𝜓1 ≤ 𝜋
𝒗12
𝑝
Likewise, spiral angle 𝜓2 of workpiece 2 is referred to as rotating angle by which |𝒗12 | is rotated
𝑝
about 𝑵2𝑏 to 𝑾′ , that is,
𝒗12
𝑝
𝜓2 = cos−1 (𝑾′ ∙ |𝒗12|) (4.1.2-12)
𝑝
Where: 𝑾′ is calculated by expression (4.1.2-6) and 𝒗12 ′

𝑝 = 𝒗𝑝 − 𝒗𝑝 .
𝜋
𝑖𝑓 (𝒗12 ′ 12 ′
𝑝 ∙ 𝑾 )[𝒗𝑝 ∙ (𝑵2𝑏 × 𝑾 )] < 0 , 𝑡ℎ𝑒𝑛 0 ≤ 𝜓2 ≤ 𝑅𝑖𝑔ℎ𝑡 𝐻𝑎𝑛𝑑,
2
𝜋 }
𝑖𝑓 (𝒗12 ′ 12 ′
𝑝 ∙ 𝑾 )[𝒗𝑝 ∙ (𝑵2𝑏 × 𝑾 )] > 0, 𝑡ℎ𝑒𝑛 ≤ 𝜓1 ≤ 𝜋 𝐿𝑒𝑓𝑡 𝐻𝑎𝑛𝑑.
2
𝜋 𝜋
For right hand gear: 0 ≤ 𝜓2 ≤ 2 and for left hand gear: 2 ≤ 𝜓2 ≤ 𝜋.
3 Pressure Angle
~ 329 ~
Since unit normal 𝑵1𝑝 to tooth profile of workpiece 1 is perpendicular to 𝒕 , 𝑵1𝑝 is formed by
rotating 𝑵1𝑏 × 𝒕 by an angle ∅𝑔 about 𝒕 as an axis, that is,
𝑵1𝑝 = (∅𝑔 𝒕) ⊗ (𝑵1𝑏 × 𝒕 ) = cos ∅𝑔 𝑵1𝑏 × 𝒕 + sin ∅𝑔 𝑵1𝑏 (4.1.2-13)
𝑵1𝑝 𝑵𝑜 𝑵1𝑏
∆∅𝑔
∅0 ∅𝑔𝑜
∆∅𝑔
𝒌 𝑵1𝑝 𝑵1𝑏 × 𝒕
∅0 ∅𝑔𝑖 𝑵𝑜
𝑵1𝑏 × 𝒕
𝜓1
𝒗12
𝑝
𝒕 = ± |𝒗12| 𝑾
𝑝
Right hand gear
𝒗12
𝑝
𝒕 = ± |𝒗12 | 𝒌
𝑝
𝜓1
Left hand gear
Figure 4.1.2-3 Tooth Profile Parameters
~ 330 ~
Corresponding angle ∅𝑔 in expression (4.1.2-13) is referred to as pressure angle, that is,
∅𝑔 = cos−1 (|𝑵1𝑝 ∙ (𝑵1𝑏 × 𝒕)|) (4.1.2-14)

𝜋 𝜋
Where: for convex flank: 0 ≤ ∅𝑔 ≤ 2 , and for concave flank: 2 ≤ ∅𝑔 ≤ 𝜋 as shown in figure
4.1.2-3.
Similarly, limit unit normal 𝑵𝑜 is also formed through rotating 𝑵1𝑏 × 𝒕 by an angle ∅0 about 𝒕
𝑵𝑜 = (∅0 𝒕) ⊗ (𝑵1𝑏 × 𝒕 ) = cos ∅0 𝑵1𝑏 × 𝒕 + sin ∅0 𝑵1𝑏 (4.1.2-15)
Where: 𝑵𝑜 is defined in expression (1.5.5-12).
Corresponding angle ∅0 in expression (4.1.2-15) is referred to as limit pressure angle, that is
(𝒗12
𝑝 ×𝑱𝑝 )∙(𝑵1𝑏 ×𝒕) −(𝑱𝑝 ∙𝑵1𝑏 )(𝒗12
𝑝 ∙𝒕)
cos ∅0 = 𝑵0 ∙ (𝑵1𝑏 × 𝒕) = |𝒗12
= |𝒗12
,
𝑝 ×𝑱𝑝 | 𝑝 ×𝑱𝑝 |
} (4.1.2-16)
(𝒗12
𝑝 ×𝑱𝑝 )∙𝑵1𝑏 (𝒕×𝑱𝑝 )∙𝑵1𝑏
sin ∅0 = 𝑵𝑜 ∙ 𝑵1𝑏 = |𝒗12
, tan ∅0 = − .
𝑝 ×𝑱𝑝 | 𝑱𝑝 ∙𝑵1𝑏
Where: 𝑱𝑝 is calculated by expression (1.5.2-7), 𝒗12

𝑝 is expressed in formular (4.1.2-3) and 𝑵1𝑏 is
decided by expression (4.1.2-4).
Because actual unit normal 𝑵1𝑝 to tooth profile is supposed to be away from limit unit normal
𝑵𝑜 , then, the pressure angle is equal to
𝑖𝑓 tan ∅0 > 0, ∅0 = tan−1 ∅0 , ∅𝑔𝑖 = ∅0 + ∆∅𝑔 , ∅𝑔𝑜 = ∅𝑔 ;

} (4.1.2-17)
𝑖𝑓 tan ∅0 < 0, ∅0 = 𝜋 + tan−1 ∅0 , ∅𝑔𝑜 =∅0 + ∆∅𝑔 , ∅𝑔𝑖 = ∅𝑔 .
Where: ∆∅𝑔 ≠ 0 and tan ∅0 is decided by expression (4.1.2-16). ∅𝑔 is any prescribed value as
shown figure 4.1.2-3
~ 331 ~
Chapter 2
4.2.1 Coordinate System

1 Motion of Machining
Milling process of 𝑞𝑡ℎ tooth profile is composed of four basic motions with respect to machine
coordinate system (𝑂𝑚 − 𝑰𝑚 , 𝑱𝑚 , 𝑲𝑚 ) as shown in figure 4.2.1-1, that is,
A. Rotation of cradle by an angle 𝜀0 about axis 𝒌𝑚 of cradle.

𝑑𝜎
B. Helical motion 𝑑𝜀 0 of cutter along cradle axis 𝒌𝑚 .
0
C. Rotation of workpiece 1 or 2 by an angle 𝜀1 or 𝜀2 about 𝝎1 or 𝝎2 as rotating axis of
workpiece 1 or 2.
D. Index cradle and workpiece to next tooth when 𝑞𝑡ℎ tooth profile is completed.
𝒌𝑚 is rotating axis of cradle and 𝒊𝑚 is vertical down. Then,
Cutter surface is a rotating conical surface which is the same as that in part 3.
𝑂𝑚
𝒋𝑚
𝒌𝑚
𝒊𝑚
Figure 4.2.1-1 Machine Coordinate System (𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 )
2 Integration of Machine Coordinate System with Coordinate Systems of

Workpiece 1 and 2
Let motion 𝜑1 of workpiece 1 be designated as motion 𝜑𝑟 and motion 𝜑2 of workpiece 2 be
signified as motion 𝜑𝑠 in expression (1.7.4-4). Machine coordinate system is (𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 ).
~ 332~
Coordinate system (𝑂𝑞 − 𝒊𝑞 , 𝒋𝑞 , 𝒌𝑞 ) is for 𝑞𝑡ℎ tooth profile of workpiece 1 and Coordinate
system (𝑂𝑞′ − 𝒊′𝑞 , 𝒋′𝑞 , 𝒌′𝑞 ) is for 𝑞𝑡ℎ tooth profile of workpiece 2.
𝑂𝑚 𝒋𝑚
𝑓1𝑞
𝑂𝑞 𝒌𝑞
𝑓2𝑞
𝑂𝑞′ 𝒌′𝑞
𝒊𝑚 (= 𝒊𝑞 = 𝒊′𝑞 = 𝒊0 )
𝒌𝑚 (= 𝒌0 = 𝝎0 )
𝑞
Workpiece 1 𝒌𝑞 (= 𝝎1 )
𝑞
𝛼𝑚 𝛼2𝑞
𝑂𝑚 𝒋𝑚
workpiece 2
𝒌′𝑞 (= −𝝎𝑞2 )
𝒋′𝑞 𝒋𝑞 𝛼1𝑞
Figure 4, 2.1-2 Coordinate Systems
Relationship of coordinate systems are as follow:
~ 333 ~
𝑞 𝑞 𝑞 𝑞
𝛼1 = 𝛼𝑚 + 𝜋, 𝛼2 = 𝛼𝑚 + 𝛼, 𝛼2𝑞 − 𝛼1𝑞 = 𝛼 − 𝜋,
𝑂𝑚 𝑂𝑞 = 𝑓1𝑞 𝒊𝑚 , ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗ 𝑂𝑚 𝑂𝑞′ = 𝑓2𝑞 𝒊𝑚 ,
𝒌𝑞 = 𝝎1𝑞 = sin 𝛼𝑚
𝑞 𝑞
𝒊𝑞 = 𝒊′𝑞 = 𝒊𝑚 , 𝒋𝑚 + cos 𝛼𝑚 𝒌𝑚 , (4.2.1-2)
𝑞 𝑞
𝒋𝑞 = 𝒌 × 𝒊𝑞 = cos 𝛼𝑚 𝒋𝑚 − sin 𝛼𝑚 𝒌𝑚 ,
𝒌′𝑞 = sin 𝛼2𝑞 𝒋𝑚 + cos 𝛼2𝑞 𝒌𝑚 , 𝒋′𝑞 = 𝒌′𝑞 × 𝒊′𝑞 = cos 𝛼2𝑞 𝒋𝑚 − sin 𝛼2𝑞 𝒌𝑚 .}
4.2.2 Calculation of Machine Setting Parameters

Corresponding to conjugate cutting position of design reference point 𝑃0𝑞 on 𝑞𝑡ℎ tooth profile of
workpiece, machine setting parameters are as follow:
A. Position of cutter with respect to machine coordinate system 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 , that is,

• Coordinate of center of cutter head for 𝑞𝑡ℎ tooth profile of workpiece, 𝑥𝑐𝑞 , 𝑦𝑐𝑞
and 𝑧𝑐𝑞 .
• Tilt angle ζ𝑞 and swivel angle Θ𝑞 of cutter head for 𝑞𝑡ℎ tooth profile of
workpiece.
B. Position of workpiece 1 & 2 with respect to machine coordinate system 𝑂𝑚 −
𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 , that is,
𝑞
• Shaft angle 𝛼𝑚 of rotating axis 𝒌(= 𝝎1 ) of workpiece 1 with respect to rotating
axis 𝒌𝑚 of machine corresponding to 𝑞𝑡ℎ tooth profile of workpiece.
𝑞
• Shaft angle 𝛼𝑚 + 𝛼 of rotating axis 𝒌′ (= −𝝎2 ) of workpiece 2 with respect to
rotating axis 𝒌𝑚 of machine corresponding to 𝑞𝑡ℎ tooth profile of workpiece.
𝑞
• Vertical position of workpiece 1, that is, 𝑂 ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑚 𝑂𝑞 = 𝑓1 𝒊𝑚 .
𝑞
• Vertical position of workpiece 2, that is, 𝑂
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗′
𝑚 𝑂𝑞 = 𝑓2 𝒊𝑚 .
C. Relative motion of cutter head with respect to workpiece 1 & 2, that is,
𝑑𝜀
0
𝑑𝜀2
• Ratio of roll for 𝑞𝑡ℎ tooth profile of workpiece 2, 𝑀2𝑞 = 𝑑𝜀 .
0
• Rate of helical feeding of cutter corresponding to 𝑞𝑡ℎ tooth profile of workpiece,

𝑑𝜎
that is, (𝑑𝜀 0 ) .
0 𝑞
2 Calculation for Machine Setting Parameters with Tilt Device
Index point 𝑃𝑎𝑞 on 𝑞th tooth of workpiece 1 in conjugate contact position is given by expression
~ 334 ~
(4.1.1-3), that is,
𝑹𝑞𝑎𝑝 = 𝑥𝑎𝑝
𝑞 𝑞 𝑞
𝒊𝑞 + 𝑦𝑎𝑝 𝒋𝑞 + 𝑧𝑎𝑝 𝒌𝑞 (4.2.2-1)
𝑞 𝑞 𝑞
Where: 𝑥𝑎𝑝 , 𝑦𝑎𝑝 and 𝑧𝑎𝑝 are function of 𝜀1,𝑞 , and

𝑠 =𝑞𝑝 1
𝜀1,𝑞 = ∫𝑠 0=0 𝑑𝑠𝑎 ,
0 2 2 2
√(𝑑𝑥𝑎 ) +(𝑑𝑦𝑎 ) +(𝑑𝑧𝑎)

1
𝑠 =(𝑞+ )𝑝 1
𝜀1,𝑞 = ∫𝑠 0=0 2 𝑑𝑠𝑎 ,
0 2 𝑑𝑦 2 𝑑𝑧 2
√(𝑑𝑥𝑎 ) +( 𝑎 ) +( 𝑎)
}
𝑑𝑥 𝑑𝑦 𝑑𝑧
Here: 𝑑𝜀𝑎, 𝑑𝜀𝑎 and 𝑑𝜀𝑎 are calculated by application of expressions (4.1.1-10). 𝑞 =
1 1 1
0, 1, 2, 3, ⋯ , 𝑁 − 1.
Unit normal 𝑵𝑞𝑎𝑝 to 𝑞th tooth profile of workpiece 1 at index point 𝑃𝑎𝑞 in conjugate contact
position is expressed as follow:
𝑵𝑞𝑎𝑝 = (𝛽𝑞 𝒌𝑞 ) ⊗ {(𝛾1𝑞 𝒋𝑞 ) ⊗ {(−𝜓1𝑞 𝒊𝑞 ) ⊗ [(∅𝑞𝑔 𝒌𝑞 ) ⊗ (−𝒋𝑞 )]}}

= 𝐴𝑞𝑎𝑝 𝒊𝑞 + 𝐵𝑎𝑝
𝑞 𝑞 (4.2.2-3)
𝒋𝑞 + 𝐶𝑎𝑝 𝒌𝑞
𝐴𝑞𝑎𝑝 𝒊𝑚 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
= + (𝐵𝑎𝑝 cos 𝛼𝑚 + 𝐶𝑎𝑝 sin 𝛼𝑚 )𝒋𝑚 + (−𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 )𝒌𝑚
𝑞
𝑞 𝑦𝑎𝑝
𝑞
Where: tan 𝛽𝑞 = 𝑥 𝑞 , 𝑥𝑎𝑝 and 𝑦𝑎𝑝 are calculated in expression (4.1.1-3), 𝛾1𝑞 is expressed in
𝑎𝑝
formular (4.1.2-7), 𝜓1𝑞 is determined by expression (4.1.2-9), and ∅𝑞𝑔 is calculated by application
of expression (4.1.2-17),
𝐴𝑞𝑎𝑝 = (cos 𝜓1𝑞 sin 𝛽𝑞 + sin 𝜓1𝑞 sin 𝛾1𝑞 cos 𝛽𝑞 ) cos ∅𝑞𝑔 + cos 𝛾1𝑞 cos 𝛽𝑞 sin ∅𝑞𝑔 ,
𝑞
𝐵𝑎𝑝 = (sin 𝜓1𝑞 sin 𝛾1𝑞 sin 𝛽𝑞 − cos 𝜓1𝑞 cos 𝛽𝑞 ) cos ∅𝑞𝑔 + cos 𝛾1𝑞 sin 𝛽𝑞 sin ∅𝑞𝑔 , } (4.2.2-4)
𝑞
𝐶𝑎𝑝 = − sin ∅𝑞𝑔 sin 𝛾1𝑞 + cos ∅𝑞𝑔 sin 𝜓1𝑞 cos 𝛾1𝑞 .
Let 𝑹𝑞𝑐 be a Point on cutter surface corresponding to point 𝑃𝑎𝑞 on 𝑞th tooth of workpiece 1 as
expressed in expression (3.2.2-3). Unit normal to cutter surface at point 𝑹𝑞𝑐 is given in
expression (3.2.2-6), i.e., 𝑵𝑞𝑐 = 𝐴𝑞𝑚 𝒊𝑚 + 𝐵𝑚
𝑞 𝑞
𝒋𝑚 + 𝐶𝑚 𝒌𝑚 .
~ 335 ~
𝑞 𝑞 𝑞
𝑹𝑐 = 𝑹𝑎𝑝 + 𝑓1 𝒊𝑚 ,
} (4.2.2-5)
𝑵𝑞𝑐 = −𝑵𝑞𝑎𝑝 ,
With help of expressions (4.2.1-1), (3.2.2-3), (3.2.2-6), (4.2.2-1) and (4.2.2-4), expression (4.2.2-
5) is expanded as follow:
𝑥𝑐𝑞 + 𝑠𝑐𝑞 cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 𝑞 𝑞

{ 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 )} = 𝑥𝑎𝑝 + 𝑓1 ,
+(𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 cos Θ − sin 𝜇 cos ζ sin Θ
(𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 )(cos 𝜇 𝑞 sin Θ𝑞 + sin 𝜇 𝑞 cos ζ𝑞 cos Θ𝑞 ) 𝑞 𝑞 𝑞 𝑞
{ 𝑞 𝑞 𝑞 𝑞
} = 𝑦𝑎𝑝 cos 𝛼𝑚 + 𝑧𝑎𝑝 sin 𝛼𝑚 ,
+𝑦𝑐 − 𝑠𝑐 cos ∅𝑐 sin ζ cos Θ (4.2.2-6)
𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 cos ζ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ = −𝑦𝑎𝑝 sin 𝛼𝑚 + 𝑧𝑎𝑝 cos 𝛼𝑚 ,
sin ∅𝑐 sin ζ𝑞 sin Θ𝑞 − cos ∅𝑐 (cos 𝜇 𝑞 cos Θ𝑞 − sin 𝜇 𝑞 cos ζ𝑞 sin Θ𝑞 ) = −𝐴𝑞𝑎𝑝 ,
𝑞 𝑞 𝑞 𝑞
−sin ∅𝑐 cos ζ𝑞 + cos ∅𝑐 sin 𝜇 𝑞 sin ζ𝑞 = −𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 , }
𝑓1𝑞 in simultaneous equation (4.2.2-6) is vertical position of workpiece 1 which is decided by

𝑓 sin 𝛼1 cos 𝛼2 𝑓 sin(𝛼𝑚 +𝜋) cos(𝛼𝑚 +𝛼) 𝑓 sin 𝛼𝑚 cos(𝛼𝑚 +𝛼)
𝑓1𝑞 = 𝑞 𝑞 = = (4.2.2-7)
sin(𝛼2 −𝛼1 ) sin(𝛼−𝜋) sin 𝛼
Vertical position 𝑓2𝑞 of workpiece 2 is yielded by application of expression (1.7.4-4), that is,
𝑞 𝑞
𝑓 sin(𝛼𝑚 +𝛼) cos 𝛼𝑚
𝑓2𝑞 = (4.2.2-8)
sin 𝛼
Ratio of rolls for workpiece 1 and 2 are calculated by application of expression (1.7.4-4) as
follow:
𝑞 𝑞 𝑞
𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑀1𝑞 = (𝑑𝜀1) = 𝑞 ,
0 𝑞 𝑀12 sin 𝛼
𝑞 𝑞 𝑞 (4.2.2-9)
𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑀2𝑞 = (𝑑𝜀2 ) = 𝑀12
𝑞
𝑀1𝑞 = .
0 𝑞 sin 𝛼 }
Helical motion of cutter head is yielded by application of expression (1.7.4-4), that is,
𝑞 𝑞 𝑞 𝑞
𝑑𝜎 −𝑓𝑀1 𝑀2 sin 𝛼𝑚 sin(𝛼𝑚 +𝛼)
= −𝑓1𝑞 tan(𝛼𝑚
𝑞
+ 𝛼) = −𝑓2𝑞 tan 𝛼𝑚
𝑞
( 𝑑𝜀 0) = 𝑞 𝑞 𝑞 𝑞 (4.2.2-10)
0 𝑞 𝑀2 sin(𝛼𝑚 +𝛼)+𝑀1 sin 𝛼𝑚
There are five equations in expression (4.2.2-6) and eight unknown variables, i.e., 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 ,
𝑠𝑐𝑞 , 𝜇 𝑞 , ζ𝑞 , Θ𝑞 , and 𝛼𝑚
𝑞
. Three of them can be prescribed.
~ 336 ~
𝑞
𝜋 𝜋 𝑧
Let 𝑠𝑐𝑞 = 0, 𝜇 𝑞 = − 2 and 𝛼𝑚
𝑞 𝑎𝑝
= 2 − tan−1 (𝑦 𝑞 ) , simultaneous equation (4.2.2-6) gives
𝑎𝑝
𝑞
𝑞 𝑞 𝑞 𝑞 𝐴𝑎𝑝
ζ𝑞 = sin−1(𝐵𝑎𝑝 sin 𝛼𝑚 − 𝐶𝑎𝑝 cos 𝛼𝑚 ) − ∅𝑐 , Θ𝑞 = sin−1 (cos(∅ 𝑞
),
𝑐 +ζ )
𝑥𝑐𝑞 = 𝑥𝑎𝑝
𝑞
+ 𝑓1𝑞 − 𝑟𝑐 cos ζ𝑞 sin Θ𝑞 , (4.2.2-11)
𝑦𝑐𝑞 𝑞 𝑞 𝑞 𝑞
= 𝑦𝑎𝑝 cos 𝛼𝑚 + 𝑧𝑎𝑝 sin 𝛼𝑚 + 𝑟𝑐 cos ζ𝑞 cos Θ𝑞 ,
𝑧𝑐𝑞 𝑞 𝑞 𝑞 𝑞
= −𝑦𝑎𝑝 sin 𝛼𝑚 + 𝑧𝑎𝑝 cos 𝛼𝑚 + 𝑟𝑐 sin ζ𝑞 . }
𝑞 𝑞 𝑞
Where: 𝑥𝑎𝑝 , 𝑦𝑎𝑝 and 𝑧𝑎𝑝 are given by expression (4.1.1-3). 0 < Θ𝑞 < 𝜋 for right-hand of
𝑞 𝑞
workpiece 1 and −𝜋 < Θ𝑞 < 0 for left-hand of workpiece 1. 0 < sin−1(𝐵𝑎𝑝 sin 𝛼𝑚 −
𝑞 𝑞 𝜋 𝜋 𝑞 𝑞 𝑞 𝑞
𝐶𝑎𝑝 cos 𝛼𝑚 )< for inner blade and < sin−1 (𝐵𝑎𝑝 sin 𝛼𝑚 − 𝐶𝑎𝑝 cos 𝛼𝑚 ) < 𝜋 for outer blade.
2 2
Combination of expressions (4.2.2-7), (4.2.2-8), (4.2.2-9), (4.2.2-10) and (4.2.2-11) yields

machine setting parameters for the case of tilt device as follow:
𝑞 𝜋 𝑧
= 2 − tan−1 (𝑦 𝑞 ) , 𝑓1𝑞 = 𝑓 sin 𝛼𝑚 cos(𝛼𝑚+𝛼) , 𝑓2𝑞 = 𝑓 sin(𝛼𝑚 +𝛼) cos 𝛼𝑚 ,
𝑎𝑝
𝛼𝑚
𝑎𝑝sin 𝛼 sin 𝛼
𝑀1𝑞 = (𝑑𝜀1 ) = 𝑞 , 𝑀2𝑞 = (𝑑𝜀2) = ,
0 𝑞 𝑀12 sin 𝛼 0 𝑞 sin 𝛼
𝑑𝜎
(𝑑𝜀 0) = −𝑓1𝑞 tan(𝛼𝑚
+ 𝛼) , ζ𝑞 = sin−1(𝐵𝑎𝑝 sin 𝛼𝑚 − 𝐶𝑎𝑝 cos 𝛼𝑚 ) − ∅𝑐 , (4.2.2-12)
0 𝑞
𝑞
𝐴𝑎𝑝 𝑞 𝑞 𝑞
Θ𝑞 = sin−1 (cos(∅ ) 𝑥𝑐 = 𝑥𝑎𝑝 + 𝑓1 − 𝑟𝑐 cos ζ𝑞 sin Θ𝑞
𝑞) ,
,
𝑐 +ζ
𝑦𝑐𝑞 = 𝑦𝑎𝑝
𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 + 𝑧𝑎𝑝 sin 𝛼𝑚 + 𝑟𝑐 cos ζ𝑞 cos Θ𝑞 ,
𝑧𝑐𝑞 = −𝑦𝑎𝑝
𝑞 𝑞 𝑞 𝑞
sin 𝛼𝑚 + 𝑧𝑎𝑝 cos 𝛼𝑚 + 𝑟𝑐 sin ζ𝑞 , }
3 Calculation for Machine Setting Parameters without Tilt Device

In the case of no tilt device, i.e., ζ𝑞 = Θ𝑞 = 0, then, expression (4.2.2-6) is simplified as follow:
𝑥𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 ) cos 𝜇 𝑞 = 𝑥𝑎𝑝

𝑞
+ 𝑓1𝑞 ,
𝑦𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐𝑞 sin ∅𝑐 ) sin 𝜇 𝑞 = 𝑦𝑎𝑝
𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 + 𝑧𝑎𝑝 sin 𝛼𝑚 ,
𝑧𝑐 + 𝑠𝑐 cos ∅𝑐 = −𝑦𝑎𝑝 sin 𝛼𝑚 + 𝑧𝑎𝑝 cos 𝛼𝑚 , (4.2.2-13)
cos ∅𝑐 cos 𝜇 = 𝐴𝑞𝑎𝑝 , 𝑞
𝑞 𝑞 𝑞 𝑞
−sin ∅𝑐 = −𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 , }
There are five equations in simultaneous equation (4.2.2-13) and six unknown variables, i.e.,
𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , 𝑠𝑐𝑞 , 𝜇 𝑞 and 𝛼𝑚
𝑞
. Let 𝑠𝑐𝑞 = 0, then, left five variables are resulted from equation
~ 337 ~
(4.2.2-13) as follow:
𝑞 𝑞
𝐴
𝑎𝑝 𝑎𝑝 𝐶 𝑞 sin ∅𝑐
𝜇 𝑞 = cos −1 (cos ∅ ) , 𝛿 𝑞 = tan−1 (𝐵𝑞 ) , 𝛼𝑚 = tan−1 (cos ∅ 𝑞
) + 𝛿𝑞,
𝑐 𝑎𝑝 𝑐 sin 𝜇
𝑞
+ 𝑓1𝑞 − 𝑟𝑐 cos 𝜇 𝑞 , 𝑦𝑐𝑞 = 𝑦𝑎𝑝
𝑞 𝑞
cos 𝛼𝑚 𝑞
+ 𝑧𝑎𝑝 𝑞
sin 𝛼𝑚 − 𝑟𝑐 sin 𝜇 𝑞 , (4.2.2-14)
𝑞 𝑞 𝑞 𝑞
sin 𝛼𝑚 + 𝑧𝑎𝑝 cos 𝛼𝑚 . }
Combination of expressions (4.2.2-7), (4.2.2-8), (4.2.2-9), (4.2.2-10) and (4.2.2-14) results in

machine setting parameters for non tilt device as follow:
𝑞 𝑞
𝐴 𝐶 𝑑𝜎
( 𝑑𝜀 0 ) = −𝑓1𝑞 tan(𝛼𝑚
𝑎𝑝 𝑎𝑝 𝑞
𝜇 𝑞 = cos −1 (cos ∅ ) , 𝛿 𝑞 = tan−1 (𝐵𝑞 ), + 𝛼) ,
𝑐 𝑎𝑝 0 𝑞
𝑞 𝑞 𝑞 𝑞
𝑓 sin 𝛼𝑚 cos(𝛼𝑚 +𝛼) 𝑓 sin(𝛼𝑚 +𝛼) cos 𝛼𝑚 sin ∅𝑐
𝑓1𝑞 = , 𝑓2𝑞 = 𝑞
, 𝛼𝑚 = tan−1 (cos ∅ 𝑞
) + 𝛿𝑞,
sin 𝛼 sin 𝛼 𝑐 sin 𝜇
𝑞 𝑞
sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑞
𝑑𝜀
𝑞 𝑞 𝑞
sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼) (4.2.2-15)
𝑀1𝑞 = 𝑞 , 𝑀2𝑞 = (𝑑𝜀2 ) = ,
𝑀12 sin 𝛼 𝑞 0 sin 𝛼
𝑞
+ 𝑓1𝑞 − 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
𝑟𝑐 cos 𝜇 , 𝑦𝑐 = 𝑦𝑎𝑝 cos 𝛼𝑚 + 𝑧𝑎𝑝 sin 𝛼𝑚 − 𝑟𝑐 sin 𝜇 𝑞 ,
𝑞 𝑞 𝑞 𝑞
sin 𝛼𝑚 + 𝑧𝑎𝑝 cos 𝛼𝑚 . }
𝑞 𝑞 𝑞
Where: 𝑥𝑎𝑝 , 𝑦𝑎𝑝 and 𝑧𝑎𝑝 are given by expression (4.1.1-3). 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1.
~ 338 ~
Chapter 3
Calculation of Tooth Profile

1 Instantaneous Contact Point and Instantaneous Contact Line in the Case of Tilt
Device
Let point 𝑃 be any point in coordinate plane 𝑂 − 𝒋𝑞 , 𝒌𝑞 within the region corresponding to
tooth profile of 𝑞th tooth of workpiece 1 as shown figure 4.3.1-1, and defined by two
parameters of 𝑙ℎ and 𝑙𝑤 as follow:
𝑷𝑞0 = (𝜌𝑎 + 𝑙𝑤 )𝜻𝑞 + 𝑙ℎ 𝜼𝑞 = 𝐴𝒋𝑞 + 𝐵𝒌𝑞 (4.3.1-1)
Where: 𝜃 𝑞 is decided in expression (4.1.1-8)

} (4.3.1-2)
𝜻𝑞 = sin 𝜃 𝑞 𝒋𝑞 + cos 𝜃 𝑞 𝒌𝑞 , 𝜼𝑞 = 𝜻𝑞 × 𝒊 = cos 𝜃 𝑞 𝒋𝑞 − sin 𝜃 𝑞 𝒌𝑞 .
𝒌𝑞
𝜻𝑞
𝜃𝑞 𝑃
𝜌𝑎 𝑙ℎ
𝜼𝑞 𝑙𝑤
𝑂 𝒋𝑞
Figure 4.3.1-1 Coordinate of Point 𝑃
Point 𝑃(𝑷𝑞0 ) becomes point 𝑹1𝑝

𝑞
on 𝑞th tooth profile of workpiece 1 as follow:
𝑞
= (𝜉𝑝 𝒌𝑞 ) ⊗ 𝑷𝑞0 = (𝜉𝑝 𝒌𝑞 ) ⊗ (𝐴𝒋𝑞 + 𝐵𝒌𝑞 ) = 𝑥1𝑝
𝑞 𝑞 𝑞
𝑹1𝑝 𝒊𝑞 + 𝑦1𝑝 𝒋𝑞 + 𝑧1𝑝 𝒌𝑞 (4.3.1-3)
𝑞 𝑞 𝑞
Where: 𝑥1𝑝 = −𝐴 sin 𝜉𝑝 , 𝑦1𝑝 = 𝐴 cos 𝜉𝑝 and 𝑧1𝑝 = 𝐵.
~ 339 ~
𝑞 𝑞
Point 𝑹1𝑝 on 𝑞th tooth profile of workpiece 1 reaches conjugate cutting position 𝑹𝑝 after
rotating by an angle ∆𝜀1,𝑞 about 𝒌𝑞 as an axis, that is,
𝑹𝑞𝑝 = (∆𝜀1,𝑞 𝒌𝑞 ) ⊗ 𝑹1𝑝

𝑞
= 𝑥𝑝𝑞 𝒊𝑞 + 𝑦𝑝𝑞 𝒋𝑞 + 𝑧𝑝𝑞 𝒌𝑞
= (∆𝜀1,𝑞 𝒌𝑞 ) ⊗ (−𝐴 sin 𝜉𝑝 𝒊𝑞 + 𝐴 cos 𝜉𝑝 𝒋𝑞 + 𝐵𝒌𝑞 )
= 𝑥𝑝𝑞 𝒊𝑚 + (𝑦𝑝𝑞 cos 𝛼𝑚 + 𝑧𝑝𝑞 sin 𝛼𝑚 )𝒋𝑚 + (−𝑦𝑝𝑞 sin 𝛼𝑚 + 𝑧𝑝𝑞 cos 𝛼𝑚 )𝒌𝑚 (4.3.1-4)
−𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) 𝒊𝑚 + [𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) cos 𝛼𝑚 + 𝐵 sin 𝛼𝑚 ]𝒋𝑚
={ }
+[−𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 ]𝒌𝑚
On the other hand, let initial position of cutter be defined by machine setting parameters, i.e.,
𝑞
equation (4.2.2-12), then, point 𝑹𝑐 on cutter surface corresponding to point 𝑃 on tooth profile
is expressed by application of expression (3.2.2-3), that is,
𝑹𝑞𝑐 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂0 𝑂𝑐 + (𝜇𝒌𝑐 ) ⊗ (𝑟𝑐 𝒊𝑐 + 𝑠𝑐 𝒕𝑐 ) = 𝑥 𝑞 𝒊𝑚 + 𝑦 𝑞 𝒋𝑚 + 𝑧 𝑞 𝒌𝑚
(4.3.1-5)
= 𝑥𝑐𝑞 𝒊𝑚 + 𝑦𝑐𝑞 𝒋𝑚 + 𝑧𝑐𝑞 𝒌𝑚 + (𝜇𝒌𝑐 ) ⊗ (𝑟𝑐 𝒊𝑐 + 𝑠𝑐 𝒕𝑐 )
Where: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 and Θ𝑞 are calculated by expression (4.2.2-12). 𝒊𝑐 and 𝒕𝑐 are defined by
expressions (3.2.1-1) and (3.2.1-2) respectively, and
𝑥 𝑞 = 𝑥𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ),
𝑦 𝑞 = 𝑦𝑐𝑞 − 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 )(cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ),}
𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 .
Unit normal 𝑵𝑞𝑐 to cutter surface at point 𝑃 is calculated by expression (3.2.2-6), that is,
Where: ζ𝑞 and Θ𝑞 are calculated by expression (4.2.2-12) and
𝐴𝑞 = sin ∅𝑐 sin ζ𝑞 sin Θ𝑞 − cos ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ),

𝐵 𝑞 = − sin ∅𝑐 sin ζ𝑞 cos Θ𝑞 − cos ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ),}
𝐶 𝑞 = sin ∅𝑐 cos ζ𝑞 − cos ∅𝑐 sin 𝜇 sin ζ𝑞 .
After rotating by an angle ∆𝜀0𝑞 about 𝒌0 as an axis together with a displacement ∆𝜎0 𝒌𝑚 in
direction 𝒌𝑚 , point 𝑹𝑞𝑐 reaches conjugate cutting position as follow:
~ 340~
𝑑𝜎
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 + ∆𝜎0 𝒌𝑚 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ (𝑥 𝑞 𝒊𝑚 + 𝑦 𝑞 𝒋𝑚 + 𝑧 𝑞 𝒌𝑚 ) + ( 𝑑𝜀 0) ∆𝜀0𝑞 𝒌𝑚
0 𝑞
𝑞 𝑞 𝑞
= 𝑥𝑝𝑚 𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚
+ 𝑧𝑝𝑚 𝒌𝑚 , (4.3.1-7)
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑞 𝑞
𝑵𝑐 = (∆𝜀0 𝒌𝑚 ) ⊗ (𝐴 𝒊𝑚 + 𝐵 𝑞 𝒋𝑚
𝑞
+ 𝐶 𝑞 𝒌𝑚 )
𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 }
Where:
𝑞
={ }
𝑞
={ }
𝑞
𝑧𝑝𝑚 = 𝑧 𝑞 + ∆𝜎0 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 + ∆𝜎0 ,
𝐴𝑞𝑝𝑚 = 𝐴𝑞 cos ∆𝜀0𝑞 − 𝐵 𝑞 sin ∆𝜀0𝑞
sin ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )
={ },
𝑞
𝐵𝑝𝑚 = 𝐴𝑞 sin ∆𝜀0𝑞 + 𝐵 𝑞 cos ∆𝜀0𝑞
− sin ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
={ 𝑞 𝑞 },
− cos ∅𝑐 [cos 𝜇 sin(Θ𝑞 + ∆𝜀0 ) + sin 𝜇 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0 )]
𝑞
𝐶𝑝𝑚 = sin ∅𝑐 cos ζ𝑞 − cos ∅𝑐 sin 𝜇 sin ζ𝑞 . }
𝑹𝑞𝑝 = 𝑥𝑝𝑞 𝒊𝑞 + 𝑦𝑝𝑞 𝒋𝑞 + 𝑧𝑝𝑞 𝒌𝑞 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 + ∆𝜎0 𝒌𝑚 − 𝑓1𝑞 𝒊𝑚

𝑞 (4.3.1-8)
− 𝑓1𝑞 )𝒊𝑚 + 𝑦𝑝𝑚
𝑞 𝑞
= (𝑥𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚
Where:

𝑞
𝑦𝑝 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) , }
With help of expressions (4.2.1-2), (4.3.1-4) and (4.3.1-7), expression (4.3.1-8) gives
~341 ~
𝑥𝑐 cos ∆𝜀0 − 𝑦𝑐 sin ∆𝜀0 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0 )
{ }
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
{ } (4.3.1-9)
𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 + ∆𝜎0
= −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 . }
𝑞
Where: 𝛼𝑚 , 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 and Θ𝑞 are calculated by expression (4.2.2-12). 𝐴 and 𝐵 are decided
by expression (4.3.1-2). ∆𝜀1,𝑞 and ∆𝜎0 are determined by application of expressions (4.2.2-9)
and (4.2.2-10) respectively, that is,
∆𝜀0 ∆𝜀0 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
∆𝜀1,𝑞 = ∫0 𝑀1𝑞 𝑑𝜀0𝑞 = ∫0 𝑞 𝑑𝜀0𝑞
𝑀12 sin 𝛼
𝑑𝜎
} (4.3.1-10)
∆𝜎0 = (𝑑𝜀 0 ) ∆𝜀0𝑞 = −𝑓1𝑞 tan(𝛼𝑚
𝑞
+ 𝛼) ∆𝜀0𝑞 .
0 𝑞
Let 𝜀0 be visualized as virtual time parameter, velocity of point 𝑃(𝑹𝑞𝑝 ) on workpiece 1 is as

follow:
𝑑𝜀1
𝒗𝑞𝑝 = 𝝎1 × 𝑹𝑞𝑝 = 𝑀1 𝝎1 × (𝑥𝑝𝑞 𝒊𝑞 + 𝑦𝑝𝑞 𝒋𝑞 + 𝑧𝑝𝑞 𝒌𝑞 ) = 𝑀1 (−𝑦𝑝𝑞 𝒊𝑞 + 𝒋𝑞 )
𝑑𝜀0
(4.3.1-11)
= 𝑀1 (−𝑦𝑝𝑞 𝒊𝑚 + 𝑥𝑝𝑞 cos 𝛼𝑚
𝑞
𝒋𝑚 − 𝑥𝑝𝑞 sin 𝛼𝑚
𝑞
𝒌𝑚 )
Velocity of common contact point 𝑃(𝑹𝑞𝑝 ) on cutter surface is as follow:
𝑑𝜎
𝒗𝑐 = 𝒌𝑚 × (𝑹𝑞𝑝 + 𝑓1𝑞 𝒊𝑚 ) + ( 𝑑𝜀 0) 𝒌𝑚
0 𝑞
𝑑𝜎0
(4.3.1-12)
= −(𝑦𝑝𝑞 cos 𝛼𝑚 + 𝑧𝑝𝑞 sin 𝛼𝑚
𝑞
)𝒊𝑚 + (𝑥𝑝𝑞 + 𝑓1𝑞 )𝒋𝑚 + ( ) 𝒌𝑚
𝑑𝜀0 𝑞
(4.3.1-11) and (4.3.1-12) as follow:
[𝑦𝑝𝑞 (𝑀1 − cos 𝛼𝑚 ) − 𝑧𝑝𝑞 sin 𝛼𝑚

𝑞
]𝒊𝑚
𝒗𝑐 − 𝒗𝑞𝑝 = { 𝑑𝜎 } (4.3.1-13)
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑓1𝑞 ]𝒋𝑚 + [( 𝑑𝜀 0 ) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚 ] 𝒌𝑚
0 𝑞
~ 342 ~
(𝒗𝑐 − 𝒗𝑞𝑝 ) ∙ [(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 ] = 0 (4.3.1-14)
Then, with help of expressions (4.3.1-7) and (4.3.1-13), expression (4.3.1-14) is expanded as
follow:

𝑞
]𝐴𝑞𝑝𝑚
{ 𝑑𝜎 }=0 (4.3.1-15)
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑓1𝑞 ]𝐵𝑝𝑚
𝑞
+ [( 𝑑𝜀 0) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚 ] 𝐶𝑝𝑚
𝑞
0 𝑞
Combination of expressions ((4.3.1-9) and (4.3.1-15) gives simultaneous equation for the case
of tilt device
{ }
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
{ }
𝑞 𝑞
= 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) cos 𝛼𝑚 + 𝐵 sin 𝛼𝑚 , (4.3.1-16)
𝑑𝜎0
𝑧𝑐𝑞 𝑞 𝑞
+ 𝑠𝑐 cos ∅𝑐 cos ζ + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ + ( 𝑑𝜀 ) ∆𝜀0𝑞
0 𝑞
𝑞 𝑞
𝑞
]𝐴𝑞𝑝𝑚
{ 𝑑𝜎 }=0
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑓1𝑞 ]𝐵𝑝𝑚
𝑞
+ [( 𝑑𝜀 0) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚 ] 𝐶𝑝𝑚
𝑞
0 𝑞 }
Where: 𝛼𝑚 , 𝑥𝑐 , 𝑦𝑐 , 𝑧𝑐 , ζ𝑞 and Θ𝑞 are calculated by expression (4.2.2-12). 𝐴𝑝𝑚 , 𝐵𝑝𝑚 and 𝐶𝑝𝑚
are decoded by expression (4.3.1-7). 𝐴 and 𝐵 are decided by expression (3.4.1-2). ∆𝜀1,𝑞 and
𝑑𝜎
∆𝜎0 = (𝑑𝜀 0 ) ∆𝜀0𝑞 are calculated by application of expression (4.3.1-10).
0 𝑞
There are four equations in simultaneous equation (4.3.1-16) and four unknown variables, i.e.,
𝑠𝑐 , 𝜇 , ∆𝜀0𝑞 and 𝜉𝑝 which can be solved.
Then, with help of expression (4.3.1-4), instantaneous contact point is expressed in coordinate
system of workpiece 1 as follow:
𝑹𝑞𝑝 = 𝑥𝑝𝑞 𝒊𝑞 + 𝑦𝑝𝑞 𝒋𝑞 + 𝑧𝑝𝑞 𝒌𝑞 (4.3.1-17)
~ 343 ~
𝑞 𝑞 𝑞
Where: 𝑥𝑝 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , 𝑦𝑝 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) and 𝑧𝑝 = 𝐵. 𝜉𝑝 is decided by
simultaneous equation (4.3.1-16). ∆𝜀1,𝑞 is calculated by application of expression (4.3.1-10).
{ }
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
{ }
𝑞 𝑞
𝑑𝜎 (4.3.1-18)
𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 + ( 𝑑𝜀 0 ) ∆𝜀0𝑞
0 𝑞
𝑞 𝑞
= −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚
+ 𝐵 cos 𝛼𝑚 ,
𝑞 𝑞
[𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) (𝑀1 − cos 𝛼𝑚 ) − 𝐵 sin 𝛼𝑚 ]𝐴𝑝𝑚
+[−𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) (1 − 𝑀1 cos 𝛼𝑚 ) + 𝑓1𝑞 ]𝐵𝑝𝑚
𝑞
=0.
𝑑𝜎0 𝑞
+ [( 𝑑𝜀 ) − 𝑀1 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 ] 𝐶𝑝𝑚
{ 0 𝑞 } }
𝑞 𝑞 𝑞
Where: 𝐴𝑝𝑚 , 𝐵𝑝𝑚 and 𝐶𝑝𝑚 are calculated by expression (4.3.1-8). 𝐴 and 𝐵 are defined by

}
𝜻𝑞 = sin 𝜃 𝑞 𝒋𝑞 + cos 𝜃 𝑞 𝒌𝑞 , 𝜼𝑞 = 𝜻𝑞 × 𝒊𝑞 = cos 𝜃 𝑞 𝒋𝑞 − sin 𝜃 𝑞 𝒌𝑞 .
point on instantaneous contact line corresponding to instant rotating angle ∆𝜀0𝑞 of cradle.
𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 (4.3.1-19)
Where:
~ 344 ~
𝑞 𝑥𝑐 cos ∆𝜀0 − 𝑦𝑐 sin ∆𝜀0 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0 )
𝑥𝑝𝑚 ={ },
𝑦𝑝𝑚 ={ },
𝑞 𝑑𝜎
𝑧𝑝𝑚 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 + ( 𝑑𝜀 0) ∆𝜀0𝑞 .
0 𝑞 }
2 Instantaneous Contact Point and Instantaneous Contact Line in the Case of No

Tilt Device
Without tilt device, i.e., ζ𝑞 = Θ𝑞 = 0, 𝑥𝑐𝑞 , 𝑦𝑐𝑞 and 𝑧𝑐𝑞 are calculated by expression (4.2.2-13) and
then, expression (4.3.1-5) is simplified as follow:
𝑥 𝑞 = 𝑥𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos 𝜇 ,

𝑦 𝑞 = 𝑦𝑐𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 , } (4.3.1-20)
𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 .
Correspondingly, expression (4.3.1-6) is simplified as follow:
𝐴𝑞 = − cos ∅𝑐 cos 𝜇 ,
𝐵 𝑞 = − cos ∅𝑐 sin 𝜇 , } (4.3.1-21)
𝐶 𝑞 = sin ∅𝑐 .
Correspondingly, expression (4.3.1-7) is updated as follow:
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 + ∆𝜎0 𝒌𝑚 = 𝑥𝑝𝑚

𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 ,
} (4.3.1-22)
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 = 𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 .
Where:
𝑞
𝑞
𝑦𝑝𝑚 = 𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin(𝜇 + ∆𝜀0𝑞 ) ,
𝑞 𝑑𝜎
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 + (𝑑𝜀 0 ) ∆𝜀0𝑞 ,
0 𝑞
𝐴𝑞𝑝𝑚 ∆𝜀0𝑞 ), 𝑞
= − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) , 𝑞
= − cos ∅𝑐 cos(𝜇 + 𝐵𝑝𝑚 𝐶𝑝𝑚 = sin ∅𝑐 .}
~ 345 ~
𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞
𝑹𝑝 = 𝑥𝑝 𝒊𝑞 + 𝑦𝑝 𝒋𝑞 + 𝑧𝑝 𝒌𝑞 = (𝑥𝑝𝑚 − 𝑓1 )𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 (4.3.1-23)
With help of expression (4.2.1-2) and (4.3.1-22), expression (4.3.1-23) leads
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin(𝜇 + ∆𝜀0𝑞 ) (4.3.1-24)
𝑞 𝑞
𝑑𝜎0
𝑧𝑐𝑞 ∆𝜀0𝑞 𝑞 𝑞
+ 𝑠𝑐 cos ∅𝑐 + ( ) = −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 ,
𝑑𝜀0 𝑞 }
𝑞
Where: 𝛼𝑚 , 𝑥𝑐𝑞 , 𝑦𝑐𝑞 and 𝑧𝑐𝑞 are calculated by expression (4.2.2-15). ∆𝜀1,𝑞 is determined by
application of expressions (4.2.2-9), that is,
∆𝜀1,𝑞 = ∫0 𝑀1𝑞 𝑑𝜀0𝑞 = ∫0 𝑞 𝑑𝜀0𝑞 (4.3.1-25)
𝑀12 sin 𝛼
With help of expression (4.3.1-23), velocity of common contact point 𝑃(𝑹𝑞𝑝 ) on cutter surface is
as follow:
𝑑𝜎
𝒗𝑐 = 𝒌𝑚 × (𝑹𝑞𝑝 + 𝑓1𝑞 𝒊𝑚 ) + (𝑑𝜀 0) 𝒌𝑚
0 𝑞
𝑑𝜎0
(4.3.1-26)
−(𝑦𝑝𝑞 𝑧𝑝𝑞 𝑞
(𝑥𝑝𝑞 𝑞
= cos 𝛼𝑚 + sin 𝛼𝑚 )𝒊𝑚 + + 𝑓1 )𝒋𝑚 +( ) 𝒌𝑚
𝑑𝜀0 𝑞
(4.3.1-11) and (4.3.1-26) as follow:
[𝑦𝑝𝑞 (𝑀1 − cos 𝛼𝑚

𝑞
) − 𝑧𝑝𝑞 sin 𝛼𝑚
𝑞
]𝒊𝑚
𝒗𝑐 − 𝒗𝑞𝑝 = { 𝑑𝜎 } (4.3.1-27)
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚
𝑞
) + 𝑓1𝑞 ]𝒋𝑚 + [( 𝑑𝜀 0 ) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚
𝑞
] 𝒌𝑚
0 𝑞
(𝒗𝑐 − 𝒗𝑞𝑝 ) ∙ [(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 ] = 0 (4.3.1-28)
With help of expressions (4.3.1-22) and (4.3.1-27), expression (4.3.1-28) is expanded as follow:
~ 346 ~
[𝑦𝑝 (𝑀1 − cos 𝛼𝑚 ) − 𝑧𝑝 sin 𝛼𝑚 ] cos ∅𝑐 cos(𝜇 + ∆𝜀0 )
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚
𝑞
) + 𝑓1𝑞 ] cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 )
=0 (4.3.1-29)
𝑑𝜎0
− [(𝑑𝜀 ) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚
𝑞
] sin ∅𝑐
{ 0 𝑞 }
Where: 𝑥𝑝𝑞 , 𝑦𝑝𝑞 and 𝑧𝑝𝑞 are calculated by expression (4.3.1-4).
Combination of expressions (4.3.1-24) and (4.3.1-29) gives simultaneous equation for the case
of no tilt device
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
𝑞 𝑞
𝑑𝜎
𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 + (𝑑𝜀 0 ) ∆𝜀0𝑞 = −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚
𝑞 𝑞
+ 𝐵 cos 𝛼𝑚 , (4.3.1-30)
𝑞 0
𝑞 𝑞
𝑞
[𝑦𝑝 (𝑀1 − cos 𝛼𝑚 ] cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 )
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚𝑞
) + 𝑓1𝑞 ] cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 )
= 0.
𝑑𝜎0
− [( 𝑑𝜀 ) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚 ] sin ∅𝑐
{ 0 𝑞 } }
𝑑𝜎 𝑞 𝑞 𝑞 𝑞 𝑞
Where: ( 𝑑𝜀 0) , 𝑓1 , 𝛼𝑚 , 𝑥𝑐 , 𝑦𝑐 and 𝑧𝑐 are calculated by expression (4.2.2-15). 𝐴 and 𝐵 are
0 𝑞
decided by expression (4.3.1-2). ∆𝜀1,𝑞 and ∆𝜎0 are calculated by expression (4.3.1-10).
There are four equations in expression (4.3.1-30) and four unknown variables, i.e., 𝑠𝑐 , 𝜇, ∆𝜀0𝑞
and 𝜉𝑝 which can be solved.
Then, with help of expression (4.3.1-4), instantaneous contact point is expressed in coordinate
system of workpiece 1 as follow:

𝑞 𝑞 𝑞
Where: 𝑥𝑝 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , 𝑦𝑝 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) and 𝑧𝑝 = 𝐵. 𝜉𝑝 and ∆𝜀1,𝑞 are
decided by simultaneous equation (4.3.1-30).
~347 ~
𝑥𝑐 cos ∆𝜀0 − 𝑦𝑐 sin ∆𝜀0 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) cos(𝜇 + ∆𝜀0 )
= −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
𝑞 𝑞
𝑑𝜎
𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 + (𝑑𝜀 0 ) ∆𝜀0𝑞 = −𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚
𝑞 𝑞
+ 𝐵 cos 𝛼𝑚 , (4.3.1-32)
𝑞 0
𝑞 𝑞
𝑞
[𝑦𝑝 (𝑀1 − cos 𝛼𝑚 ] cos ∅𝑐 cos(𝜇 + ∆𝜀0𝑞 )
+[𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚𝑞
) + 𝑓1𝑞 ] cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 )
= 0.
𝑑𝜎0
− [( 𝑑𝜀 ) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚 ] sin ∅𝑐
{ 0 𝑞 } }
Where: 𝐴 and 𝐵 are defined by expression (4.3.1-2), that is,

}
𝜻𝑞 = sin 𝜃 𝑞 𝒋𝑞 + cos 𝜃 𝑞 𝒌𝑞 , 𝜼𝑞 = 𝜻𝑞 × 𝒊𝑞 = cos 𝜃 𝑞 𝒋𝑞 − sin 𝜃 𝑞 𝒌𝑞 .
point on instantaneous contact line corresponding to instant rotating angle ∆𝜀0𝑞 of cradle.
𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 (4.3.1-33)
Where:
𝑞
𝑞
𝑞 𝑑𝜎
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 + ( 𝑑𝜀 0 ) ∆𝜀0𝑞 .
0 𝑞 }
4.3.2 Tooth Profile

After rotating by an angle −(𝜀1,𝑞 + ∆𝜀1,𝑞 ) about 𝒌 as an axis, instantaneous contact point
𝑹𝑞𝑝 reaches initial position 𝑹1𝑞 of point 𝑃 on tooth profile of 𝑞𝑡ℎ tooth of workpiece 1, that is,
~ 348 ~
𝑹1 = [−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ 𝑹𝑝 = 𝑥1 𝒊 + 𝑦1 𝒋 + 𝑧1 𝒌
(4.3.2-1)
= [−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ (𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌)
Here:

𝑦1𝑞 = −𝑥𝑝𝑞 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) + 𝑦𝑝𝑞 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) ,}
𝑧1𝑞 = 𝑧𝑝𝑞 .
Where: 𝑥𝑝𝑞 , 𝑦𝑝𝑞 and 𝑧𝑝𝑞 are calculated by expression (4.3.1-4). ∆𝜀1,𝑞 is decided by expression
(4.3.1-25). 𝜀1,𝑞 is calculated by application of expression (4.2.2-2).
Likewise, with help of expression (4.2.1-2), unit normal to tooth profile in initial position is as
follow:
𝑵1𝑞 = −[−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ (𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚

𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 ) = 𝐴1𝑞 𝒊 + 𝐵1𝑞 𝒋 + 𝐶1𝑞 𝒌
𝐴𝑞𝑝𝑚 𝒊 + (𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 )𝒋 (4.3.2-2)
= −[−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ [ 𝑞 𝑞 𝑞 𝑞 ]
+(𝐵𝑝𝑚 sin 𝛼𝑚 + 𝐶𝑝𝑚 cos 𝛼𝑚 )𝒌
Where:
𝐴1𝑞 = −𝐴𝑞𝑝𝑚 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) − (𝐵𝑝𝑚

𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 ) sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) ,
𝐵1𝑞 = 𝐴𝑞𝑝𝑚 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) − (𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 ) cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) , }
𝐶1𝑞 = −𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
sin 𝛼𝑚 − 𝐶𝑝𝑚 cos 𝛼𝑚 .
Here: 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚

𝑞 𝑞
and 𝐶𝑝𝑚 are decided by expression (4.3.1-7) for the case of tilt device or
simultaneous equation (4.3.1-22) for the case of no tilt device.
After rotating by an angle −(𝜀2,𝑞 + ∆𝜀2,𝑞 ) about 𝝎2 as an axis, instantaneous contact point
𝑹𝑞𝑝 reaches initial position 𝑹𝑞2 of point 𝑃 on tooth profile of 𝑞𝑡ℎ tooth of workpiece 2, that is,
𝑹𝑞2 = [−(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝝎2 ] ⊗ (𝑹𝑞𝑝 − 𝑓𝒊) = 𝑥2𝑞 𝒊′ + 𝑦2𝑞 𝒋′ + 𝑧2𝑞 𝒌′

= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ [(𝑥𝑝𝑞 − 𝑓)𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌]
(4.3.2-3)
′
(𝑥𝑝𝑞 − 𝑓)𝒊′ + (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼)𝒋′
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌 ] ⊗ [ ]
+(𝑦𝑝𝑞 sin 𝛼 + 𝑧𝑝𝑞 cos 𝛼)𝒌′
Where:
~ 349 ~
𝑞 𝑞 𝑞 𝑞
𝑥2 = (𝑥𝑝 − 𝑓) cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) − (𝑦𝑝 cos 𝛼 − 𝑧𝑝 sin 𝛼) sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,
𝑦2𝑞 = (𝑥𝑝𝑞 − 𝑓) sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) + (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼) cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,}
Here: 𝑥𝑝𝑞 , 𝑦𝑝𝑞 and 𝑧𝑝𝑞 are calculated by expression (4.3.1-4). ∆𝜀2,𝑞 is calculated by application of
𝑞 𝑞 𝑞 𝑞
∆𝜀2,𝑞 = ∫0 𝑀2 𝑑𝜀0 = ∫0 𝑑𝜀0 ,
sin 𝛼 } (4.3.2-4)
𝜀1,𝑞
𝜀2,𝑞 = ∫0 𝑀 12 𝑑 𝜀1 .
Likewise, unit normal to tooth profile of workpiece 2 in initial position is as follow:
𝑵𝑞2 = [−(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝝎2 ] ⊗ [(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 ] = 𝐴𝑞2 𝒊′ + 𝐵2𝑞 𝒋′ + 𝐶2𝑞 𝒌′

= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ (𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 )
(4.3.2-5)
𝐴𝑞𝑝𝑚 𝒊′ + [𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
′
cos(𝛼𝑚 + 𝛼) − 𝐶𝑝𝑚 sin(𝛼𝑚 + 𝛼)]𝒋′
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌 ] ⊗ [ 𝑞 𝑞 𝑞 𝑞 ]
+[𝐵𝑝𝑚 sin(𝛼𝑚 + 𝛼) + 𝐶𝑝𝑚 cos(𝛼𝑚 + 𝛼)]𝒌′
Where:
𝐴𝑞2 = 𝐴𝑞𝑝𝑚 cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) − [𝐵𝑝𝑚

𝑞 𝑞 𝑞 𝑞
cos(𝛼𝑚 + 𝛼) − 𝐶𝑝𝑚 sin(𝛼𝑚 + 𝛼)] sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,
𝐵2𝑞 = 𝐴𝑞𝑝𝑚 sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) + [𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
cos(𝛼𝑚 + 𝛼) − 𝐶𝑝𝑚 sin(𝛼𝑚 + 𝛼)] cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,}
𝐶2𝑞 = 𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
sin(𝛼𝑚 + 𝛼) + 𝐶𝑝𝑚 cos(𝛼𝑚 + 𝛼) .

𝑞 𝑞
and 𝐶𝑝𝑚 are decided by expression (4.3.1-7) for the case of tilt device or
simultaneous equation (4.3.1-22) for the case of no tilt device.
Example 4. 1 Design a pair of non-circular gear set with varied transmission ratio of crossed
rotating axes and manufactured by tilt device
𝑑𝜀 1−𝑒 2 𝑑𝑀12 2𝑒(1−𝑒 2 ) sin 𝜀1

𝛼 = 90°, 𝑓 = −20, 𝑒 = 0.2, 𝑀12 = 2 = , = (1+2𝑒 cos 𝜀 .
𝑑𝜀 1+2𝑒 cos 𝜀 1 1 +𝑒 2 𝑑𝜀1 1 +𝑒
2 )2
Parameters of Cutter Head:
𝑟𝑐𝑖 = 60.0, ∅𝑐𝑖 = 30°, 𝑟𝑐𝑜 = 70.0, ∅𝑐𝑜 = 155°.
~ 350 ~
𝑝 = 15.9287, 𝑍1 = 25, 𝜌𝑎 = 90, ∅𝑔𝑖 = 35, ∅𝑔𝑜 = 150.
Figure Example 4.1
~ 351 ~
Calculation:
1. Parameters of Gear Blank.
That is, pitch angles 𝛾1𝑞 and 𝛾2𝑞 of workpiece 1 & 2. Spiral angles 𝜓1𝑞 and 𝜓2𝑞 of workpiece 1
& 2 as listed in Table 4.1.1.
2. Machine Setting Parameters for workpiece 1 & 2 as listed in Table 4.1.2 and Table 4.1.3
Parameters of Gear Blank (Example 4.1) ----Table 4.1.1
𝑞𝑡ℎ Convex Flank of Workpiece 1 & Concave Flank of Concave Flank of Workpiece 1 & Convex Flank of
tooth Workpiece 2 Workpiece 2
𝛾1 (deg) 𝜓1 (deg) 𝛾2 (deg) 𝜓2 (deg) 𝛾1 (deg) 𝜓1 (deg) 𝛾2 (deg) 𝜓2 (deg)
1 33.49 176.1 55.862 171.279 33.5815 176.081 55.7696 171.297

2 33.8553 176.024 55.4932 171.353 34.3078 175.93 55.0364 171.445
3 34.9316 175.799 54.407 171.573 35.7157 175.632 53.6163 171.735
4 36.6463 175.433 52.6785 171.93 37.707 175.203 51.6104 172.154
5 38.8796 174.947 50.4308 172.404 40.1443 174.668 49.1598 172.676
6 41.4806 174.37 47.8183 172.967 42.8671 174.06 46.428 173.27
7 44.282 173.742 45.0109 173.58 45.7035 173.422 43.5889 173.892
8 47.1095 173.106 42.1843 174.2 48.4778 172.799 40.8188 174.499
9 49.7868 172.508 39.514 174.784 51.0151 172.236 38.2911 175.048
10 52.1419 171.99 37.1702 175.289 53.1479 171.771 36.1705 175.502
11 54.0152 171.585 35.3094 175.684 54.7282 171.433 34.6019 175.832
12 55.2739 171.318 34.0606 175.944 55.6429 171.241 33.6948 176.02
13 55.8294 171.202 33.51 176.058 55.8313 171.201 33.508 176.058
14 55.6509 171.239 33.6869 176.021 55.2939 171.314 34.0408 175.948
15 54.7696 171.425 34.5608 175.84 54.09 171.569 35.2352 175.699
16 53.2692 171.745 36.0501 175.527 52.3232 171.95 36.99 175.328
17 51.2688 172.181 38.0387 175.103 50.1233 172.433 39.1789 174.856
18 48.9044 172.704 40.3934 174.592 47.6299 172.989 41.6647 174.314
19 46.3172 173.284 42.9756 174.027 44.9837 173.584 44.3087 173.734
20 43.6468 173.885 45.6469 173.44 42.3235 174.182 46.9729 173.151
21 41.0311 174.471 48.2694 172.869 39.7868 174.747 49.5189 172.599
22 38.608 175.007 50.704 172.346 37.5118 175.246 51.8069 172.112
23 36.5156 175.461 52.8102 171.902 35.636 175.649 53.6967 171.718
24 34.8889 175.808 54.45 171.564 34.2892 175.934 55.0552 171.441
25 33.8496 176.025 55.4989 171.352 33.5808 176.081 55.7704 171.297
~ 352 ~
Machine Setting Parameters for Convex Flank of Workpiece 1 & Concave Flank of Workpiece 2 (Example 4.1.) --Table 4.1.2
𝑞 ( (
𝑞𝑡ℎ 𝑥𝑐𝑞 𝑦𝑐𝑞 𝑧𝑐𝑞 𝛼𝑚 ζ𝑞 Θ𝑞 𝑓1𝑞 𝑓2𝑞 (𝑑𝜎0 ) 𝜀1,𝑞 𝑑𝑒𝑔) 𝜀2,𝑞 𝑑𝑒𝑔)
tooth
𝑑𝜀0 𝑞
1 58.5703 70.3285 31.0827 33.6901 -3.29788 -102.098 6.15385 -13.8462 9.23077 0 0
2 58.6596 71.1478 30.1356 34.0603 -3.17356 -101.717 6.27346 -13.7265 9.2797 18.18 12.1739
3 58.9065 73.4928 27.2883 35.1514 -2.83125 -100.588 6.62952 -13.3705 9.41487 36.0653 24.4792
4 59.2494 77.0079 22.5873 36.8901 -2.36023 -98.7623 7.20679 -12.7932 9.60198 53.2986 36.9719
5 59.6 81.1571 16.191 39.1549 -1.88447 -96.3472 7.97381 -12.0262 9.79258 69.6703 49.7363
6 59.8671 85.3421 8.40807 41.7922 -1.52748 -93.4962 8.88261 -11.1174 9.93738 85.1246 62.8896
~ 353 ~
7 59.9811 89.028 -0.293353 44.631 -1.38043 -90.4027 9.87121 -10.1288 9.99917 99.7233 76.5761
8 59.9125 91.8467 -9.31581 47.4931 -1.48092 -87.2827 10.8692 -9.13084 9.96216 113.595 90.9516
9 59.6794 93.6566 -17.9935 50.1991 -1.80492 -84.3545 11.8049 -8.1951 9.83577 126.894 106.156
10 59.3425 94.5472 -25.6684 52.5752 -2.27205 -81.8177 12.6135 -7.38646 9.65243 139.766 122.273
11 58.9897 94.7847 -31.7633 54.4618 -2.76389 -79.8359 13.2431 -6.75691 9.45951 152.336 139.284
12 58.7118 94.7105 -35.8394 55.7277 -3.15356 -78.5259 13.6578 -6.34223 9.30703 164.694 157.02
13 58.5791 94.6183 -37.6308 56.2858 -3.34051 -77.954 13.8384 -6.16162 9.234 176.904 175.161
Machine Setting Parameters for Convex Flank of Workpiece 1 & Concave Flank of Workpiece 2 (Example 4.1) --Table 4.1.2 continue
𝑞 ( (
tooth
𝑑𝜀0 𝑞
14 58.6224 94.6519 -37.0558 56.1065 -3.27945 -78.1374 13.7805 -6.21949 9.25785 189.009 193.285
15 58.827 94.7627 -34.2087 55.2207 -2.99175 -79.0485 13.4925 -6.50751 9.3703 201.054 210.966
16 59.139 94.7401 -29.3391 53.7109 -2.55534 -80.6208 12.994 -7.00596 9.54126 213.099 227.879
17 59.4815 94.2939 -22.822 51.6948 -2.0791 -82.753 12.3157 -7.6843 9.72818 225.232 243.852
18 59.774 93.1535 -15.1244 49.3078 -1.67368 -85.3153 11.4981 -8.50195 9.88716 237.572 258.859
19 59.9503 91.15 -6.76901 46.6915 -1.42763 -88.1551 10.5901 -9.40988 9.98257 250.264 272.985
~ 354 ~
20 59.9711 88.269 1.70408 43.9875 -1.39221 -91.1049 9.64665 -10.3534 9.99376 263.475 286.375
21 59.8319 84.6703 9.77576 41.3365 -1.57399 -93.991 8.72468 -11.2753 9.91834 277.375 299.199
22 59.5632 80.6792 16.9841 38.8795 -1.93399 -96.6428 7.87975 -12.1203 9.77264 292.119 311.624
23 59.2255 76.7498 22.9524 36.7576 -2.39291 -98.9025 7.16239 -12.8376 9.58895 307.814 323.805
24 58.8972 73.4019 27.4027 35.1082 -2.84413 -100.633 6.6153 -13.3847 9.40977 324.471 335.867
25 58.6582 71.1352 30.1504 34.0546 -3.17546 -101.723 6.2716 -13.7284 9.27896 341.961 347.907
Machine Setting Parameters for Concave Flank of Workpiece 1 & Convex Flank of Workpiece 2 (Example 4.1) --Table 4.1.3
𝑞 ( (
tooth
𝑑𝜀0 𝑞
1 66.8524 101.445 24.7658 33.7828 -7.79951 -74.5692 6.18373 -13.8163 9.24316 9.10026 6.07324
2 67.0599 101.22 22.0887 34.519 -8.23513 -75.4615 6.42252 -13.5775 9.33818 27.1847 18.3071
3 67.4334 100.544 16.9302 35.9465 -9.00717 -77.2549 6.89207 -13.1079 9.50478 44.7803 30.6976
4 67.8882 99.0572 9.73272 37.9658 -9.9265 -79.9219 7.5692 -12.4308 9.70006 61.5989 43.3136
5 68.3083 96.426 1.14532 40.4374 -10.7573 -83.3581 8.41408 -11.5859 9.87344 77.5104 56.2558
6 68.5747 92.5082 -8.06235 43.1975 -11.2786 -87.3495 9.37122 -10.6288 9.98021 92.5238 69.6565
~ 355~
7 68.6054 87.4498 -17.114 46.0704 -11.3485 -91.5763 10.3736 -9.62644 9.99302 106.741 83.6682
3
8 68.3901 81.6797 -25.3399 48.8767 -10.9486 -95.6664 11.3491 -8.6509 9.90858 120.307 98.443
9 67.9946 75.8156 -32.2564 51.4389 -10.1901 -99.2775 12.2287 -7.77129 9.74848 133.375 114.099
10 67.5331 70.5341 -37.5901 53.5888 -9.27892 -102.164 12.9533 -7.04667 9.55394 146.082 130.673
11 67.1263 66.4512 -41.2472 55.179 8.4536 -104.192 13.4789 -6.52114 9.37537 158.537 148.078
12 66.869 64.0316 -43.2472 56.0985 -7.92106 -105.318 13.7779 -6.22207 9.2589 170.815 166.065
13 66.8142 63.5287 -43.6483 56.2878 -7.8066 -105.546 13.839 -6.16098 9.23374 182.967 184.253
Machine Setting Parameters for Concave Flank of Workpiece 1 & Convex Flank of Workpiece 2 (Example 4.1) --Table 4.1.3 continue
𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 ( (
𝑞𝑡ℎ 𝑥𝑐 𝑦𝑐 𝑧𝑐 𝛼𝑚 ζ𝑞 Θ𝑞 𝑓1 𝑓2 (𝑑𝜎0 ) 𝜀1,𝑞 𝑑𝑒𝑔) 𝜀2,𝑞 𝑑𝑒𝑔)
tooth
𝑑𝜀0 𝑞
14 66.9689 64.9593 -42.4943 55.7478 -8.12882 -104.893 13.6643 -6.3357 9.30446 195.036 202.205
15 67.2967 68.1158 -39.8009 54.5371 -8.80168 -103.385 13.2679 -6.73209 9.45097 207.072 219.534
16 67.7244 72.6101 -35.5812 52.7579 -9.65972 -101.066 12.675 -7.32496 9.63557 219.148 235.988
17 68.1538 77.9333 -29.8945 50.5388 -10.4982 -98.0273 11.9214 -8.0786 9.81368 231.367 251.473
18 68.481 83.5207 -22.8964 48.0195 -11.1193 -94.4276 11.052 -8.94796 9.94451 243.864 266.024
19 68.6219 88.82 -14.8749 45.3417 -11.3769 -90.5034 10.1193 -9.88073 9.99929 256.794 279.762
~ 356 ~
20 68.5397 93.3679 -6.26145 42.6466 -11.2098 -86.544 9.17943 -10.8206 9.96628 270.328 292.847
21 68.2569 96.8657 2.38667 40.0749 -10.6565 -82.8442 8.28927 -11.7107 9.85258 284.633 305.451
22 67.8477 99.2299 10.4319 37.7679 -9.8457 -79.6543 7.50224 -12.4978 9.68304 299.844 317.737
23 67.4133 100.591 17.2211 35.8656 -8.96607 -77.1511 6.86525 -13.1347 9.49597 316.027 329.844
24 67.0547 101.227 22.1573 34.5001 -8.22426 -75.4383 6.41637 -13.5836 9.33582 333.126 341.885
25 66.8522 101.445 24.7684 33.782 -7.79907 -74.5683 6.18349 -13.8165 9.24307 350.936 353.94
Example 4. 2 Design a pair of non-circular gear set with varied transmission ratio of crossed
rotating axes and manufactured by no tilt device
𝑑𝜀 1−𝑒 2 𝑑𝑀12 2𝑒(1−𝑒 2 ) sin 𝜀1

𝛼 = 90°, 𝑓 = −10, 𝑒 = 0.2, 𝑀12 = 2 = , = (1+2𝑒 cos 𝜀 .
𝑑𝜀 1+2𝑒 cos 𝜀1 1 +𝑒 2 𝑑𝜀1 1 +𝑒
2 )2
Figure Example 4.2 Gear Set Manufactured without tilt device
~ 357 ~
𝑟𝑐𝑖 = 70.0, ∅𝑐𝑖 = 25°, 𝑟𝑐𝑜 = 70.0, ∅𝑐𝑜 = 145°.
𝑟𝑐𝑖 = 70.0, ∅𝑐𝑖 = 25°, 𝑟𝑐𝑜 = 70.0, ∅𝑐𝑜 = 145°.
Parameters of Gear Set:
𝑝 = 8.83939, 𝑍1 = 25, 𝜌𝑎 = 50, ∅𝑔𝑖 = 35° , ∅𝑔𝑜 = 140°.
Calculation:
• Parameters of Gear Blank.
That is, pitch angles 𝛾1𝑞 and 𝛾2𝑞 of workpiece 1 & 2. Spiral angles 𝜓1𝑞 and 𝜓2𝑞 of workpiece 1
& 2 as listed in Table 4.2.1.
• Machine Setting Parameters for workpiece 1 & 2 as listed in Table 4.2.2 and Table 4.2.3
~ 358 ~
𝛾1 (deg) 𝜓1 (deg) 𝛾2 (deg) 𝜓2 (deg) 𝛾1 (deg) 𝜓1 (deg) 𝛾2 (deg) 𝜓2 (deg)
1 33.5279 176.487 55.9465 172.135 33.6195 176.47 55.8541 172.152

2 33.8938 176.419 55.5778 172.202 34.3467 176.334 55.1213 172.285
3 34.9709 176.216 54.4927 172.401 35.7551 176.067 53.7031 172.547
4 36.6856 175.888 52.7669 172.723 37.7458 175.681 51.7008 172.925
5 38.9177 175.451 50.5233 173.151 40.1815 175.2 49.2545 173.396
6 41.5167 174.934 47.9152 173.658 42.9021 174.655 46.5268 173.931
7 44.3162 174.37 45.1111 174.211 45.737 174.083 43.69 174.492
8 47.1428 173.799 42.2853 174.77 48.5116 173.524 40.9189 175.04
9 49.8218 173.262 39.6122 175.297 51.0523 173.018 38.3862 175.536
10 52.1825 172.796 37.261 175.754 53.1929 172.599 36.2557 175.946
11 54.0659 172.431 35.3878 176.111 54.7857 172.293 34.6725 176.246
12 55.3392 172.188 34.1227 176.349 55.7167 172.117 33.7479 176.419
13 55.912 172.08 33.554 176.454 55.9229 172.078 33.5432 176.456
14 55.7509 172.111 33.7139 176.425 55.4016 172.176 34.0608 176.36
15 54.8838 172.274 34.575 176.264 54.2092 172.403 35.2453 176.138
16 53.3919 172.56 36.0578 175.984 52.4476 172.744 36.9971 175.804
17 51.393 172.951 38.0468 175.602 50.2457 173.178 39.1897 175.379
18 49.0235 173.421 40.4083 175.14 47.7441 173.678 41.6849 174.889
19 46.4254 173.944 43.002 174.628 45.085 174.214 44.3419 174.363
20 43.7405 174.486 45.6873 174.097 42.4094 174.754 47.0204 173.834
21 41.1091 175.015 48.3239 173.578 39.8572 175.265 49.5799 173.333
22 38.6713 175.5 50.7708 173.103 37.5688 175.716 51.8788 172.891
23 36.567 175.91 52.8863 172.7 35.6827 176.08 53.776 172.534
24 34.9321 176.223 54.5317 172.394 34.3298 176.337 55.1384 172.282
25 33.8886 176.42 55.5829 172.201 33.6189 176.47 55.8548 172.152
~ 359 ~
Machine Setting Parameters for Convex Flank of Workpiece 1 & Concave Flank of Workpiece 2 (Example 4.2.) --Table 4.2.2
𝑞𝑡ℎ 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑑𝜎0 𝜀1,𝑞 (𝑑𝑒𝑔) 𝜀2,𝑞 (𝑑𝑒𝑔)
𝑥𝑐 𝑦𝑐 𝑧𝑐 𝛼𝑚 𝑓1 𝑓2 ( )
tooth 𝑑𝜀0 𝑞
1 65.7619 22.5379 26.0817 24.8014 1.7596 -8.2404 3.8079 0 0

2 65.6827 22.6348 26.0197 24.5124 1.7213 -8.2787 3.7750 18.1712 12.168
3 65.4448 22.9028 25.8461 23.6486 1.6090 -8.3910 3.6744 36.0359 24.4586
4 65.0516 23.2749 25.5989 22.2322 1.4315 -8.5684 3.5023 53.2404 36.9283
5 64.5161 23.654 25.3353 20.3071 1.2044 -8.7955 3.2549 69.5788 49.6621
6 63.8652 23.9383 25.1187 17.9419 0.9489 -9.0510 2.9307 84.9985 62.7772
7 63.1413 24.0486 25.0013 15.2375 0.6907 -9.3093 2.5358 99.563 76.4184

8 62.4 23.9509 25.0084 12.3388 0.4566 -9.5433 2.0876 113.402 90.7419
9 61.7019 23.666 25.1303 9.4379 0.2689 -9.7311 1.6176 126.671 105.889
10 61.1018 23.2648 25.3262 6.7638 0.1387 -9.8613 1.1696 139.516 121.948
11 60.6398 22.8483 25.5378 4.5564 0.0631 -9.9369 0.7919 152.065 138.905
12 60.3385 22.5206 25.7064 3.0297 0.0279 -9.9720 0.5278 164.408 156.601
13 60.2062 22.3615 25.7886 2.3343 0.0166 -9.9834 0.4070 176.612 174.724
14 60.2432 22.4069 25.7651 2.5304 0.0195 -9.9805 0.4411 188.719 192.854
15 60.4451 22.6419 25.6438 3.5788 0.0390 -9.9610 0.6230 200.775 210.565
16 60.8031 23.0069 25.4567 5.3535 0.0870 -9.9130 0.9289 212.838 227.523
17 61.3003 23.4142 25.2519 7.6699 0.1781 -9.8219 1.3227 224.994 243.55
18 61.9086 23.7702 25.0825 10.3177 0.3208 -9.6792 1.7621 237.361 258.615
19 62.5883 23.9956 24.9947 13.0905 0.5130 -9.4870 2.2060 250.084 272.795
20 63.2915 24.0427 25.0154 15.8072 0.7420 -9.2580 2.6210 263.328 286.234
21 63.9689 23.9052 25.146 18.3219 0.9882 -9.0118 2.9842 277.262 299.1
22 64.5764 23.6182 25.361 20.5244 1.2292 -8.7708 3.2835 292.04 311.562
23 65.0793 23.2514 25.6148 22.3319 1.4438 -8.5562 3.5147 307.767 323.77
24 65.4534 22.8937 25.8521 23.68 1.6131 -8.3870 3.6781 324.449 335.853
25 65.6839 22.6335 26.0206 24.5165 1.7219 -8.2781 3.7754 341.957 347.905
~ 360 ~
Machine Setting Parameters for Concave Flank of Workpiece 1 & Convex Flank of Workpiece 2 (Example 4.2.) --Table 4.2.3
𝑞𝑡ℎ 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑑𝜎0 𝜀1,𝑞 (𝑑𝑒𝑔) 𝜀2,𝑞 (𝑑𝑒𝑔)
𝑥𝑐 𝑦𝑐 𝑧𝑐 𝛼𝑚 𝑓1 𝑓2 ( )
tooth 𝑑𝜀0 𝑞
1 67.0081 4.4172 -29.4662 92.4066 9.9824 -0.0176 -0.4195 9.0975 6.0714

2 66.8391 4.2758 -29.5138 91.7453 9.9907 -0.0093 -0.3044 27.167 18.2949
3 66.5113 4.0263 -29.5951 90.4503 9.9994 -0.0006 -0.0786 44.7374 30.666
4 66.0474 3.7287 -29.6863 88.588 9.9939 -0.0061 0.2463 61.5245 43.2556
5 65.4808 3.4525 -29.7604 86.2596 9.9574 -0.0426 0.6510 77.4017 56.1634
6 64.8517 3.2588 -29.795 83.5951 9.8756 -0.1244 1.1086 92.3805 69.5224
7 64.2036 3.1863 -29.7777 80.7485 9.7415 -0.2585 1.5868 106.564 83.4853

8 63.5795 3.2435 -29.7085 77.8943 9.5602 -0.4398 2.0505 120.098 98.2052
9 63.0194 3.4072 -29.6 75.2223 9.3494 -0.6506 2.4663 133.138 113.802
10 62.5576 3.6279 -29.4752 72.9279 9.1381 -0.8619 2.8063 145.821 130.32
11 62.2207 3.8413 -29.3626 71.1953 8.9610 -1.0391 3.0514 158.257 147.677
12 62.0267 3.9854 -29.2889 70.1724 8.8495 -1.1505 3.1908 170.525 165.634
13 61.9841 4.0192 -29.2718 69.9449 8.8240 -1.1760 3.2213 182.675 183.816
14 62.0922 3.9350 -29.3145 70.5195 8.8879 -1.1121 3.1440 194.751 201.786
15 62.3419 3.7592 -29.4053 71.8249 9.0270 -0.9730 2.9636 206.801 219.153
16 62.7172 3.5425 -29.5221 73.7312 9.2152 -0.7848 2.6893 218.898 235.659
17 63.1959 3.3437 -29.6391 76.0766 9.421 0.5790 2.3356 231.143 251.2
18 63.7509 3.2150 -29.7328 78.6906 9.6154 -0.3846 1.923 243.668 265.807
19 64.3518 3.1913 -29.7865 81.4095 9.7769 -0.2231 1.4770 256.63 279.597
20 64.9653 3.2849 -29.7925 84.0826 9.8937 -0.1063 1.0255 270.198 292.728
21 65.5561 3.4837 -29.7529 86.5727 9.9643 -0.0357 0.5968 284.537 305.371
22 66.0887 3.7525 -29.6793 88.7552 9.9953 -0.0047 0.2172 299.782 317.689
23 66.5281 4.0383 -29.5913 90.5173 9.9992 -0.0008 -0.0903 315.993 329.821
24 66.843 4.2790 -29.5127 91.7607 9.9906 -0.0094 -0.3071 333.114 341.878
25 67.0082 4.4173 -29.4662 92.4072 9.9824 -0.0176 -0.4196 350.935 353.941
~ 361 ~
Chapter 4
Calculation of Curvature
In manufacturing process of tooth profile, cutter surface is referred to the first conjugate
surface 𝐴 and workpiece is signified as the second conjugate surface 𝐴̅.

1 Curvature of Cutter Surface in Direction of Tangent to Cutting Edge
1) With Tilt Device
Corresponding to any point 𝑃 on tooth profile of 𝑞𝑡ℎ tooth of workpiece 1, the point 𝑹𝑞𝑐𝑝 on
cutter surface and its unit normal 𝑵𝑞𝑐𝑝 to cutter surface at point 𝑹𝑞𝑐𝑝 are calculated by
𝑹𝑞𝑐𝑝 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 + ∆𝜎0 𝒌𝑚 = 𝑥𝑝𝑚

𝑞 𝑞 𝑞
} (4.4.1-1)
𝑵𝑞𝑐𝑝 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 = 𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞
where:
𝑞 𝑥𝑐 cos ∆𝜀0 − 𝑦𝑐 sin ∆𝜀0 + 𝑠𝑐 cos ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0 )
𝑥𝑝𝑚 ={ }
𝑦𝑝𝑚 ={ }
𝑞
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 cos ζ𝑞 + (𝑟𝑐 + 𝑠𝑐 sin ∅𝑐 ) sin 𝜇 sin ζ𝑞 + ∆𝜎0 ,
𝑞
sin ∅𝑐 sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0 )
𝐴𝑞𝑝𝑚 ={ },
𝑞 − sin ∅𝑐 sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
𝐵𝑝𝑚 ={ },
− cos ∅𝑐 [cos 𝜇 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜇 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞
𝐶𝑝𝑚 = sin ∅𝑐 cos ζ𝑞 − cos ∅𝑐 sin 𝜇 sin ζ𝑞 . }
Here: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 and Θ𝑞 are determined by expression (4.2.2-12). 𝑠𝑐 , 𝜇, ∆𝜎0 and ∆𝜀0𝑞 are
calculated by simultaneous equation (4.3.1-16).
Unit tangent 𝜻𝑝 to cutting edge in conjugate cutting position is determined by expression

~ 362 ~
Where:
[sin ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ) + cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 ] cos ∆𝜀0𝑞
𝜁𝑝𝑥 = { },
−[sin ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ) − cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 ] sin ∆𝜀0𝑞
[sin ∅𝑐 (cos 𝜇 cos Θ𝑞 − sin 𝜇 cos ζ𝑞 sin Θ𝑞 ) + cos ∅𝑐 sin ζ𝑞 sin Θ𝑞 ] sin ∆𝜀0𝑞
𝜁𝑝𝑦 ={ },
+[sin ∅𝑐 (cos 𝜇 sin Θ𝑞 + sin 𝜇 cos ζ𝑞 cos Θ𝑞 ) − cos ∅𝑐 sin ζ𝑞 cos Θ𝑞 ] cos ∆𝜀0𝑞
𝜁𝑝𝑧 = sin ∅𝑐 sin 𝜇 sin ζ𝑞 + cos ∅𝑐 cos ζ𝑞 . }
Here: ζ𝑞 and Θ𝑞 are determined by expression (4.2.2-10). ∆𝜀0𝑞 and 𝜇 are calculated by
simultaneous equation (4.3.1-16).

𝑝 of cutter surface 𝐴 with respect to workpiece 1 at point 𝑃 is decided by
𝑞
𝒗12 12 12 12

𝑞
𝑞
]𝒊𝑚
(4.4.1-3)
={ 𝑑𝜎0 }
+[𝑥𝑝𝑞 (1 𝑞
𝑓1𝑞 ]𝒋𝑚 𝑀1 𝑥𝑝𝑞 𝑞
− 𝑀1 cos 𝛼𝑚 ) + + [( 𝑑𝜀 ) + sin 𝛼𝑚 ] 𝒌𝑚
0 𝑞
𝑑𝜎
Where: 𝑥𝑝𝑞 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , 𝑦𝑝𝑞 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) and 𝑧𝑝𝑞 = 𝐵. 𝛼𝑚
𝑞
, 𝑓1𝑞 and ( 𝑑𝜀 0 ) are
0 𝑞
calculated by expression (4.2.2-10). 𝜉𝑝 and ∆𝜀1,𝑞 are determined by (4.3.1-16) and
= 𝑦𝑝𝑞 (𝑀1 − cos 𝛼𝑚

𝑞
12 𝑞
𝑣𝑝𝑥 ,
= 𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚
𝑞
12
𝑣𝑝𝑦 ) + 𝑓1𝑞 ,
𝑑𝜎
= ( 𝑑𝜀 0) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚
12 𝑞
𝑣𝑝𝑧 .
0 𝑞 }
𝒗12
𝑝
Then, curvature of cutter surface 𝐴 at point 𝑃 in direction of relative velocity |𝒗12| = 𝝀 is
𝑝
expressed in expression (3.5.2-8)

cos ∅𝑐
𝐾𝜆 = − 𝑟 +𝑠 sin2 𝜃𝜁𝜆 ,
cos ∅𝑐
} (4.4.1-4)
𝐺𝜆 = − 𝑟 +𝑠 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .
Where: cos 𝜃𝜁𝜆 and sin 𝜃𝜁𝜆 are decided by expression (3.5.2-6), that is,
~ 363 ~
𝒗12
sin 𝜃𝜁𝜆 = |𝒗12| ∙ (𝑵𝑞𝑐𝑝 × 𝜻𝑝 ),
𝑝
𝑝
𝒗12
} (4.4.1-5)
𝑝
cos 𝜃𝜁𝜆 = |𝒗12 | ∙ 𝜻𝑝 .
𝑝
Here: 𝑵𝑞𝑐𝑝 is calculated by expression (4.4.1-1). 𝜻𝑝 is determined by formular (4.4.1-2) and 𝒗12
𝑝
is decided by expression (4.4.1-3).
𝒗12
Also, curvature of cutter surface 𝐴 at point 𝑃 in direction of ∆= 𝑵𝑞𝑐𝑝 × |𝒗12 | is calculated by
𝑝

𝐾∆ = − ,
cos ∅𝑐
} (4.4.1-6)
2) Without Tilt Device
Expression (4.4.1-1) is updated as follow:
𝑹𝑞𝑐𝑝 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞𝑐 + ∆𝜎0 𝒌𝑚 = 𝑥𝑝𝑚

𝑞 𝑞 𝑞
} (4.4.1-7)
𝑵𝑞𝑐𝑝 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑵𝑞𝑐 = 𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞
Where:
𝑞
𝑞
𝑞 𝑑𝜎
𝑧𝑝𝑚 = 𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑠𝑐 cos ∅𝑐 + ( 𝑑𝜀 0 ) ∆𝜀0𝑞 ,
0 𝑞
𝐴𝑞𝑝𝑚 𝑞
= − cos ∅𝑐 cos(𝜇 + ∆𝜀0 ),
𝑞
𝐵𝑝𝑚 = − cos ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) ,
𝑞
𝐶𝑝𝑚 = sin ∅𝑐 . }
𝑑𝜎
Here: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 and ( 𝑑𝜀 0) are determined by expression (4.2.2-15). 𝑠𝑐 , 𝜇, ∆𝜎0 and ∆𝜀0𝑞 are
0 𝑞
calculated by simultaneous equation (4.3.1-30).
Expression (4.4.1-2) is simplified as follow:
Where:
~ 364 ~
𝑞
𝜁𝑝𝑥 = sin ∅𝑐 cos(𝜇 + ∆𝜀0 ) ,
𝜁𝑝𝑦 = sin ∅𝑐 sin(𝜇 + ∆𝜀0𝑞 ) , }
𝜁𝑝𝑧 = cos ∅𝑐 .
Here: 𝜇 and ∆𝜀0𝑞 are calculated by simultaneous equation (4.3.1-30).

𝑝 of cutter surface 𝐴 with respect to workpiece 1 at point 𝑃 is decided by
simplification of expression (4.3.1-13) as follow:
𝑞
𝒗12 12 12 12

𝑞
𝑞
]𝒊𝑚
(4.4.1-9)
={ 𝑑𝜎0 }
+[𝑥𝑝𝑞 (1 𝑞
𝑓1𝑞 ]𝒋𝑚 𝑀1 𝑥𝑝𝑞 𝑞
− 𝑀1 cos 𝛼𝑚 ) + + [( 𝑑𝜀 ) + sin 𝛼𝑚 ] 𝒌𝑚
0 𝑞
𝑑𝜎
Where: 𝑥𝑝𝑞 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , 𝑦𝑝𝑞 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) and 𝑧𝑝𝑞 = 𝐵. 𝛼𝑚
𝑞
, 𝑓1𝑞 and ( 𝑑𝜀 0 ) are
0 𝑞
calculated by expression (4.2.2-15). 𝜉𝑝 and ∆𝜀1,𝑞 are determined by (4.3.1-30) and

𝑞
12 𝑞
𝑣𝑝𝑥 ,
= 𝑥𝑝𝑞 (1 − 𝑀1 cos 𝛼𝑚
𝑞
12
𝑣𝑝𝑦 ) + 𝑓1𝑞 ,
𝑑𝜎
= ( 𝑑𝜀 0) + 𝑀1 𝑥𝑝𝑞 sin 𝛼𝑚
12 𝑞
𝑣𝑝𝑧 .
0 𝑞 }
𝒗12
𝑝
Then, curvature of cutter surface 𝐴 at point 𝑃 in direction of relative velocity |𝒗12| = 𝝀 is
𝑝
expressed in expression (3.5.2-8)

cos ∅𝑐
cos ∅𝑐
} (4.4.1-10)
Where: cos 𝜃𝜁𝜆 and sin 𝜃𝜁𝜆 are decided by expression (3.5.2-6), that is,
𝒗12
sin 𝜃𝜁𝜆 = |𝒗12| ∙ (𝑵𝑞𝑐𝑝 × 𝜻𝑝 ),
𝑝
𝑝
𝒗12
} (4.4.1-11)
𝑝
cos 𝜃𝜁𝜆 = |𝒗12 | ∙ 𝜻𝑝 .
𝑝
Here: 𝑵𝑞𝑐𝑝 is calculated by expression (4.4.1-7). 𝜻𝑝 is determined by formular (4.4.1-8) and 𝒗12
𝑝
is decided by expression (4.4.1-9).
~ 365 ~
𝒗12
Also, curvature of cutter surface 𝐴 at point 𝑃 in direction of ∆= 𝑵𝑞𝑐𝑝 × |𝒗12 | is calculated by
𝑝

𝐾∆ = − ,
cos ∅𝑐
} (4.4.1-12)

A. With Tilt Device
In manufacturing process of tooth profile of workpiece 1, motion conditions are as follow;

𝑞 𝑞 𝑞 𝑞
𝑑𝜀 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼) 𝑑𝑀 𝑑𝑀1
𝑀 = 𝑀1𝑞 = (𝑑𝜀1) = , = =−
𝑑𝑀12 𝑀1 sin 𝛼𝑚
2 sin 𝛼 ,
0 𝒒 𝑀12 sin 𝛼 𝑑𝜀1 𝑑𝜀0 𝑑𝜀1 𝑀12
𝑞 𝑞
𝑓 sin 𝛼𝑚 cos(𝛼𝑚 +𝛼) 𝑑𝜎1 𝑑𝜎
𝑓 = 𝑓1𝑞 = = ( 𝑑𝜀 0 ) = −𝑓1𝑞 tan(𝛼𝑚
𝑞
, + 𝛼) ,
sin 𝛼 𝑑𝜀1 0 𝑞 (4.4.1-13)
𝑑𝑓 𝑑ℎ 𝑑2 𝑓 𝑑2 ℎ 𝑑𝜎2 𝑑2 𝜎1 𝑑2 𝜎2
ℎ = 𝑑𝜀 = 𝑑𝜀 = = = 0, = = = 0,
1 1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12
𝑞 𝑞
𝑞
Where: 𝛼𝑚 is calculated by expression (4.2.2-12).

𝑞 𝑞 𝑞 𝑞
consideration 𝑥𝑝 = 𝑥𝑝𝑚 , 𝑦𝑝 = 𝑦𝑝𝑚 , 𝑧𝑝 = 𝑧𝑝𝑚 and 𝛼 = 𝛼1 = 𝛼𝑚 + 180°
𝑱𝑝 = 𝐽𝑝1 𝒊𝑚 + 𝐽𝑝2 𝒋𝑚 + 𝐽𝑝3 𝒌𝑚 (4.4.1-14)
Where:
−𝑀1𝑞 𝑓1𝑞 [cos 𝛼𝑚

𝑞 𝑞 𝑞
+ tan(𝛼𝑚 + 𝛼) sin 𝛼𝑚 ]
𝐽𝑝1 = { 𝑑𝑀12 𝑀1𝑞 sin 𝛼𝑚
𝑞
𝑞 𝑞 𝑞 𝑞 },
+ 2 (𝑦𝑝𝑚 cos 𝛼𝑚 − 𝑧𝑝𝑚 sin 𝛼𝑚 )
𝑑𝜀1 𝑀12 sin 𝛼
𝑞 𝑞
𝐽𝑝2 = −𝑀1𝑞 𝑧𝑝𝑚
𝑞 𝑞 𝑞
− 𝑓1𝑞 ) cos 𝛼𝑚
𝑞
sin 𝛼𝑚 − 2 sin 𝛼 (𝑥𝑝𝑚 ,
𝑑𝜀1 𝑀12
𝑞 𝑞
𝐽𝑝3 = 𝑀1𝑞 𝑦𝑝𝑚
𝑞 𝑞 𝑞
− 𝑓1𝑞 ) sin 𝛼𝑚
𝑞
sin 𝛼𝑚 + 2 sin 𝛼 (𝑥𝑝𝑚 . }
𝑑𝜀1 𝑀12
𝑞 𝑞 𝑞
Here: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are calculated by expression (4.4.1-1).
~366 ~
B. Without Tilt Device
𝑱𝑝 = 𝐽𝑝1 𝒊𝑚 + 𝐽𝑝2 𝒋𝑚 + 𝐽𝑝3 𝒌𝑚 (4.4.1-15)

𝑞 𝑞 𝑞 𝑞
Where: 𝛼𝑚 is calculated by expression (4.2.2-14). 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are decided by expression
(4.4.1-7) and

𝑞 𝑞 𝑞
𝐽𝑝1 = { 𝑞
𝑞
− 2 sin 𝛼 (−𝑦𝑝𝑚 cos 𝛼𝑚 + 𝑧𝑝𝑚 sin 𝛼𝑚 )
𝑑𝜀1 𝑀12
𝑞 𝑞
𝑞 𝑞 𝑞
𝑞
𝑑𝜀1 𝑀12
𝑞 𝑞
𝑞 𝑞 𝑞
𝑞
𝑑𝜀1 𝑀12
A. With Tilt Device
With consideration of expression (4.4.1-13), 𝐷𝑝 and 𝐸𝑝 are calculated by expression (1.5.2-11)
𝒗12
𝑝
𝐷𝑝 = {|𝒗12
𝑝 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ]} ∙ |𝒗12 |
𝑝
[(1 − 𝑀1𝑞 cos 𝛼𝑚

𝑞
)𝒌𝑚 − 𝑀1𝑞 sin 𝛼𝑚 𝑞
12
𝒋𝑚 ] 𝒗12 𝑝
= 𝐾𝜆 |𝒗𝑝 | − { 𝑞 𝑞 𝑞 } ∙ |𝒗12|
12 𝑞
[𝐶𝑝𝑚 𝑀1𝑞 sin 𝛼𝑚
𝑞
+ (1 − 𝑀1𝑞 cos 𝛼𝑚 𝑞 𝑞
12 1 −𝑣𝑝𝑥 )𝐵𝑝𝑚 ] (4.4.1-16)
= 𝐾𝜆 |𝒗𝑝 | − |𝒗12| { 12 𝑞}
+𝑣𝑝𝑦 (1 − 𝑀1𝑞 cos 𝛼𝑚𝑞
𝑝 )𝐴𝑞𝑝𝑚 + 𝑣𝑝𝑧
12 𝑞
𝐴𝑝𝑚 𝑀1𝑞 sin 𝛼𝑚
𝒗12
𝑝
𝐸𝑝 = |𝒗12𝑝 |𝐺𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12 |
𝑝
1 𝑞 𝑞
= |𝒗12
𝑝 |𝐺𝜆 + |𝒗12 |
12
)𝑣𝑝𝑧 ].
𝑝 }
𝑞
is decided by expression (4.2.2-10). 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚
𝑞 𝑞
Where: 𝛼𝑚 and 𝐶𝑝𝑚 are calculated by expression
(4.4.1-1). 𝒗12
𝑝 is determined by expression (4.4.1-3). 𝐾𝜆 and 𝐺𝜆 is calculated by expression
(4.4.1-4).
~367 ~
𝒗12
𝑝
𝐷𝑝 = {|𝒗12
𝑝 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ]} ∙ |𝒗12 |
𝑝
12 𝑞
[𝐶𝑝𝑚 𝑀1𝑞 sin 𝛼𝑚
𝑞
+ (1 − 𝑀1𝑞 cos 𝛼𝑚
𝑞 𝑞
1 −𝑣𝑝𝑥 )𝐵𝑝𝑚 ]
= 𝐾𝜆 |𝒗12
𝑝 |− 12 { 12 𝑞
|𝒗𝑝 | +𝑣 (1 − 𝑀 cos 𝛼 )𝐴 𝑞 𝑞 12 𝑞 𝑞 𝑞 },
𝑝𝑦 1 𝑚 𝑝𝑚 + 𝑣𝑝𝑧 𝐴𝑝𝑚 𝑀1 sin 𝛼𝑚 (4.4.1-17)
𝒗12
𝑝
𝐸𝑝 = |𝒗12
𝑝 |𝐺1𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12 |
𝑝
1 𝑞 𝑞
= |𝒗12
𝑝 |𝐺𝜆 + |𝒗12 |
12
)𝑣𝑝𝑧 ].
𝑝 }
𝑞
𝑞 𝑞
(4.4.1-7). 𝒗12
(4.4.1-10).
A. With Tilt Device

𝒗𝟏𝟐 𝒗𝟏𝟐 𝒗𝟏𝟐

𝒆 = (𝜃𝜆𝑒 𝑵𝑞𝑐𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑒 + (𝑵𝑞𝑐𝑝 × |𝒗𝟏𝟐|) sin 𝜃𝜆𝑒
𝒑 𝒑 𝒑
(4.4.1-18)
𝒑 𝒑 𝒑
Where: 𝑵𝑞𝑐𝑝 is calculated by expression (4.4.1-1). 𝒗12

𝑝 is decided by expression (4.4.1-3).
𝐷𝑝
𝐸𝑝
cos 𝜃𝜆𝑒 = ,
𝒈 = 𝑵𝑞𝑐𝑝 × 𝒆. }
Then, curvatures of cutter surface 𝐴 at point 𝑃 in directions of 𝒆 and 𝒈 are given by application
of expression (1.2.1-23), that is,

(4.4.1-19)
𝐺𝑔 = −𝐺𝑒 . }
~ 368 ~
Where: 𝐾𝜆 and 𝐺𝜆 are decided by expression (4.4.1-4). 𝐾∆ is calculated by expression (4.4.1-6).

𝐷𝑝
𝐸𝑝
cos 𝜃𝜆𝑒 = , (4.4.1-20)
𝒈 = 𝑵𝑞𝑐𝑝 × 𝒆. }
Then, curvatures of cutter surface 𝐴 at point 𝑃 in directions of 𝒆 and 𝒈 are given by application

(4.4.1-21)
𝐺𝑔 = −𝐺𝑒 . }
Where: 𝐾𝜆 and 𝐺𝜆 are decided by expression (4.4.1-10) and 𝐾∆ is calculated by expression
(4.4.1-12).

𝝉 = (𝜃𝑒𝜏 𝑵𝑞𝑐𝑝 ) ⊗ 𝒆 = cos 𝜃𝑒𝜏 𝒆 + sin 𝜃𝑒𝜏 𝑵𝑞𝑐𝑝 × 𝒆 (4.4.1-22)

} (4.4.1-23)
Where: 𝐾𝑒 and 𝐾𝑔 are calculated by expression (4.4.1-19) for the case of tilt device and
Therefore, curvature of 𝑞𝑡ℎ tooth profile of workpiece 1 in any tangent direction 𝝉 is derived by
~ 369 ~
𝐾1𝜏 = 𝑞 − 𝐾𝜏 ,
𝐷𝑝 |𝒗12
𝒑 |+𝑱𝑝 ∙𝑵𝑐𝑝
} (4.4.1-24)
𝐺1𝜏 = 𝐺𝜏 − 𝑞 .
𝐷𝑝 |𝒗12
Where: 𝑵𝑞𝑐𝑝 is decided by expression (4.4.1-1) for the case of tilt device and expression (4.4.1-7)
for the case of no tilt device. 𝑱𝑝 is expressed in formular (4.4.1-14) for the case of tilt device
and expression (4.4.1-15) for the case of no tilt device. 𝐷𝑝 and 𝐸𝑝 are decided by expression
(4.4.1-16) for the case of tilt device and expression (4.4.1-17) for the case of no tilt device. 𝐾𝜏
and 𝐺𝜏 is determined by expression (4.4.1-23).

Tooth profile of 𝑞𝑡ℎ tooth of workpiece 2 is manufactured by cutter surface identical to that for
tooth profile of 𝑞𝑡ℎ tooth of workpiece 1 with opposite direction from void to entity. Therefore,
unit normal 𝑵𝑞′𝑐𝑝 to cutter surface 𝐴 for workpiece 2 is as follow:
𝑵𝑞′ 𝑞
𝑐𝑝 = −𝑵𝑐𝑝 (4.4.2-1)
for the case of no tilt device.
for the case of no tilt device.

1) With Tilt Device
Velocity of point 𝑹𝑞𝑐𝑝 on cutter surface is as follow:
𝑑𝜎
𝒗𝑐 = 𝒌𝑚 × 𝑹𝑞𝑐𝑝 + ( 𝑑𝜀 0) 𝒌𝑚 (4.4.2-2)
0 𝑞
Where: 𝑹𝑞𝑐𝑝 is expressed in expression (4.4.1-1).
Corresponding to point 𝑹𝑞𝑐𝑝 on cutter surface, velocity of point 𝑃(𝑹𝑞𝑝 ) on workpiece 2 is as

follow:
~ 370 ~
𝑑𝜀
𝒗𝑞𝑝 = (𝑑𝜀2 ) 𝝎2 × (𝑹𝑞𝑐𝑝 − 𝑓2𝑞 𝒊𝑚 ) (4.4.2-3)
0 𝑞
Where: 𝝎2 = − sin(𝛼𝑚 + 𝛼) 𝒋𝑚 − cos(𝛼𝑚 + 𝛼) 𝒌𝑚 .

𝑝 of cutter surface with respect to workpiece 2 at point 𝑃 is given as follow:
𝑞
𝒗12 12 12 12
𝑑𝜀 𝑑𝜀 𝑑𝜎
= [𝒌𝑚 − (𝑑𝜀2) 𝝎2 ] × 𝑹𝑞𝑐𝑝 + (𝑑𝜀2) 𝑓2𝑞 𝝎2 × 𝒊𝑚 + ( 𝑑𝜀 0) 𝒌𝑚
0 𝑞 0 𝑞 0 𝑞
𝑑𝜀
𝑞 𝑞 𝑑𝜀
{(𝑑𝜀2 ) 𝑧𝑝𝑚 sin(𝛼𝑚 + 𝛼) − [1 + (𝑑𝜀2 ) cos(𝛼𝑚 + 𝛼)] 𝑦𝑝𝑚 } 𝒊𝑚
0 𝑞 0 𝑞 (4.4.2-4)
𝑞 𝑑𝜀 𝑑𝜀
= + {[1 + (𝑑𝜀2) cos(𝛼𝑚 + 𝛼)] 𝑥𝑝𝑚 − (𝑑𝜀2 ) 𝑓2𝑞 cos(𝛼𝑚 + 𝛼)} 𝒋𝑚
0 𝑞 0 𝑞
𝑑𝜎 𝑞 𝑑𝜀
+ [(𝑑𝜀 0) − (𝑑𝜀2 ) (𝑥𝑝𝑚 − 𝑓2𝑞 ) sin(𝛼𝑚 + 𝛼)] 𝒌𝑚
{ 0 𝑞 0 𝑞 }
𝑞 𝑑𝜀 𝑑𝜎
, 𝑓2𝑞 , 𝑀2𝑞 = (𝑑𝜀2 ) and (𝑑𝜀 0) are calculated by expression (4.2.2-12). 𝑥𝑝𝑚
𝑞 𝑞
Where: 𝛼𝑚 , 𝑦𝑝𝑚 and
0 𝑞 0 𝑞
𝑞
𝑧𝑝𝑚 are determined by (4.4.1-1) and
= 𝑀2𝑞 𝑧𝑝𝑚
𝑞
sin(𝛼𝑚 + 𝛼) − [1 + 𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑦𝑝𝑚
12 𝑞
𝑣𝑝𝑥 ,
= [1 + 𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑥𝑝𝑚
𝑞
12
𝑣𝑝𝑦 − 𝑀2𝑞 𝑓2𝑞 cos(𝛼𝑚 + 𝛼) ,
𝑑𝜎
= ( 𝑑𝜀 0 ) − 𝑀2𝑞 (𝑥𝑝𝑚
𝑞
12
𝑣𝑝𝑧 − 𝑓2𝑞 ) sin(𝛼𝑚 + 𝛼)
0 𝑞 }
𝒗12
𝑝
𝑝
by an angle ′
𝜃𝜁𝜆 about unit normal 𝑵𝑞′
𝑐𝑝 to cutter surface, that is,
𝒗12
= 𝝀 = (𝜃𝜁𝜆 𝑵𝑞′
𝑝 𝑞′
|𝒗12 𝑐𝑝 ) ⊗ 𝜻𝑝 = cos 𝜃𝜁𝜆 𝜻𝑝 + sin 𝜃𝜁𝜆 𝑵𝑐𝑝 × 𝜻𝑝 (4.4.2-5)
𝑝 |
Where: 𝜻𝑝 is calculated by expression (4.4.1-2). 𝑵𝑞′

𝑐𝑝 is calculated by expression (4.4.2-1).
Then,
𝒗12
𝑝
cos 𝜃𝜁𝜆 = |𝒗12| ∙ 𝜻𝑝 ,
𝑝
𝒗12 ′
} (4.4.2-6)
sin 𝜃𝜁𝜆 = |𝒗12| ∙ (𝑵𝑞𝑐𝑝 × 𝜻𝑝 ) .
𝑝
~ 371 ~
Where: 𝒗12
𝑝 is calculated by expression (4.4.2-4).
Application of expression (1.2.1-23) gives curvature of cutter surface at point 𝑃 in direction of

𝒗12
𝑝
relative velocity |𝒗12| = 𝝀, that is,
𝑝
cos ∅𝑐
𝐾𝜆 = 𝐾𝑞 sin2 𝜃𝜁𝜆 = − 𝑟 +𝑠 sin2 𝜃𝜁𝜆 ,
cos ∅𝑐
} (4.4.2-7)
𝐺𝜆 = 𝐾𝑞 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 = − 𝑟 +𝑠 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .
Where: 𝐾𝑞 is calculated by expression (3.5.1-7). cos 𝜃𝜁𝜆 and sin 𝜃𝜁𝜆 are determined by
𝒗12
𝑝
Also, curvature of cutter surface at point 𝑃 in direction of ∆= 𝑵′𝑝 × |𝒗12| is as follow,
𝑝
cos ∅𝑐
cos ∅𝑐
} (4.4.2-8)
𝐺∆ = −𝐾𝑞 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 = 𝑟 +𝑠 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .
2) Without Tilt Device

𝑝 of cutter surface with respect to workpiece 2 at point 𝑃 is given as follow:
𝑞
𝒗12 12 12 12
𝑑𝜀 𝑞 𝑞 𝑑𝜀
{(𝑑𝜀2 ) 𝑧𝑝𝑚 sin(𝛼𝑚 + 𝛼) − [1 + (𝑑𝜀2 ) cos(𝛼𝑚 + 𝛼)] 𝑦𝑝𝑚 } 𝒊𝑚
0 𝑞 0 𝑞
𝑑𝜀2 𝑑𝜀2
(4.4.2-9)
𝑞
= + {[1 + (𝑑𝜀 ) cos(𝛼𝑚 + 𝛼)] 𝑥𝑝𝑚 − (𝑑𝜀 ) 𝑓2𝑞 cos(𝛼𝑚 + 𝛼)} 𝒋𝑚
0 𝑞 0 𝑞
𝑑𝜎 𝑑𝜀𝑞
+ [( 𝑑𝜀 0) − (𝑑𝜀2 ) (𝑥𝑝𝑚 − 𝑓2𝑞 ) sin(𝛼𝑚 + 𝛼)] 𝒌𝑚
{ 0 𝑞 0 𝑞 }
𝑞 𝑑𝜀 𝑑𝜎
, 𝑓2𝑞 , 𝑀2𝑞 = (𝑑𝜀2 ) and (𝑑𝜀 0 ) are calculated by expression (4.2.2-14). 𝑥𝑝𝑚
𝑞 𝑞
Where: 𝛼𝑚 , 𝑦𝑝𝑚 and
0 𝑞 0 𝑞
𝑞
𝑧𝑝𝑚 are determined by (4.4.1-7).
= 𝑀2𝑞 𝑧𝑝𝑚
𝑞
sin(𝛼𝑚 + 𝛼) − [1 + 𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑦𝑝𝑚
12 𝑞
𝑣𝑝𝑥 ,
= [1 + 𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑥𝑝𝑚
𝑞
12
𝑣𝑝𝑦 − 𝑀2𝑞 𝑓2𝑞 cos(𝛼𝑚 + 𝛼) ,
𝑑𝜎
= ( 𝑑𝜀 0 ) − 𝑀2𝑞 (𝑥𝑝𝑚
𝑞
12
𝑣𝑝𝑧 − 𝑓2𝑞 ) sin(𝛼𝑚 + 𝛼)
0 𝑞 }
~ 372 ~
Then,
𝒗12
𝑝
cos 𝜃𝜁𝜆 = |𝒗12| ∙ 𝜻𝑝 ,
𝑝
𝒗12 ′
} (4.4.2-10)
(𝑵𝑞𝑐𝑝
𝑝
sin 𝜃𝜁𝜆 = |𝒗12
∙ × 𝜻𝑝 ) .
𝑝 |
Where: 𝑵𝑞′ 𝑞 12
𝑐𝑝 = −𝑵𝑐𝑝 is calculated by expression (4.4.1-7). 𝒗𝑝 is determined by expression
(4.4.2-9).
Application of expression (1.2.1-23) gives curvature of cutter surface at point 𝑃 in direction of

𝒗12
𝑝
relative velocity |𝒗12| = 𝝀, that is,
𝑝
cos ∅𝑐
cos ∅𝑐
} (4.4.2-11)
Where: cos 𝜃𝜁𝜆 and sin 𝜃𝜁𝜆 are determined by expression (4.4.2-10).
𝒗12
𝑝
Also, curvature of cutter surface at point 𝑃 in direction of ∆= 𝑵′𝑝 × |𝒗12| is as follow,
𝑝
cos ∅𝑐
cos ∅𝑐
} (4.4.2-12)
𝐺∆ = −𝐾𝑞 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 = 𝑟 +𝑠 sin 𝜃𝜁𝜆 cos 𝜃𝜁𝜆 .
Where: cos 𝜃𝜁𝜆 and sin 𝜃𝜁𝜆 are determined by expression (4.4.2-10).

A. With Tilt Device
In manufacturing process of tooth profile of workpiece 2, motion conditions are as follow:

𝑀 = 𝑀2𝑞 = (𝑑𝜀2 ) = 𝑑𝑀12 𝑀1 sin(𝛼𝑚 +𝛼)
, = = ,
0 𝑞 sin 𝛼 𝑑𝜀1 𝑑𝜀0 𝑑𝜀1 sin 𝛼
𝑑𝑓 𝑑ℎ 𝑑2 𝑓 𝑑2 ℎ 𝑑𝜎1 𝑑𝜎
= (𝑑𝜀 0) = −𝑓1𝑞 tan(𝛼𝑚
𝑞
𝑓 = 𝑓2𝑞 , ℎ = 𝑑𝜀1 = 𝑑𝜀1 = 𝑑𝜀12
= 𝑑𝜀12
= 0, 𝑑𝜀1 0
+ 𝛼) , (4.4.2-13)
𝑞
𝑑𝜎2 𝑑2 𝜎1 𝑑2 𝜎2
= = = 0, 𝝎1 = 𝒌𝑚 , 𝝎2 = − sin(𝛼𝑚 + 𝛼) 𝒋𝑚 − cos(𝛼𝑚 + 𝛼) 𝒌𝑚 .}
~ 373 ~
𝑞 𝑞 𝑞 𝑞
Where: 𝛼𝑚 , 𝑓1 , 𝑓2 and 𝑀1 are calculated by expression (4.2.2-12).

𝑞 𝑞 𝑞
consideration 𝑥𝑝 = 𝑥𝑝𝑚 , 𝑦𝑝 = 𝑦𝑝𝑚 , 𝑧𝑝 = 𝑧𝑝𝑚 and 𝛼 = 𝛼2
𝑱𝑝 = 𝐽𝑝1 𝒊𝑚 + 𝐽𝑝2 𝒋𝑚 + 𝐽𝑝3 𝒌𝑚 (4.4.2-14)
Where:
𝑀2𝑞 [𝑓2𝑞 cos(𝛼𝑚

𝑞
+ 𝛼) + 𝑓1𝑞 tan(𝛼𝑚
𝑞 𝑞
+ 𝛼) sin(𝛼𝑚 + 𝛼)]
𝐽𝑝1 = { 𝑑𝑀12
𝑞 𝑞 𝑞
𝑀 sin(𝛼 +𝛼) 𝑞 𝑞 𝑞 𝑞 },
+ 𝑑𝜀 1𝑀2 sin𝑚𝛼 [𝑦𝑝𝑚 cos(𝛼𝑚 + 𝛼) − 𝑧𝑝𝑚 sin(𝛼𝑚 + 𝛼)]
1 12
𝑞 𝑞 𝑞
𝑑𝑀12 𝑀1 sin(𝛼𝑚 +𝛼)
𝑀2𝑞 𝑧𝑝𝑚
𝑞 𝑞 𝑞
− 𝑓2𝑞 ) cos(𝛼𝑚
𝑞
𝐽𝑝2 = sin(𝛼𝑚 + 𝛼) − 2 sin 𝛼 (𝑥𝑝𝑚 + 𝛼)
𝑑𝜀1 𝑀12
𝑞 𝑞 𝑞
𝐽𝑝3 = −𝑀2𝑞 𝑦𝑝𝑚
𝑞 𝑞 𝑞
− 𝑓2𝑞 ) sin 𝛼(𝛼𝑚
𝑞
sin(𝛼𝑚 + 𝛼) + 2 sin 𝛼 (𝑥𝑝𝑚 + 𝛼) .}
𝑑𝜀1 𝑀12
𝑞 𝑞 𝑞

𝑀 = 𝑀2𝑞 = (𝑑𝜀2 ) = 𝑑𝑀12 𝑀1 sin(𝛼𝑚 +𝛼)
, = = ,
𝑑𝑓 𝑑ℎ 𝑑2 𝑓 𝑑2 ℎ 𝑑𝜎1 𝑑𝜎0
) = −𝑓1𝑞 tan(𝛼𝑚
𝑞
𝑓 = 𝑓2𝑞 , ℎ = 𝑑𝜀1 = 𝑑𝜀1 = 𝑑𝜀12
=
𝑑𝜀12
= 0,
𝑑𝜀1
=(
𝑑𝜀0 𝑞
+ 𝛼) , (4.4.2-15)
𝑑𝜎2 𝑑2 𝜎1 𝑑2 𝜎2
= = = 0, 𝝎1 = 𝒌𝑚 , 𝝎2 = − sin(𝛼𝑚 + 𝛼) 𝒋𝑚 − cos(𝛼𝑚 + 𝛼) 𝒌𝑚 .}
𝑞
Where: 𝛼𝑚 , 𝑓1𝑞 , 𝑓2𝑞 and 𝑀1𝑞 are calculated by expression (4.2.2-15).

𝑞 𝑞 𝑞
consideration 𝑥𝑝 = 𝑥𝑝𝑚 , 𝑦𝑝 = 𝑦𝑝𝑚 , 𝑧𝑝 = 𝑧𝑝𝑚 and 𝛼 = 𝛼2
𝑱𝑝 = 𝐽𝑝1 𝒊𝑚 + 𝐽𝑝2 𝒋𝑚 + 𝐽𝑝3 𝒌𝑚 (4.4.2-16)
Where:
~ 374 ~
𝑀2 [𝑓2 cos(𝛼𝑚 + 𝛼) + 𝑓1 tan(𝛼𝑚 + 𝛼) sin(𝛼𝑚 + 𝛼)]
𝐽𝑝1 = { 𝑑𝑀12
𝑞 𝑞 𝑞
𝑀 sin(𝛼 +𝛼) 𝑞 𝑞 𝑞 𝑞 },
+ 𝑑𝜀 1𝑀2 sin𝑚𝛼 [𝑦𝑝𝑚 cos(𝛼𝑚 + 𝛼) − 𝑧𝑝𝑚 sin(𝛼𝑚 + 𝛼)]
1 12
𝑞 𝑞 𝑞
𝑞 𝑞 𝑞
− 𝑓2𝑞 ) cos(𝛼𝑚
𝑞
𝐽𝑝2 = sin(𝛼𝑚 + 𝛼) − 2 sin 𝛼 (𝑥𝑝𝑚 + 𝛼)
𝑑𝜀1 𝑀12
𝑞 𝑞 𝑞
𝑞 𝑞 𝑞
− 𝑓2𝑞 ) sin 𝛼(𝛼𝑚
𝑞
sin(𝛼𝑚 + 𝛼) + 2 sin 𝛼 (𝑥𝑝𝑚 + 𝛼) .}
𝑑𝜀1 𝑀12
𝑞 𝑞 𝑞
A. With Tilt Device
With consideration of expression (4.4.2-13) and 𝑵1𝑝 = 𝑵𝑞′ 𝑞

𝑐𝑝 = −𝑵𝑐𝑝 , 𝐷𝑝 and 𝐸𝑝 are calculated
by expression (1.5.2-11) as follow:
𝒗12
𝑝
𝐷𝑝 = {|𝒗12
𝑝 |𝛀𝜆 × 𝑵1𝑝 − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ]} ∙ |𝒗12 |
𝑝
𝑞
𝑀2𝑞 sin(𝛼𝑚 + 𝛼) − 𝐵𝑝𝑚
𝑞
{𝐶𝑝𝑚 [1+𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]}𝑣𝑝𝑥 12
= 𝐾𝜆 |𝒗12
𝑝 |+ { 𝑞 },
+𝐴𝑝𝑚 [1+𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑣𝑝𝑦12 12 𝑞
− 𝑣𝑝𝑧 𝐴𝑝𝑚 𝑀2𝑞 sin(𝛼𝑚 + 𝛼) (4.4.2-17)
𝒗12
𝑝
𝐸𝑝 = |𝒗12
𝑝 |𝐺𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12 |
𝑝
1
= |𝒗12
𝑝 |𝐺𝜆 + {𝑣 12 𝑀𝑞
|𝒗12 | 𝑝𝑦 2
sin(𝛼𝑚 + 𝛼) + [1+𝑀2𝑞 12
cos(𝛼𝑚 + 𝛼)]𝑣𝑝𝑧 }.
𝑝 }
𝑞
𝑞 𝑞
(4.4.1-1). 𝒗12
(4.4.2-7).

𝑞
𝑀2𝑞 sin(𝛼𝑚 + 𝛼) − 𝐵𝑝𝑚
𝑞
{𝐶𝑝𝑚 [1+𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]}𝑣𝑝𝑥
12
𝐷𝑝 = 𝐾𝜆 |𝒗12
𝑝 | +{ },
+𝐴𝑞𝑝𝑚 [1+𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑣𝑝𝑦
12 12 𝑞
− 𝑣𝑝𝑧 𝐴𝑝𝑚 𝑀2𝑞 sin(𝛼𝑚 + 𝛼) (4.4.2-18)
1 𝑞 𝑞
𝐸𝑝 = |𝒗12
𝑝 |𝐺𝜆 + [𝑣 12 𝑀
|𝒗12 | 𝑝𝑦 2
sin(𝛼𝑚 + 𝛼) + [1+𝑀2 cos(𝛼𝑚 + 12
𝛼)]𝑣𝑝𝑧 ].
𝑝 }
𝑞
𝑞 𝑞
(4.4.1-7). 𝒗12
𝑝 is determined by expression (4.4.2-9). 𝐾𝜆 and 𝐺1𝜆 is calculated by expression
(4.4.2-11).
~ 375 ~
A. With Tilt Device

𝒗𝟏𝟐 𝒗𝟏𝟐 𝒗𝟏𝟐

𝒆 = (𝜃𝜆𝑒 𝑵𝑞′
𝒑 𝒑 𝑞′ 𝒑
𝑐𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑒 + (𝑵𝑐𝑝 × |𝒗𝟏𝟐 |) sin 𝜃𝜆𝑒 (4.4.2-19)
𝒑 𝒑 𝒑
Where: 𝑵𝑞′ 𝑞 12
𝑐𝑝 = −𝑵𝑐𝑝 is calculated by expression (4.4.1-7). 𝒗𝑝 is decided by expression (4.4.2-
4).
𝐷𝑝
𝐸𝑝
cos 𝜃𝜆𝑒 = , (4.4.2-20)
𝒈 = 𝑵𝑞′
𝑐𝑝 × 𝒆. }

(4.4.2-21)
𝐺𝑔 = −𝐺𝑒 . }
Where: 𝐾𝜆 and 𝐺𝜆 are decided by expression (4.4.1-4) and 𝐾∆ is calculated by expression (4.4.1-
6). sin 𝜃𝜆𝑒 and cos 𝜃𝜆𝑒 are determined by expression (4.4.2-20).

𝐷𝑝
𝐸𝑝
cos 𝜃𝜆𝑒 = , (4.4.2-22)
𝒈 = 𝑵𝑞′
𝑐𝑝 × 𝒆. }
~ 376 ~

(4.4.2-23)
𝐺𝑔 = −𝐺𝑒 . }
Where: 𝐾𝜆 and 𝐺𝜆 are decided by expression (4.4.1-10) and 𝐾∆ is calculated by expression
(4.4.1-12). sin 𝜃𝜆𝑒 and cos 𝜃𝜆𝑒 are determined by expression (4.4.2-22).

𝝉 = (𝜃𝑒𝜏 𝑵𝑞′ 𝑞
𝑐𝑝 ) ⊗ 𝒆 = cos 𝜃𝑒𝜏 𝒆 + sin 𝜃𝑒𝜏 𝑵𝑐𝑝 × 𝒆 (4.4.2-24)
Thus, curvature of cutter surface at point 𝑃 in direction of 𝝉 is generated as follow:

} (4.4.2-25)
Where: 𝐾𝑒 and 𝐾𝑔 are calculated by expression (4.4.2-21) for the case of tilt device and
Therefore, curvature of 𝑞𝑡ℎ tooth profile of workpiece 2 in any tangent direction 𝝉 is derived by

𝐾2𝜏 = 𝑞 − 𝐾𝜏 ,
𝐷𝑝 |𝒗12
} (4.4.2-26)
𝐺2𝜏 = 𝐺𝜏 − 𝑞 .
𝐷𝑝 |𝒗12
Where: 𝑱𝑝 is expressed in formular (4.4.2-14) for the case of tilt device and expression (4.4.2-
16) for the case of no tilt device. 𝑵𝑞′ 𝑞
𝑐𝑝 = −𝑵𝑐𝑝 is decided by expression (4.4.1-1) for the case of
tilt device and expression (4.4.1-7) for the case of no tilt device. 𝐾𝜏 and 𝐺𝜏 is determined by
~ 377 ~
Chapter 5
Helical Gear Set with Varied Transmission Ratio between Crossed

Rotating Axes
4.5.1 Index Curve

Corresponding to conjugate motion defined by expressions (4.1.1-1) and (4.1.1-2), expression
(4.1.1-3) shows that screw axis at instant rotating angle 𝜀1 intersects mutual perpendicular line,
i.e., 𝒊 – axis, between two rotating axes of workpieces 1 & 2. Therefore, in the case of large
offset 𝑓 between two rotating axes, intersecting point of co-perpendicular line, i.e., 𝒊 – axis,
with screw axis 𝑹𝑎𝑝 at instant rotating angle 𝜀1 can be also used as design reference point.
Intersecting point 𝑹𝑎𝑝 at instant rotating angle 𝜀1 is decided by application of expression (4.1.1-
3) as follow:
𝑹𝑎𝑝 = 𝑥𝑎𝑝 𝒊 + 𝑦𝑎𝑝 𝒋 + 𝑧𝑎𝑝 𝒌 (4.5.1-1)
𝑀𝑓(𝑀+cos 𝛼)
Where: 𝑥𝑎𝑝 = 𝐸 = 1+2𝑀 cos 𝛼+𝑀2, 𝑦𝑎𝑝 = 𝑧𝑎𝑝 = 0.
2 Index Curve of Workpiece 1

Index curve of workpiece 1 is determined by updating expression (4.1.1-5) as follow:
𝑹𝑎 = 𝑥𝑎 𝒊 + 𝑦𝑎 𝒋 + 𝑧𝑎 𝒌,
𝑀𝑓(𝑀+cos 𝛼) 𝑑𝐸 2𝑀+cos 𝛼+𝑀2 cos 𝛼 𝑑𝑀
𝐸 = 1+2𝑀 cos 𝛼+𝑀2 , = (1+2𝑀 cos 𝛼+𝑀2 )2 𝑑𝜀1
𝑓
𝑑𝜀1
(4.5.1-2)
𝑥𝑎 = 𝐸 cos 𝜀1 , 𝑦𝑎 = −𝐸 sin 𝜀1 , 𝑧𝑎 = 0,
𝑑𝑥𝑎 𝑑𝐸 𝑑𝑦𝑎 𝑑𝐸 𝑑𝑧𝑎
= 𝑑𝜀 cos 𝜀1 − 𝐸 sin 𝜀1 , = − 𝑑𝜀 sin 𝜀1 − 𝐸 cos 𝜀1 , = 0.
𝑑𝜀1 1 𝑑𝜀1 1 𝑑𝜀1 }
Where: 𝜀1 is independent parameter.
𝑑𝑠𝑎 = √( 𝑑𝜀𝑎) + ( 𝑑𝜀𝑎) 𝑑𝜀1 (4.5.1-3)
1 1
~ 378 ~
3 Index Curve of Workpiece 2
Similarly, index curve of workpiece 2 is given by application of expression (4.1.1-6) as follow:
𝑹′𝑎 = 𝑥𝑎′ 𝒊′ + 𝑦𝑎′ 𝒋′ + 𝑧𝑎′ 𝒌′ (4.5.1-4)
Where:
𝑑𝜀
𝑥𝑎′ = (𝐸 − 𝑓) cos 𝜀2 , 𝑦𝑎′ = (𝐸 − 𝑓) sin 𝜀2 , 𝑧𝑎′ = 0, 𝑀 = 𝑑𝜀 ,
2
1
′
𝑑𝑥𝑎 𝑑𝐸 𝑑𝑦𝑎′ 𝑑𝐸 𝑑𝑧𝑎′
}
= 𝑑𝜀 cos 𝜀2 − 𝑀(𝐸 − 𝑓) sin 𝜀2 , = 𝑑𝜀 sin 𝜀2 + 𝑀(𝐸 − 𝑓) cos 𝜀2 , = 0.
𝑑𝜀1 1 𝑑𝜀1 1 𝑑𝜀1
2 2
𝑑𝑥 ′ 𝑑𝑦 ′
𝑑𝑠𝑎′ = √( 𝑑𝜀𝑎) + ( 𝑑𝜀𝑎) 𝑑𝜀1 (4.5.1-5)
1 1
4.5.2 Pitch Angle, Spiral Angle and Pressure Angle

1 Unit Normal to Gear Blank Surface of Workpiece 1
With consideration of 𝑦𝑝 = 𝑧𝑝 = 𝑦𝑎𝑝 = 𝑧𝑎𝑝 = 0 in expression (4.1.2-4), unit normal 𝑵1𝑏 to gear
blank surface of workpiece 1 is resulted from expression (4.1.2-4) as follow:
𝒗𝑝 ×𝒗′𝑝
𝑵1𝑏 = ± |𝒗 ′ = 𝐴1𝑏 𝒊 + 𝐵1𝑏 𝒋 + 𝐶1𝑏 𝒌 (4.5.2-1)
𝑝 ×𝒗𝑝 |
Where: 𝐴1𝑏 = ±1, 𝐵1𝑏 = 0 and 𝐶1𝑏 = 0.
2 Pitch Angle
Unit tangent 𝑾 to intersecting curve between gear blank surface of workpiece 1 and its axial
plane through conjugate contact point 𝑹𝑎𝑝 is calculated by application of expression (4.1.2-5)
as follow:
𝑵 ×(𝒌×𝑹𝑎𝑝 )
𝑾 = |𝑵1𝑏 = 𝑊1 𝒊 + 𝑊2 𝒋 + 𝑊3 𝒌 (4.5.2-2)
1𝑏 ×(𝒌×𝑹𝑎𝑝 )|
Where: 𝑊1 = 0, 𝑊2 = 0 and 𝑊3 = 1. 𝑹𝑎𝑝 is decided by expression (4.5.1-1).
Likewise, unit tangent 𝑾′ to intersecting curve between gear blank surface of workpiece 2 and
its axial plane through conjugate contact point 𝑹𝑎𝑝 is yielded by application of expression
~ 379 ~
𝑾′ = 𝑊1′ 𝒊′ + 𝑊2′ 𝒋′ + 𝑊3′ 𝒌′ (4.5.2-3)
Where: 𝑊1′ = 0, 𝑊2′ = 0 and 𝑊3′ = 1.
Pitch angle 𝛾1 of workpiece 1 is derived as follow:
𝛾1 = cos −1(|𝒌 ∙ 𝑾|) = cos −1 (|𝑊3 |) = 0 (4.5.2-4)
Likewise, pitch angle 𝛾2 of workpiece 2 is generated as follow:
𝛾2 = cos−1 (|𝒌′ ∙ 𝑾′ |) = cos −1 (|𝑊3′ |) = 0 (4.5.2-5)
3 Spiral Angle
Relative velocity of workpiece 1 with respect to workpiece 2 at point 𝑹𝑎𝑝 = 𝑥𝑎𝑝 𝒊 is given by
𝒗12 ′ 12 12 12
𝑝 = 𝒗𝑝 − 𝒗𝑝 = 𝑣𝑝𝑥 𝒊 + 𝑣𝑝𝑦 𝒋 + 𝑣𝑝𝑦 𝒌 (4.5.2-6)
Where: 𝑥𝑎𝑝 is decided by expression (4.5.1-1) and
12 12 12
𝑣𝑝𝑥 = 0, 𝑣𝑝𝑦 = 𝑥𝑎𝑝 + 𝑀(𝑥𝑎𝑝 − 𝑓) cos 𝛼 , 𝑣𝑝𝑧 = −𝑀(𝑥𝑎𝑝 − 𝑓) sin 𝛼 ,
2 2 }
|𝒗12
𝑝 | = √(𝑥𝑎𝑝 ) + 2𝑥𝑎𝑝 𝑀(𝑥𝑎𝑝 − 𝑓) cos 𝛼 + 𝑀 (𝑥𝑎𝑝 − 𝑓) .
2
Spiral angle 𝜓1 of workpiece 1 is given by expression (4.1.2-9)
𝒗12
𝑝 𝑀(𝑥𝑎𝑝 −𝑓) sin 𝛼
𝜓1 = cos −1 (𝑾 ∙ |𝒗12|) = cos −1 [ 2 2
] (4.5.2-7)
𝑝 √(𝑥𝑎𝑝 ) +2𝑥𝑎𝑝 𝑀(𝑥𝑎𝑝 −𝑓) cos 𝛼+𝑀2 (𝑥𝑎𝑝 −𝑓)
Where:
𝜋
0 ≤ 𝜓1 ≤ 𝑅𝑖𝑔ℎ𝑡 𝐻𝑎𝑛𝑑,
2
𝜋 }
≤ 𝜓1 ≤ 𝜋 𝐿𝑒𝑓𝑡 𝐻𝑎𝑛𝑑.
2
unit vector 𝒕 be defined by expression (4.1.2-11) as follow
𝒕 = (−𝜓1 𝑵1𝑏 ) ⊗ 𝑾 = cos 𝜓1 𝑾 − sin 𝜓1 𝑵1𝑏 × 𝑾 = 𝑡1 𝒊 + 𝑡2 𝒋 + 𝑡3 𝒌 (4.5.2-8)
Where: 𝑡1 = 0, 𝑡2 = − sin 𝜓1 , 𝑡3 = cos 𝜓1 .
~380 ~
𝒗12
𝑝
Likewise, spiral angle 𝜓2 of workpiece 2 is referred to as rotating angle by which |𝒗12 | is rotated
𝑝
about 𝑵2𝑏 to 𝑾′ , that is,
𝒗12
𝑝 𝑥𝑎𝑝 sin 𝛼
𝜓2 = cos−1 (𝑾′ ∙ |𝒗12|) = cos −1 [ 2 2
] (4.5.2-8)
𝑝 √(𝑥𝑎𝑝 ) +2𝑥𝑎𝑝 𝑀(𝑥𝑎𝑝 −𝑓) cos 𝛼+𝑀2 (𝑥𝑎𝑝 −𝑓)
𝜋 𝜋
For right hand gear: 0 ≤ 𝜓2 ≤ 2 and for left hand gear: 2 ≤ 𝜓2 ≤ 𝜋.
4 Pressure Angle
(𝒕×𝑱𝑝 )∙𝑵1𝑏 𝑑𝑀 (𝑥𝑎𝑝 −𝑓) cos(𝛼+𝜓1 )

tan ∅0 = − =− (4.5.2-9)
𝑱𝑝 ∙𝑵1𝑏 𝑑𝜀1 𝑀𝑓 cos 𝛼
Where: 𝑱𝑝 is calculated by expression (1.5.2-7) as follow:

𝑑𝑀
𝑱𝑝 = 𝑑𝜀 𝝎2 × (𝑹1𝑝 − 𝑙𝒑) + 𝑀𝝎2 × 𝒗𝑝 − 𝝎1 × [𝑀𝝎2 × (𝑹1𝑝 − 𝑙𝒑)]
1
𝑑𝑀 𝑑𝑀
= 𝑀𝑓 cos 𝛼 𝒊 − 𝑑𝜀 (𝑥𝑎𝑝 − 𝑓) cos 𝛼 𝒋 + 𝑑𝜀 (𝑥𝑎𝑝 − 𝑓) sin 𝛼 𝒌
1 1
Therefore, pressure angle ∅𝑔𝑖 of convex flank of workpiece 1 is
𝑖𝑓 tan ∅0 > 0, 𝑡ℎ𝑒𝑛, ∅0 = tan−1 ∅0 , ∅𝑔𝑖 = ∅0 + ∆∅𝑔 , ∆∅𝑔 ≠ 0

} (4.5.2-10)
𝑖𝑓 tan ∅0 < 0, 𝑡ℎ𝑒𝑛, ∅𝑔𝑖 = 𝑎𝑛𝑦 𝑝𝑟𝑒𝑠𝑐𝑟𝑖𝑏𝑒𝑑 𝑣𝑎𝑙𝑢𝑒.
Pressure angle ∅𝑔𝑜 of concave flank of workpiece 1 is
𝑖𝑓 tan ∅0 < 0, 𝑡ℎ𝑒𝑛, ∅0 = 𝜋 + tan−1 ∅0 , ∅𝑔𝑜 = ∅0 + ∆∅𝑔 , ∆∅𝑔 ≠ 0

} (4.5.2-11)
𝑖𝑓 tan ∅0 > 0, 𝑡ℎ𝑒𝑛, ∅𝑔𝑜 = 𝑎𝑛𝑦 𝑝𝑟𝑒𝑠𝑐𝑟𝑖𝑏𝑒𝑑 𝑣𝑎𝑙𝑢𝑒.
4.5.3 Machine Setting Parameters

Design reference point on 𝑞th tooth of workpiece 1 in conjugate contact position is given by
𝑹𝑞𝑎𝑝 = 𝑥𝑎𝑝
𝑞
𝒊𝑞 (4.5.3-1)
~ 381 ~
𝑞 𝑀𝑓(𝑀+cos 𝛼)
𝑞 𝑞 𝑑𝜀
Where: 𝑥𝑎𝑝 = 1+2𝑀 cos 𝛼+𝑀2, 𝑦𝑎𝑝 = 𝑧𝑎𝑝 = 0. 𝑀 = (𝑑𝜀2 ) and 𝜀1,𝑞 is decided by application
1 𝜀1 =𝜀1,𝑞

𝑠 =𝑞𝑝 1
𝜀1,𝑞 = ∫𝑠 0=0 𝑑𝑠𝑎 ,
0 2 2
√(𝑑𝑥𝑎 ) +(𝑑𝑦𝑎 )
𝑑𝜀1 𝑑𝜀1

1
𝑠0 =(𝑞+ )𝑝 1
𝜀1,𝑞 = ∫ 𝑠0 =0
2 𝑑𝑠0 ,
2 2
√(𝑑𝑥𝑎 ) +(𝑑𝑦𝑎 )
𝑑𝜀1 𝑑𝜀1
}
𝑑𝑥𝑎 𝑑𝑦𝑎
Here: ( ) and ( ) are calculated by expression (4.5.1-2). 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1.
𝑑𝜀1 𝑑𝜀1
Unit normal 𝑵𝑞𝑎𝑝 to 𝑞th tooth profile of workpiece 1 at design reference point 𝑃𝑎𝑞 (𝑹𝑞𝑎𝑝 ) in
conjugate contact position is expressed as follow:
If center distance of gear set 𝑓 < 0, then,
𝑵𝑞𝑎𝑝 = (180° 𝒌𝑞 ) ⊗ {(−𝜓1𝑞 𝒊𝑞 ) ⊗ [(∅𝑞𝑔 𝒌𝑞 ) ⊗ (−𝒋𝑞 )]} = 𝐴𝑞𝑎𝑝 𝒊𝑞 + 𝐵𝑎𝑝

𝑞 𝑞
= 𝐴𝑞𝑎𝑝 𝒊𝑚 + (𝐵𝑎𝑝
cos 𝛼𝑚 + 𝐶𝑎𝑝 sin 𝛼𝑚 )𝒋𝑚 + (−𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 )𝒌𝑚 , } (4.5.3-3)
𝑞
cos 𝜓1𝑞 cos ∅𝑞𝑔 , 𝑞
𝐴𝑞𝑎𝑝 = − sin ∅𝑞𝑔 , 𝐵𝑎𝑝 = 𝐶𝑎𝑝 = cos ∅𝑞𝑔 sin 𝜓1𝑞 .
If center distance of gear set 𝑓 > 0, then,
𝑵𝑞𝑎𝑝 = (−𝜓1𝑞 𝒊𝑞 ) ⊗ [(∅𝑞𝑔 𝒌𝑞 ) ⊗ (−𝒋𝑞 )] = 𝐴𝑞𝑎𝑝 𝒊𝑞 + 𝐵𝑎𝑝

𝑞 𝑞
= 𝐴𝑞𝑎𝑝 𝒊𝑚 + (𝐵𝑎𝑝
cos 𝛼𝑚 + 𝐶𝑎𝑝 sin 𝛼𝑚 )𝒋𝑚 + (−𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 )𝒌𝑚 ,} (4.5.3-4)
𝑞
− cos 𝜓1𝑞 cos ∅𝑞𝑔 , 𝑞
𝐴𝑞𝑎𝑝 = sin ∅𝑞𝑔 , 𝐵𝑎𝑝 = 𝐶𝑎𝑝 = cos ∅𝑞𝑔 sin 𝜓1𝑞 .
Where: 𝜓1𝑞 is determined by expression (4.5.2-7) and ∅𝑞𝑔 is calculated by expression (4.5.2-10)
and (4.5.2-11)
2 Surface of Cutter
In order to avoid interference of cutter with workpiece, circular plane is used as cutter surface
instead of conical rotating surface. As shown in figure 4.5.3-1, circular plane in initial position is
𝑹𝑐 = (𝜃𝒌𝑚 )⨂(𝑟𝒊𝑚 ) = 𝑟(cos 𝜃 𝒊𝑚 + sin 𝜃 𝒋𝑚 ) (4.5.3-5)
~ 382 ~
Where: 𝜃 and 𝑟 are position parameters of point 𝑃 on circular plane and 𝑟 ≤ 𝑟0 .
𝑟0
𝑂𝑚 𝒋𝑚
𝜃𝑞 𝑟𝑞 𝑟
𝑃𝑞 𝑃0
𝒊𝑚
Figure 4.5.3-1 Circular Plane of Cutter
3 Calculation of Machine Setting Parameters
Let 𝑹𝑞𝑐 be a point 𝑃𝑞 on cutter surface corresponding to design reference point on 𝑞th tooth
of workpiece 1. When point 𝑃𝑞 reaches contact position with design reference point 𝑃𝑎𝑞 (𝑹𝑞𝑎𝑝 ),
cutter surface becomes as follow:
𝑹𝑞𝑐 = {ζ𝑞 [(Θ𝑞 𝒌𝑚 )⨂𝒊𝑚 ]}⨂[(Θ𝑞 𝒌𝑚 )⨂𝑹𝑐 ] + 𝑥𝑐𝑞 𝒊𝑚 + 𝑦𝑐𝑞 𝒋𝑚 + 𝑧𝑐𝑞 𝒌𝑚

= 𝑟𝑞 (cos 𝜃𝑞 𝒊𝑞𝑐 + sin 𝜃𝑞 𝒋𝑞𝑐 ) + 𝑥𝑐𝑞 𝒊𝑚 + 𝑦𝑐𝑞 𝒋𝑚 + 𝑧𝑐𝑞 𝒌𝑚
[𝑥𝑐𝑞 + 𝑟𝑞 (cos 𝜃𝑞 cos Θ𝑞 − sin 𝜃𝑞 cos ζ𝑞 sin Θ𝑞 )]𝒊𝑚 (4.5.3-6)
= {+[𝑦𝑐𝑞 + 𝑟𝑞 (cos 𝜃𝑞 sin Θ𝑞 + sin 𝜃𝑞 cos ζ𝑞 cos Θ𝑞 )]𝒋𝑚 }
+(𝑧𝑐𝑞 + 𝑟𝑞 sin 𝜃𝑞 sin ζ𝑞 )𝒌𝑚
𝑞
Where: ζ𝑞 is tilt angle and Θ𝑞 is swivel angle, 𝒌𝑐 is unit normal to circular plane of cutter, and
𝑥𝑐𝑞 , 𝑦𝑐𝑞 and 𝑧𝑐𝑞 are coordinate of center of circular plane of cutter.
~ 383 ~
𝑞
𝒊𝑐 = (Θ𝑞 𝒌𝑚 )⨂𝒊𝑚 = cos Θ𝑞 𝒊𝑚 + sin Θ𝑞 𝒋𝑚 ,
𝒌𝑞𝑐 = (ζ𝑞 𝒊𝑞𝑐 )⨂𝒌𝑚 = sin ζ𝑞 (sin Θ𝑞 𝒊𝑚 − cos Θ𝑞 𝒋𝑚 ) + cos ζ𝑞 𝒌𝑚 , } (4.5.3-7)
𝒋𝑞𝑐 = 𝒌𝑞𝑐 × 𝒊𝑞𝑐 = − cos ζ𝑞 sin Θ𝑞 𝒊𝑚 + cos ζ𝑞 cos Θ𝑞 𝒋𝑚 + sin ζ𝑞 𝒌𝑚 .
𝑹𝑞𝑐 = 𝑹𝑞𝑎𝑝 + 𝑓1𝑞 𝒊𝑚 ,

} (4.5.3-8)
𝒌𝑞𝑐 = 𝑵𝑞𝑎𝑝 ,
With help of expressions (4.5.3-1), (4.5.3-3) or (4.5.3-4), (4.5.3-6) and (4.5.3-7), expression
(4.5.3-8) is expanded as follow:
𝑥𝑐𝑞 + 𝑟𝑞 (cos 𝜃𝑞 cos Θ𝑞 − sin 𝜃𝑞 cos ζ𝑞 sin Θ𝑞 ) = 𝑥𝑎𝑝

𝑞
+ 𝑓1𝑞 ,
𝑦𝑐𝑞 + 𝑟𝑞 (cos 𝜃𝑞 sin Θ𝑞 + sin 𝜃𝑞 cos ζ𝑞 cos Θ𝑞 ) = 0,
𝑧𝑐𝑞 + 𝑟𝑞 sin 𝜃𝑞 sin ζ𝑞 = 0,
𝑞
(4.5.3-9)
𝑞 𝐴𝑎𝑝
tan Θ = − 𝐵𝑞 𝑞 𝑞 𝑞 ,
𝑎𝑝 cos 𝛼𝑚 +𝐶𝑎𝑝 sin 𝛼𝑚
𝑞 𝑞 𝑞 𝑞
cos ζ𝑞 = −𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 . }
There are five equations in expression (4.5.3-9) and eight unknown variables, i.e., 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 ,
𝑞 𝑞
𝑟𝑞 , 𝜃𝑞 , ζ𝑞 , Θ𝑞 , and 𝛼𝑚 . Three of them can be prescribed. Let 𝑟𝑞 , 𝜃𝑞 and 𝛼𝑚 be prescribed.
In manufacturing process, helical motion of cutter surface 𝐶 forms a generating surface 𝐺 in

reference space, tooth profiles 𝐴 & 𝐴̅ of workpiece 1 & 2 are formed by generating surface 𝐺.
Because instantaneous contact position of design reference point 𝑃𝑎𝑞 (𝑹𝑞𝑎𝑝 ) is on mutual
perpendicular line, i.e., 𝒊 – axis, between two rotating axes of workpieces 1 & 2. In order to
eliminate interference between cutter and workpiece, one of workpieces, either workpiece 1 or
workpiece 2, is enclosed by a generating surface. Therefore, offsets of workpiece 1 and 2, i.e.,
𝑓1𝑞 and 𝑓2𝑞 , are either all positive or all negative as shown in figure 4.5.3-2.
Due to expression (4.2.2-10), that is,

𝑑𝜎0
) = −𝑓1𝑞 tan(𝛼𝑚
𝑞
+ 𝛼) = −𝑓2𝑞 tan 𝛼𝑚
𝑞
(
𝑑𝜀0 𝑞
Restriction of 𝑓1𝑞 𝑓2𝑞 > 0 results in

𝑞 𝑞
tan(𝛼𝑚 + 𝛼) tan 𝛼𝑚 >0 (4.5.3-10)
𝜋 𝜋
Therefore, shaft angle 𝛼 between workpieces 1 and 2 is not equal to 2 , that is, 𝛼 ≠ ± 2 .
~ 384 ~
Workpieces 1& 2
Generating surface 𝐺 𝑓2𝑞
𝑂𝑚 𝑓1𝑞 𝒋𝑚
𝑓1𝑞
𝑓2𝑞
Workpieces 1& 2
𝒊𝑚
Figure 4.5.3-2 Offset of 𝑓1𝑞 and 𝑓2𝑞
Likewise, center of circular plane of cutter for tooth profile of workpiece 2 is as follow:
𝑞
𝒊𝑚 + 𝑦𝑐′𝑞 𝒋𝑚 + 𝑧𝑐′
⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗ 𝑞
𝑂𝑚 𝑂𝑐′ = 𝑥𝑐′ 𝒌𝑚 = ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑚 𝑂𝑐 + ⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝑂𝑐 𝑂𝑐′ (4.5.3-11)
𝑂𝑚 𝑂𝑐 = 𝑥𝑐𝑞 𝒊𝑚 + 𝑦𝑐𝑞 𝒋𝑚 + 𝑧𝑐𝑞 𝒌𝑚 and ⃗⃗⃗⃗⃗⃗⃗⃗⃗

Where: ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗ 𝑂𝑐 𝑂𝑐′ = ∆𝑥𝑐𝑞 𝒊𝑞𝑐 + ∆𝑦𝑐𝑞 𝒋𝑞𝑐 as shown in figure 4.5.3-3.
With the aid of expression (4.5.3-7), expression (4.5.3-9) gives

𝑞
𝑥𝑐′ = 𝑥𝑐𝑞 + ∆𝑥𝑐𝑞 cos Θ𝑞 − ∆𝑦𝑐𝑞 cos ζ𝑞 sin Θ𝑞 ,
𝑦𝑐′𝑞 = 𝑦𝑐𝑞 + ∆𝑥𝑐𝑞 sin Θ𝑞 + ∆𝑦𝑐𝑞 cos ζ𝑞 cos Θ𝑞 ,} (4.5.3-12)
𝑞
𝑧𝑐′ = 𝑧𝑐𝑞 + ∆𝑦𝑐𝑞 sin ζ𝑞 .
~ 385 ~
Where: ∆𝑥𝑐 and ∆𝑦𝑐 are prescribed. 𝑥𝑐 , 𝑦𝑐 , 𝑧𝑐 , ζ𝑞 and Θ𝑞 are decided by expression (4.5.3-10).
circular plane of cutter for workpiece 2
circular plane of cutter for workpiece 1 𝒋𝑞𝑐
𝑂𝑐
𝒌𝑚 𝑂𝑐′
𝒊𝑞𝑐
𝑂𝑚 𝒋𝑚
𝒊𝑚
Figure 4.5.3-3 Center of Circular Plane of Cutter
Combination of expressions (4.2.2-7), (4.2.2-8), (4.2.2-9), (4.2.2-10), (4.5.3-9) and (4.5.3-12)

generates machine setting parameters as follow:
𝑞 𝑞 𝑞 𝑞
𝑓 sin 𝛼𝑚 cos(𝛼𝑚 +𝛼) 𝑓 sin(𝛼𝑚 +𝛼) cos 𝛼𝑚 𝑑𝜎
𝑓2𝑞 = , ( 𝑑𝜀 0 ) = −𝑓1𝑞 tan(𝛼𝑚
𝑞
𝑓1𝑞 = , sin 𝛼
+ 𝛼) ,
sin 𝛼 0 𝑞
𝑑𝜀1 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼) 𝑑𝜀2 sin 𝛼𝑚 +𝑀12 sin(𝛼𝑚 +𝛼)
𝑀1𝑞 = (𝑑𝜀 ) = 𝑞 , 𝑀2𝑞 = (𝑑𝜀 ) = ,
0 𝑞 𝑀12 sin 𝛼 0 𝑞 sin 𝛼
𝑞
𝑞 𝑞 𝑞 𝑞 𝐴𝑎𝑝
ζ𝑞 = cos−1 (−𝐵𝑎𝑝 sin 𝛼𝑚 + 𝐶𝑎𝑝 cos 𝛼𝑚 ) Θ𝑞 = tan−1 (− 𝐵𝑞 𝑞 𝑞 𝑞 ), (4.5.3-13)
𝑎𝑝 cos 𝛼𝑚 +𝐶𝑎𝑝 sin 𝛼𝑚
𝑞 𝑞 𝑞
𝑥𝑐 = 𝑥𝑎𝑝 + 𝑓1 − 𝑟𝑞 (cos 𝜃𝑞 cos Θ𝑞 − sin 𝜃𝑞 cos ζ𝑞 sin Θ𝑞 ),
𝑦𝑐𝑞 = −𝑟𝑞 (cos 𝜃𝑞 sin Θ𝑞 + sin 𝜃𝑞 cos ζ𝑞 cos Θ𝑞 ), 𝑧𝑐𝑞 = −𝑟𝑞 sin 𝜃𝑞 sin ζ𝑞 ,
𝑞
𝑥𝑐′ = 𝑥𝑐𝑞 + ∆𝑥𝑐𝑞 cos Θ𝑞 − ∆𝑦𝑐𝑞 cos ζ𝑞 sin Θ𝑞 ,
𝑦𝑐′𝑞 = 𝑦𝑐𝑞 + ∆𝑥𝑐𝑞 sin Θ𝑞 + ∆𝑦𝑐𝑞 cos ζ𝑞 cos Θ𝑞 , 𝑧𝑐′
𝑞
= 𝑧𝑐𝑞 + ∆𝑦𝑐𝑞 sin ζ𝑞 . }
𝑞
Where: 𝛼𝑚 is prescribed but must satisfy expression (4.5.3-8). 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1.
~386 ~
1 Instantaneous Contact Point
Let point 𝑃 be any point in coordinate plane 𝑂 − 𝒊, 𝒌 within the region corresponding to tooth
profile of 𝑞th tooth of workpiece 1 as shown figure 4.5.4-1, and defined by two parameters of
𝑙ℎ and 𝑙𝑤 as shown in figure 4.5.4-1
𝒌 𝑙ℎ
𝑂 𝑙𝑤 𝒊
𝜌𝑞
Figure 4.5.4-1 Point 𝑃 on workpiece 1
𝑷 = (𝜌𝑞 + 𝑙ℎ )𝒊 + 𝑙𝑤 𝒌 = 𝐴𝒊 + 𝐵𝒌 (4.5.4-1)
Where: 𝐴 = (𝜌𝑞 + 𝑙ℎ ), 𝐵 = 𝑙𝑤 .
𝑞
After rotating by an angle 𝜉𝑝 about 𝒌 as an axis, point 𝑃(𝑷) becomes point 𝑹1𝑝 on 𝑞th tooth
profile of workpiece 1 in initial position, that is,
𝑞 𝑞 𝑞 𝑞
𝑹1𝑝 = (𝜉𝑝 𝒌) ⊗ 𝑷 = (𝜉𝑝 𝒌) ⊗ (𝐴𝒊 + 𝐵𝒌) = 𝑥1𝑝 𝒊 + 𝑦1𝑝 𝒋 + 𝑧1𝑝 𝒌 (4.5.4-2)
𝑞 𝑞 𝑞
Where: 𝑥1𝑝 = 𝐴 cos 𝜉𝑝 , 𝑦1𝑝 = 𝐴 sin 𝜉𝑝 and 𝑧1𝑝 = 𝐵. 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1.
𝑞
Point 𝑹1𝑝 on 𝑞th tooth profile of workpiece 1 reaches conjugate cutting position 𝑹𝑞𝑝 after
rotating by an angle ∆𝜀1,𝑞 about 𝒌 as an axis, that is,
𝑹𝑞𝑝 = (∆𝜀1,𝑞 𝒌) ⊗ 𝑹1𝑝

𝑞
= 𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌 = (∆𝜀1,𝑞 𝒌) ⊗ (𝑥1𝑝
𝑞 𝑞 𝑞
𝒊 + 𝑦1𝑝 𝒋 + 𝑧1𝑝 𝒌)
= 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) 𝒊 + 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) 𝒋 + 𝐵𝒌
𝑞 𝑞 (4.5.4-3)
𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) 𝒊𝑚 + [𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) cos 𝛼𝑚 + 𝐵 sin 𝛼𝑚 ]𝒋𝑚
={ 𝑞 𝑞 }
+[−𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚 + 𝐵 cos 𝛼𝑚 ]𝒌𝑚
Where:
~ 387 ~
𝑞
𝑥𝑝 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) ,
𝑦𝑝𝑞 = 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , }
On the other hand, let initial position of cutter be defined by machine setting parameters, i.e.,
equation (4.5.3-10), then, point 𝑃0 on cutter surface corresponding to point 𝑃 on tooth profile
is expressed with expression (4.5.3-5) by substituting 𝑟 and 𝜃 into 𝑟𝑞 and 𝜃𝑞 , that is,
𝑹𝑞0 = 𝑥 𝑞 𝒊𝑚 + 𝑦 𝑞 𝒋𝑚 + 𝑧 𝑞 𝒌𝑚 = 𝑟(cos 𝜃 𝒊𝑞𝑐 + sin 𝜃 𝒋𝑞𝑐 ) + 𝑥𝑐𝑞 𝒊𝑚 + 𝑦𝑐𝑞 𝒋𝑚 + 𝑧𝑐𝑞 𝒌𝑚

[𝑥𝑐𝑞 + 𝑟(cos 𝜃 cos Θ𝑞 − sin 𝜃 cos ζ𝑞 sin Θ𝑞 )]𝒊𝑚 (4.5.4-4)
={ }
+[𝑦𝑐𝑞 + 𝑟(cos 𝜃 sin Θ𝑞 + sin 𝜃 cos ζ𝑞 cos Θ𝑞 )]𝒋𝑚 + (𝑧𝑐𝑞 + 𝑟 sin 𝜃 sin ζ𝑞 )𝒌𝑚
Where: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 and Θ𝑞 are calculated by expression (4.5.3-13). 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1.
𝑥 𝑞 = 𝑥𝑐𝑞 + 𝑟(cos 𝜃 cos Θ𝑞 − sin 𝜃 cos ζ𝑞 sin Θ𝑞 ),

𝑦 𝑞 = 𝑦𝑐𝑞 + 𝑟(cos 𝜃 sin Θ𝑞 + sin 𝜃 cos ζ𝑞 cos Θ𝑞 ),}
𝑧 𝑞 = 𝑧𝑐𝑞 + 𝑟 sin 𝜃 sin ζ𝑞 .
After rotating by an angle ∆𝜀0𝑞 about 𝒌𝑚 as an axis together with a displacement ∆𝜎0 𝒌𝑚 in
direction 𝒌𝑚 , point 𝑃0 (𝑹𝑞0 ) reaches conjugate cutting position as follow:
𝑑𝜎
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝑹𝑞0 + ∆𝜎0 𝒌𝑚 = (∆𝜀0𝑞 𝒌𝑚 ) ⊗ (𝑥 𝑞 𝒊𝑚 + 𝑦 𝑞 𝒋𝑚 + 𝑧 𝑞 𝒌𝑚 ) + ( 𝑑𝜀 0) ∆𝜀0𝑞 𝒌𝑚
0 𝑞
𝑞 𝑞 𝑞
= 𝑥𝑝𝑚 𝒊𝑚+ 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 , (4.5.4-5)
(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝒌𝑞𝑐 = 𝑞
(∆𝜀0 𝒌𝑚 ) ⊗ (sin ζ (sin Θ 𝒊𝑚 − cos Θ𝑞 𝒋𝑚 )
𝑞 𝑞
+ cos ζ𝑞 𝒌𝑚 )
𝑞 𝑞
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 }
Where: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧 𝑞 , ζ𝑞 and Θ𝑞 are determined by expression (4.5.3-13) and

𝑞
= 𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + 𝑟[cos 𝜃 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜃 cos ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞
= 𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + 𝑟[cos 𝜃 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜃 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞 𝑑𝜎 𝑑𝜎
𝑧𝑝𝑚 = 𝑧 𝑞 + ( 𝑑𝜀 0 ) ∆𝜀0𝑞 = 𝑧𝑐𝑞 + 𝑟 sin 𝜃 sin ζ𝑞 + ( 𝑑𝜀 0) ∆𝜀0𝑞 ,
0 𝑞 0 𝑞
𝐴𝑞𝑝𝑚 𝑞 𝑞 𝑞 𝑞
= sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0 ) , 𝐵𝑝𝑚 = − sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0 ) , 𝐶𝑝𝑚 = cos ζ𝑞 . }
Due to point 𝑃(𝑹𝑞𝑝 ) being common point of cutter and workpiece 1, then,
~ 388 ~
𝑞 𝑞 𝑞 𝑞
(∆𝜀0 𝒌𝑚 ) ⊗ 𝑹0 + ∆𝜎0 𝒌𝑚 = 𝑹𝑝 + 𝑓1 𝒊𝑚 (4.5.4-6)
Substitution of expressions (4.5.4-3) and (4.5.4-5) into expression (4.5.4-6) results in
𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + 𝑟[cos 𝜃 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜃 cos ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )]
= 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + 𝑟[cos 𝜃 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜃 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )] (4.5.4-7)
𝑞 𝑞
= 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) cos 𝛼𝑚 + 𝐵 sin 𝛼𝑚 ,
𝑑𝜎
𝑧𝑐𝑞 + 𝑟 sin 𝜃 sin ζ𝑞 + (𝑑𝜀 0) ∆𝜀0𝑞 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚
𝑞 𝑞
+ 𝐵 cos 𝛼𝑚 .
0 𝑞 }
𝑞
Let 𝜀0 be visualized as virtual time parameter, velocity of point 𝑃(𝑹𝑝 ) on workpiece 1 is
𝑑𝜀
𝒗𝑞𝑝 = 𝑑𝜀1 𝝎1 × 𝑹𝑞𝑝 = 𝑀1𝑞 𝝎1 × (𝑥𝑝𝑞 𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌) = 𝑀1𝑞 (−𝑦𝑝𝑞 𝒊 + 𝑥𝑝𝑞 𝒋)
0 (4.5.4-8)
= 𝑀1𝑞 (−𝑦𝑝𝑞 𝒊𝑚 + 𝑥𝑝𝑞 cos 𝛼𝑚
𝑞
𝒋𝑚 − 𝑥𝑝𝑞 sin 𝛼𝑚
𝑞
𝒌𝑚 )
Where: 𝑥𝑝𝑞 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) , 𝑦𝑝𝑞 = 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) and 𝑧𝑝𝑞 = 𝐵.
Velocity of common contact point 𝑃(𝑹𝑞𝑝 ) on cutter surface is as follow:
𝑑𝜎
𝒗𝑞𝑐 = 𝒌𝑚 × (𝑹𝑞𝑝 + 𝑓1𝑞 𝒊𝑚 ) + ( 𝑑𝜀 0) 𝒌𝑚
0 𝑞
𝑑𝜎0
(4.5.4-9)
−(𝑦𝑝𝑞 𝑞
𝑧𝑝𝑞 𝑞
(𝑥𝑝𝑞 𝑞
= cos 𝛼𝑚 + sin 𝛼𝑚 )𝒊𝑚 + + 𝑓1 )𝒋𝑚 +( ) 𝒌𝑚
𝑑𝜀0 𝑞
Relative velocity of cutter with respect to workpiece 1 at point 𝑃 is as follow:
𝒗𝑐 − 𝒗𝑞𝑝 = 𝑣𝑐𝑝𝑥
𝑞 𝑞 𝑞
𝒊𝑚 + 𝑣𝑐𝑝𝑦 𝒋𝑚 + 𝑣𝑐𝑝𝑧 𝒌𝑚
𝑞
𝑞
]𝒊𝑚
(4.5.4-10)
={ 𝑑𝜎0 }
+[𝑥𝑝𝑞 (1 𝑀1𝑞 𝑞
𝑓1𝑞 ]𝒋𝑚 𝑀1𝑞 𝑥𝑝𝑞 𝑞
− cos 𝛼𝑚 ) + + [( 𝑑𝜀 ) + sin 𝛼𝑚 ] 𝒌𝑚
0 𝑞
Where:
𝑞
𝑞
𝑞
𝑣𝑐𝑝𝑥 ,
𝑞
= 𝑥𝑝𝑞 (1 − 𝑀1𝑞 cos 𝛼𝑚
𝑞
𝑣𝑐𝑝𝑦 ) + 𝑓1𝑞 ,
𝑞 𝑑𝜎
= ( 𝑑𝜀 0) + 𝑀1𝑞 𝑥𝑝𝑞 sin 𝛼𝑚
𝑞
𝑣𝑐𝑝𝑧
0 𝑞 }
~ 389 ~
(𝒗𝑐 − 𝒗𝑞𝑝 ) ∙ [(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝒌𝑞𝑐 ] = 0
With the aid of expressions (4.5.4-5) and (4.5.4-10), expression above gives

𝑞 𝑞
) − 𝐵 sin 𝛼𝑚 ]𝐴𝑞𝑝𝑚
{ 𝑑𝜎 }=0 (4.5.4-11)
+[𝑥𝑝𝑞 (1 − 𝑀1𝑞 cos 𝛼𝑚
𝑞
) + 𝑓1𝑞 ]𝐵𝑝𝑚
𝑞
+ [( 𝑑𝜀 0) + 𝑀1𝑞 𝑥𝑝𝑞 sin 𝛼𝑚
𝑞 𝑞
] 𝐶𝑝𝑚
0 𝑞
Combination of expressions (4.5.4-7) and (4.5.4-11) yields
𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + 𝑟[cos 𝜃 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜃 cos ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )]
= 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) + 𝑓1𝑞 ,
𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + 𝑟[cos 𝜃 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜃 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )]
𝑞 𝑞
= 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) cos 𝛼𝑚 + 𝐵 sin 𝛼𝑚 ,
𝑑𝜎
𝑧𝑐𝑞 + 𝑟 sin 𝜃 sin ζ𝑞 + (𝑑𝜀 0) ∆𝜀0𝑞 = −𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) sin 𝛼𝑚
𝑞 𝑞
+ 𝐵 cos 𝛼𝑚 , (4.5.4-12)
0 𝑞
𝑞 𝑞
) − 𝐵 sin 𝛼𝑚 ] sin ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )
−[𝑥𝑝𝑞 (1 − 𝑀1𝑞 cos 𝛼𝑚
𝑞
) + 𝑓1𝑞 ] sin ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )
=0
𝑑𝜎0
𝑀1𝑞 𝑥𝑝𝑞 𝑞
+ [(𝑑𝜀 ) + sin 𝛼𝑚 ] cos ζ𝑞
{ 0 𝑞 } }
𝑑𝜎
Where: 𝑥𝑐𝑞 , 𝑦𝑐𝑞 , 𝑧𝑐𝑞 , ζ𝑞 , Θ𝑞 , 𝑓1𝑞 , (𝑑𝜀 0 ) , 𝛼𝑚
𝑞
and 𝑀1𝑞 are calculated by simultaneous equation
0 𝑞
(4.5.3-13). 𝑥𝑝𝑞 and 𝑦𝑝𝑞 are expressed in formula (4.5.4-3).
There are four equations in simultaneous equation (4.5.4-12) and four unknown variables, i.e.,
𝑟, 𝜃 , ∆𝜀0𝑞 and 𝜉𝑝 which can be solved. ∆𝜀1,𝑞 is calculated by application of expression (4.2.2-9).
Then, instantaneous contact point is expressed by expression (4.5.4-3) in coordinate system of

workpiece 1 as follow:
Where:
𝑥𝑝𝑞 = 𝐴 cos(𝜉𝑝 + ∆𝜀1,𝑞 ) ,

𝑦𝑝𝑞 = 𝐴 sin(𝜉𝑝 + ∆𝜀1,𝑞 ) , }
~390 ~
2 Instantaneous Contact Line
Given ∆𝜀0𝑞 , there are four equations in simultaneous equation (4.5.4-12) and five unknown
variables, i.e., 𝑟, 𝜃 , 𝜉𝑝 , 𝑙𝑤 and 𝑙ℎ . Let 𝑙ℎ be prescribed, 𝑟, 𝜃, 𝜉𝑝 and 𝑙𝑤 can be solved which are
parameters of point on instantaneous contact line corresponding to instant rotating angle ∆𝜀0𝑞
of cradle. When 𝑙ℎ changes through entire tooth profile, the entire instantaneous contact line
𝑹𝑞𝑝𝑙 corresponding to ∆𝜀0𝑞 is generated in machine coordinate system 𝑂𝑚 − 𝒊𝑚 , 𝒋𝑚 , 𝒌𝑚 as
follow:
𝑹𝑞𝑝𝑙 = 𝑹𝑞𝑝 + 𝑓1𝑞 𝒊𝑚 = 𝑥𝑝𝑚

𝑞 𝑞 𝑞
𝒊𝑚 + 𝑦𝑝𝑚 𝒋𝑚 + 𝑧𝑝𝑚 𝒌𝑚 (4.5.4-14)
Where:
𝑞
𝑥𝑝𝑚 = 𝑥𝑐𝑞 cos ∆𝜀0𝑞 − 𝑦𝑐𝑞 sin ∆𝜀0𝑞 + 𝑟[cos 𝜃 cos(Θ𝑞 + ∆𝜀0𝑞 ) − sin 𝜃 cos ζ𝑞 sin(Θ𝑞 + ∆𝜀0𝑞 )],
𝑞
𝑦𝑝𝑚 = 𝑥𝑐𝑞 sin ∆𝜀0𝑞 + 𝑦𝑐𝑞 cos ∆𝜀0𝑞 + 𝑟[cos 𝜃 sin(Θ𝑞 + ∆𝜀0𝑞 ) + sin 𝜃 cos ζ𝑞 cos(Θ𝑞 + ∆𝜀0𝑞 )],
𝑞 𝑑𝜎
𝑧𝑝𝑚 = 𝑧𝑐𝑞 + 𝑟 sin 𝜃 sin ζ𝑞 + (𝑑𝜀 0 ) ∆𝜀0𝑞 .
0 𝑞 }
4.5.5 Tooth Profiles of Workpiece 1 & 2

After rotating by an angle −(𝜀1,𝑞 + ∆𝜀1,𝑞 ) about 𝒌 as an axis, instantaneous contact point
𝑹𝑞𝑝 reaches initial position 𝑹1𝑞 of point 𝑃 on 𝑞𝑡ℎ tooth profile of workpiece 1, that is,
𝑹1𝑞 = [−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ 𝑹𝑞𝑝 = 𝑥1𝑞 𝒊 + 𝑦1𝑞 𝒋 + 𝑧1𝑞 𝒌 (4.5.5-1)
Here:

}
𝑦1𝑞 = −𝑥𝑝𝑞 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) + 𝑦𝑝𝑞 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) , 𝑧1𝑞 = 𝑧𝑝𝑞 .
Where: 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1. 𝜀1,𝑞 is calculated by application of expression (4.5.3-2), ∆𝜀1,𝑞 is

𝑞 𝑞 𝑞
calculated by application of expression (4.2.2-9). 𝑥𝑝 , 𝑦𝑝 and 𝑧𝑝 are calculated by expression
(4.5.4-3).
Likewise, with help of expression (4.2.1-2), unit normal to tooth profile in initial position is as
follow:
~391 ~
𝑵1 = −[−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ (𝐴𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚 𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 ) = 𝐴1 𝒊 + 𝐵1 𝒋 + 𝐶1 𝒌
𝐴𝑞𝑝𝑚 𝒊 + (𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 )𝒋 (4.5.5-2)
= −[−(𝜀1,𝑞 + ∆𝜀1,𝑞 ) 𝒌] ⊗ [ 𝑞 𝑞 𝑞 𝑞 ]
+(𝐵𝑝𝑚 sin 𝛼𝑚 + 𝐶𝑝𝑚 cos 𝛼𝑚 )𝒌
Where:
𝐴1𝑞 = −𝐴𝑞𝑝𝑚 cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) − (𝐵𝑝𝑚

𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 ) sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) ,
𝐵1𝑞 = 𝐴𝑞𝑝𝑚 sin(𝜀1,𝑞 + ∆𝜀1,𝑞 ) − (𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
cos 𝛼𝑚 − 𝐶𝑝𝑚 sin 𝛼𝑚 ) cos(𝜀1,𝑞 + ∆𝜀1,𝑞 ) , }
𝐶1𝑞 = −𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
sin 𝛼𝑚 − 𝐶𝑝𝑚 cos 𝛼𝑚 .
Here: 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚

𝑞 𝑞
and 𝐶𝑝𝑚 are decided by expression (4.5.4-5).
After rotating by an angle −(𝜀2,𝑞 + ∆𝜀2,𝑞 ) about 𝝎2 as an axis, instantaneous contact point
𝑹𝑞𝑝 reaches initial position 𝑹𝑞2 of point 𝑃 on 𝑞𝑡ℎ tooth profile of workpiece 2, that is,
𝑹𝑞2 = [−(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝝎2 ] ⊗ (𝑹𝑞𝑝 − 𝑓𝒊) = 𝑥2𝑞 𝒊′ + 𝑦2𝑞 𝒋′ + 𝑧2𝑞 𝒌′

= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ [(𝑥𝑝𝑞 − 𝑓)𝒊 + 𝑦𝑝𝑞 𝒋 + 𝑧𝑝𝑞 𝒌]
(4.5.5-3)
′
(𝑥𝑝𝑞 − 𝑓)𝒊′ + (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼)𝒋′
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌 ] ⊗ [ ]
+(𝑦𝑝𝑞 sin 𝛼 + 𝑧𝑝𝑞 cos 𝛼)𝒌′
Where: 𝑞 = 0, 1, 2, 3, ⋯ , 𝑁 − 1. 𝑥𝑝𝑞 , 𝑦𝑝𝑞 and 𝑧𝑝𝑞 are calculated by expression (4.5.4-3) and ∆𝜀2,𝑞
is calculated by application of expression (4.2.2-9), that is,
𝑥2𝑞 = (𝑥𝑝𝑞 − 𝑓) cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) − (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼) sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,
𝑦2𝑞 = (𝑥𝑝𝑞 − 𝑓) sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) + (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝𝑞 sin 𝛼) cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,}
Likewise, unit normal to tooth profile of workpiece 2 in initial position is as follow:
𝑵𝑞2 = [−(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝝎2 ] ⊗ [(∆𝜀0𝑞 𝒌𝑚 ) ⊗ 𝒌𝑞𝑐 ] = 𝐴𝑞2 𝒊′ + 𝐵2𝑞 𝒋′ + 𝐶2𝑞 𝒌′

𝑞 𝑞 𝑞
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌′ ] ⊗ (𝐴𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚 𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 )
(4.5.5-4)
𝐴𝑞𝑝𝑚 𝒊′ + [𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
′
cos(𝛼𝑚 + 𝛼) − 𝐶𝑝𝑚 sin(𝛼𝑚 + 𝛼)]𝒋′
= [(𝜀2,𝑞 + ∆𝜀2,𝑞 )𝒌 ] ⊗ [ 𝑞 𝑞 𝑞 𝑞 ]
+[𝐵𝑝𝑚 sin(𝛼𝑚 + 𝛼) + 𝐶𝑝𝑚 cos(𝛼𝑚 + 𝛼)]𝒌′
Where:
~ 392 ~
𝐴2 = 𝐴𝑝𝑚 cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) − [𝐵𝑝𝑚 cos(𝛼𝑚 + 𝛼) − 𝐶𝑝𝑚 sin(𝛼𝑚 + 𝛼)] sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,
𝐵2𝑞 = 𝐴𝑞𝑝𝑚 sin(𝜀2,𝑞 + ∆𝜀2,𝑞 ) + [𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
cos(𝛼𝑚 + 𝛼) − 𝐶𝑝𝑚 sin(𝛼𝑚 + 𝛼)] cos(𝜀2,𝑞 + ∆𝜀2,𝑞 ) ,}
𝐶2𝑞 = 𝐵𝑝𝑚
𝑞 𝑞 𝑞 𝑞
sin(𝛼𝑚 + 𝛼) + 𝐶𝑝𝑚 cos(𝛼𝑚 + 𝛼) .

𝑞 𝑞
and 𝐶𝑝𝑚 are decided by expression (4.5.4-5).
Example 4. 5 Design a pair of helical gear set with varied transmission ratio of crossed rotating
axes and manufactured by circular plane of grinding wheel as shown in figure Example 4.5 (a)
and (b)
Circular Plane of Cutter Workpiece
(a) Manufacturing Process
(b) A pair of Gear Sets
Figure Example 4.5
~ 393 ~
𝑑𝜀 1−𝑒 2 𝑑𝑀12 2𝑒(1−𝑒 2 ) sin 𝜀1

𝛼 = 30°, 𝑓 = −50, 𝑒 = 0.2, 𝑀12 = 2 = , = (1+2𝑒 cos 𝜀 .
𝑑𝜀 1+2𝑒 cos 𝜀1 1 +𝑒 2 𝑑𝜀1 1 +𝑒
2 )2
𝑟𝑞𝑐𝑜𝑛𝑣𝑒𝑥 = 40.0, 𝜃𝑞𝑐𝑜𝑛𝑣𝑒𝑥 = 0°, 𝑟𝑞𝑐𝑜𝑛𝑐𝑎𝑣𝑒 = 40.0, 𝜃𝑞𝑐𝑜𝑛𝑐𝑎𝑣𝑒 = 0°,
𝑟1𝑐𝑜𝑛𝑣𝑒𝑥 = 41.258, 𝑟1𝑐𝑜𝑛𝑐𝑎𝑣𝑒 = 41.258, 𝑟2𝑐𝑜𝑛𝑐𝑎𝑣𝑒 = 41.803, 𝑟2𝑐𝑜𝑛𝑣𝑒𝑥 = 41.803.

𝑞 𝑞 𝑞 𝑞
∆𝑥𝑐𝐶𝑜𝑛𝑣𝑒𝑥 = 80.0, ∆𝑦𝑐𝐶𝑜𝑛𝑣𝑒𝑥 = 0, ∆𝑥𝑐𝐶𝑜𝑛𝑐𝑎𝑣𝑒 = 80.0, ∆𝑦𝑐𝐶𝑜𝑛𝑐𝑎𝑣𝑒 = 0.
Common Machine-Setting Parameters:
𝑞 𝑑𝜎
𝛼𝑚 = 15° , 𝑓1𝑞 = −18.301, 𝑓2𝑞 = −68.301, ( 𝑑𝜀 0 ) = 18.301.
0 𝑞
Parameters of Gear Set:
𝑝 = 6.22, 𝑍1 = 25, ∅𝑔𝑖 = 40° , ∅𝑔𝑜 = 140°.
Calculation:
• Parameters of Gear Blank.

𝑞
That is, Index points 𝑥𝑎𝑝 of workpiece 1 & 2. Spiral angles 𝜓1𝑞 and 𝜓2𝑞 of workpiece 1 & 2 as
listed in Table 4.5.1.
• Machine Setting Parameters for workpiece 1 & 2 as listed in Table 4.5.2 and Table 4.5.3
~ 394 ~
𝑥𝑎𝑝 𝜓1 (deg) 𝜓2 (deg) 𝑥𝑎𝑝 𝜓1 (deg) 𝜓2 (deg)
1 -19.656 168.068 161.932 -19.7006 168.042 161.958

2 -19.833 167.966 162.034 -20.050 167.841 162.159
3 -20.347 167.67 162.33 -20.720 167.455 162.545
4 -21.161 167.202 162.798 -21.662 166.914 163.086
5 -22.215 166.597 163.403 -22.809 166.256 163.744
6 -23.436 165.896 164.104 -24.086 165.524 164.476
7 -24.748 165.145 164.855 -25.412 164.764 165.236
8 -26.070 164.387 165.613 -26.710 164.02 165.98
9 -27.324 163.668 166.332 -27.903 163.336 166.664
10 -28.436 163.03 166.97 -28.918 162.753 167.247
11 -29.339 162.511 167.489 -29.694 162.307 167.693
12 -29.975 162.145 167.855 -30.180 162.027 167.973
13 -30.303 161.956 168.044 -30.344 161.932 168.068
14 -30.301 161.957 168.043 -30.175 162.03 167.97
15 -29.968 162.149 167.851 -29.685 162.312 167.688
16 -29.329 162.517 167.483 -28.906 162.76 167.24
17 -28.423 163.037 166.963 -27.889 163.344 166.656
18 -27.310 163.676 166.324 -26.697 164.028 165.972
19 -26.057 164.395 165.605 -25.4 164.771 165.229
20 -24.737 165.151 164.849 -24.076 165.53 164.47
21 -23.428 165.901 164.099 -22.802 166.26 163.74
22 -22.209 166.6 163.4 -21.658 166.916 163.084
23 -21.159 167.203 162.797 -20.719 167.456 162.544
24 -20.346 167.67 162.33 -20.049 167.841 162.159
25 -19.832 167.966 162.034 -19.701 168.042 161.958
~ 395 ~
Machine Setting Parameters for Convex Flank of Workpiece 1 & Concave Flank of Workpiece 2
(Example 4.5) --Table 4.5.2
𝑞 𝑞 ( (
𝑞𝑡ℎ 𝑥𝑐𝑞 𝑦𝑐𝑞 𝑧𝑐𝑞 𝑥𝑐′ 𝑦𝑐′𝑞 𝑧𝑐′ ζ𝑞 Θ𝑞 𝜀1,𝑞 𝑑𝑒𝑔) 𝜀2,𝑞 𝑑𝑒𝑔)
tooth
1 -67.0856 27.4146 0 -8.8297 -27.4146 0 69.6978 -43.2644 0 0
2 -67.2495 27.4277 0 -9.0182 -27.4277 0 69.6239 -43.2902 18.0705 12.0999
3 -67.7278 27.4663 0 -9.56939 -27.4663 0 69.4083 -43.3661 35.7811 24.2794
4 -68.4831 27.5282 0 -10.4417 -27.5282 0 69.0684 -43.4881 52.8381 36.6273
5 -69.459 27.6098 0 -11.5729 -27.6098 0 68.6301 -43.6494 69.064 49.2446
6 -70.5878 27.7066 0 -12.8871 -27.7066 0 68.124 -43.8414 84.4 62.2451
~ 396 ~
7 -71.7965 27.8133 0 -14.3015 -27.8133 0 67.5828 -44.0537 98.8807 75.749
8 -73.0112 27.9238 0 -15.7309 -27.9238 0 67.0394 -44.2744 112.6 89.873
9 -74.1602 28.0315 0 -17.0906 -28.0315 0 66.5255 -44.4902 125.683 104.713
10 -75.1761 28.1293 0 -18.2993 -28.1293 0 66.0708 -44.6869 138.262 120.321
11 -75.9984 28.2103 0 -19.2824 -28.2103 0 65.7025 -44.8504 150.465 136.682
12 -76.5766 28.2684 0 -19.9763 -28.2684 0 65.4433 -44.9678 162.412 153.688
13 -76.8743 28.2986 0 -20.3344 -28.2986 0 65.3097 -45.029 174.21 171.133

Machine Setting Parameters for Convex Flank of Workpiece 1 & Concave Flank of Workpiece 2 (Example 4.5) --
Table 4.5.2 (continue)
𝑞 𝑞 ( (
tooth
14 -76.8721 28.2984 0 -20.3317 -28.2984 0 65.3107 -45.0285 185.959 188.738
15 -76.5703 28.2677 0 -19.9687 -28.2677 0 65.4461 -44.9665 197.756 206.189
16 -75.9887 28.2094 0 -19.2708 -28.2094 0 65.7068 -44.8485 209.699 223.206
17 -75.1643 28.1281 0 -18.2852 -28.1281 0 66.0761 -44.6846 221.896 239.581
18 -74.1476 28.0303 0 -17.0755 -28.0303 0 66.5311 -44.4877 234.465 255.205
19 -72.9991 27.9227 0 -15.7166 -27.9227 0 67.0448 -44.2722 247.535 270.062
20 -71.7862 27.8124 0 -14.2893 -27.8124 0 67.5875 -44.0519 261.238 284.202
~397 ~
3
21 -70.5801 27.7059 0 -12.878 -27.7059 0 68.1275 -43.8401 275.698 297.721
22 -69.4541 27.6093 0 -11.5671 -27.6093 0 68.6323 -43.6486 291.009 310.734
23 -68.4806 27.5279 0 -10.4388 -27.5279 0 69.0695 -43.4877 307.209 323.361
24 -67.727 27.4663 0 -9.56842 -27.4663 0 69.4086 -43.366 324.242 335.715
25 -67.2493 27.4277 0 -9.01809 -27.4277 0 69.6239 -43.2901 341.936 347.899

Machine Setting Parameters for Concave Flank of Workpiece 1 & Convex Flank of Workpiece 2
(Example 4.5) --Table 4.5.3
𝑞 𝑞 ( (
toot
h
1 -67.1268 -27.4179 0 -8.87703 27.4179 0 110.321 -136.729 9.05827 6.04516
2 -67.4512 -27.444 0 -9.2505 27.444 0 110.467 -136.678 26.9915 18.1744
3 -68.074 -27.4945 0 -9.9689 27.4945 0 110.748 -136.578 44.4053 30.4263
4 -68.9475 -27.5667 0 -10.9795 27.5667 0 111.14 -136.436 61.0612 42.8954
5 -70.0088 -27.6566 0 -12.2122 27.6566 0 111.617 -136.258 76.842 55.6895
6 -71.1868 -27.7591 0 -13.587 27.7591 0 112.144 -136.054 91.7423 68.9266
7 -72.4077 -27.8685 0 -15.0196 27.8685 0 112.691 -135.836 105.828 82.7268
~ 398 ~
3
8 -73.5983 -27.9784 0 -16.4246; 27.9784 0 113.223 -135.616 119.213 97.1989
9 -74.6888 -28.082 0 -17.7187 28.082 0 113.711 -135.408 132.027 112.42
10 -75.6149 -28.1723 0 -18.8233 28.1723 0 114.126 -135.226 144.403 128.412
11 -76.3207 -28.2426 0 -19.6688 28.2426 0 114.442 -135.084 156.464 145.115
12 -76.7622 -28.2872 0 -20.1994 28.2872 0 114.64 -134.994 168.323 162.372
13 -76.9111 -28.3023 0 -20.3787 28.3023 0 114.707 -134.963 180.085 179.935

Machine Setting Parameters for Concave Flank of Workpiece 1 & Convex Flank of Workpiece 2 (Example 4.5) --
Table 4.5.3 (continue)
𝑞 𝑞 ( (
tooth
14 -76.7578 -28.2867 0 -20.1942 28.2867 0 114.638 -134.995 191.846 197.502
15 -76.3126 -28.2418 0 -19.6591 28.2418 0 114.438 -135.086 203.703 214.767
16 -75.604 -28.1712 0 -18.8103 28.1712 0 114.121 -135.229 215.758 231.482
1 Curvature of Workpiece 1
17 -74.6764 -28.0808 0 -17.7039 28.0808 0 113.705 -135.411 228.126 247.49
4.5.6 Calculation of Curvature

18 -73.5857 -27.9773 0 -16.4098 27.9773 0 113.218 -135.619 240.929 262.728
19 -72.3963 27.8675 0 -15.0063 27.8675 0 112.686 -135.838 254.3 277.217
~ 399~
20 -71.1777 -27.7583 0 -13.5764 27.7583 0 112.14 -136.056 268.367 291.032
21 -70.0025 -27.656 0 -12.2048 27.656 0 111.614 -136.259 283.243 304.283
22 -68.9439 -27.5664 0 -10.9752 27.5664 0 111.139 -136.436 298.999 317.088
23 -68.0725 -27.4944 0 -9.96712 27.4944 0 110.747 -136.579 315.63 329.565
24 -67.4508 -27.4439 0 -9.25006 27.4439 0 110.467 -136.678 333.022 341.823
25 -67.1268 -27.4439 0 -8.87702 27.4179 0 110.321 -136.729 350.943 353.954
In manufacturing process of workpiece 1, surface of cutter is treated as first conjugate surface

and tooth surface of workpiece 1 is used as second conjugate surface. Since surface of cutter is
a plane, its curvature in arbitrary tangent direction 𝝉 is 𝐾𝜏 = 𝐺𝜏 = 0.
1.1 Calculation of Some Parameters
A. Calculation of 𝑱𝑝
Conjugate motion of workpiece 1 with respect to cutter are given as follow:

𝑞 𝑞 𝑞 𝑞
𝑀 = 𝑀1𝑞 = (𝑑𝜀1) = , = =−
2 sin 𝛼 ,
0 𝒒 𝑀12 sin 𝛼 𝑑𝜀1 𝑑𝜀0 𝑑𝜀1 𝑀12
𝑞 𝑑𝜎1 𝑑𝜎 𝑞 𝑞
𝑓 = 𝑓1 , = (𝑑𝜀 0 ) = −𝑓1 tan(𝛼𝑚 + 𝛼) ,
𝑑𝜀1 0 𝑞 (4.5.6-1)
ℎ = 𝑑𝜀 = 𝑑𝜀 = = = 0, = = = 0,
1 1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12
𝑞 𝑞
Then, application of expression (1.5.2-7) results in
𝑱𝑝 = 𝐽𝑝1 𝒊 + 𝐽𝑝2 𝒋 + 𝐽𝑝3 𝒌 (4.5.6-2)

𝑞 𝑞 𝑞
Here: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are calculated by expression (4.5.4-5) and

𝑞 𝑞 𝑞
𝐽𝑝1 = { 𝑑𝑀12 𝑀1𝑞 sin 𝛼𝑚
𝑞
+ 𝑑𝜀 𝑀2 sin 𝛼 (𝑦𝑝𝑚 cos 𝛼𝑚 − 𝑧𝑝𝑚 sin 𝛼𝑚 )
1 12
𝑞 𝑞
𝑞 𝑞 𝑞
𝑞
𝑑𝜀1 𝑀12
𝑞 𝑞
𝑞 𝑞 𝑞
𝑞
𝑑𝜀1 𝑀12
B. Calculation of 𝐷𝑝 and 𝐸𝑝
𝒗12
𝑝
Let 𝝀 = |𝒗12 | be relative velocity of cutter with respect to workpiece 1 as defined in expression
𝑝
(4.5.4-10), due to surface of cutter being a plane, curvature of cutter surface in tangent
direction 𝝀 are zero, that is, 𝐾𝜆 = 𝐺𝜆 = 0.
With help of expressions (4.5.4-5) and (4.5.4-10), 𝐷𝑝 and 𝐸𝑝 are calculated by expression (1.5.2-
11), that is,
~ 400 ~
𝒗𝟏𝟐
𝒑
𝐷𝑝 = 𝐾1𝜆 |𝒗12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵1𝑝 ] ∙ |𝒗𝟏𝟐 |
𝒑
𝒗𝟏𝟐
= {[𝑀1𝑞 sin 𝛼𝑚
𝑞
𝒋𝑚 − (1 − 𝑀1𝑞 cos 𝛼𝑚
𝑞
)𝒌𝑚 ] × (𝐴𝑞𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚
𝑞 𝑞 𝒑
𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 )} ∙ |𝒗𝟏𝟐|
𝒑
𝑞
𝑀1𝑞 sin 𝛼𝑚
𝑞 𝑞
(1 − 𝑀1𝑞 cos 𝛼𝑚
𝑞 𝑞
1 [𝐶𝑝𝑚 + 𝐵𝑝𝑚 )]𝑣𝑐𝑝𝑥
= |𝒗𝟏𝟐
{ 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞 𝑞}
𝒑 | −𝑣
𝑐𝑝𝑦 𝐴𝑝𝑚 (1 − 𝑀1 cos 𝛼𝑚 ) − 𝑣𝑐𝑝𝑧 𝐴𝑝𝑚 𝑀1 sin 𝛼𝑚 (4.5.6-3)
𝒗12
𝑝
𝐸𝑝 = |𝒗12
𝑝 |𝐺1𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12 |
𝑝
𝒗12
[−𝑀1𝑞 𝑞
𝑀1𝑞 𝑞 𝑝
= sin 𝛼𝑚 𝒋𝑚 + (1 − cos 𝛼𝑚 )𝒌𝑚 ] ∙ |𝒗12 |
𝑝
1 𝑞
𝑀1𝑞 sin 𝛼𝑚
𝑞 𝑞 𝑞 𝑞
= |𝒗𝟏𝟐 | [−𝑣𝑐𝑝𝑦 + (1 − 𝑀1 cos 𝛼𝑚 )𝑣𝑐𝑝𝑧 ]
𝒑 }
𝑞 𝑞 𝑞
Where: 𝑵1𝑝 = 𝐴𝑝𝑚 𝒊𝑚 + 𝐵𝑝𝑚 𝒋𝑚 + 𝐶𝑝𝑚 𝒌𝑚 is determined by expression (4.5.4-5). 𝒗12
𝑝 =
𝑞 2 𝑞 𝑞 2 2
√(𝑣𝑐𝑝𝑥 ) + (𝑣𝑐𝑝𝑦 ) + (𝑣𝑐𝑝𝑧 ) is calculated by expression (4.5.4-10).
C. Direction of Instantaneous Contact Line 𝒆
Application of expression (1.5.2-17) yields direction of Instantaneous Contact Line 𝒆 as follow:
𝒑 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐 𝒑 𝒗𝟏𝟐

𝒆 = (𝜃𝜆𝑒 𝑵1𝑝 ) ⊗ (|𝒗𝟏𝟐 |) = |𝒗𝟏𝟐 | cos 𝜃𝜆𝑒 + (𝑵1𝑝 × |𝒗𝟏𝟐|) sin 𝜃𝜆𝑒
𝒑 𝒑 𝒑 (4.5.6-4)
= 𝑒𝑥 𝒊𝑚 + 𝑒𝑦 𝒋𝑚 + 𝑒𝑧 𝒌𝑚
Where:
1 𝑞 𝑞 𝑞 𝑞 𝑞
𝑒𝑥 = |𝒗𝟏𝟐 | [𝑣𝑐𝑝𝑥 cos 𝜃𝜆𝑒 + (𝐵𝑝𝑚 𝑣𝑐𝑝𝑧 − 𝐶𝑝𝑚 𝑣𝑐𝑝𝑦 ) sin 𝜃𝜆𝑒 ],
𝒑
1 𝑞 𝑞 𝑞
− 𝐴𝑞𝑝𝑚 𝑣𝑐𝑝𝑧
𝑞
𝑒𝑦 = |𝒗𝟏𝟐 | [𝑣𝑐𝑝𝑦 cos 𝜃𝜆𝑒 + (𝐶𝑝𝑚 𝑣𝑐𝑝𝑥 ) sin 𝜃𝜆𝑒 ],
𝒑
1 𝑞
cos 𝜃𝜆𝑒 + (𝐴𝑞𝑝𝑚 𝑣𝑐𝑝𝑦
𝑞 𝑞 𝑞
𝑒𝑧 = |𝒗𝟏𝟐 | [𝑣𝑐𝑝𝑧 − 𝐵𝑝𝑚 𝑣𝑐𝑝𝑥 ) sin 𝜃𝜆𝑒 ].
𝒑
𝐷𝑝 𝐸𝑝
sin 𝜃𝜆𝑒 = − , cos 𝜃𝜆𝑒 = .
√𝐷𝑝2 +𝐸𝑝2 √𝐷𝑝2 +𝐸𝑝2 }
1.2 Curvature of Tooth Profile of Workpiece 1

Curvature of tooth profile of workpiece 1 in any tangent direction 𝝉 is resulted from expression
(1.5.4-2), that is,
~ 401~
(𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏 (𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏 (𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏
𝐾1𝜏 = − 𝐾𝜏 = =𝐷 𝑞 𝑞 𝑞 ,
𝐷𝑝 |𝒗12
𝒑 |+𝑱𝑝 ∙𝑵1𝑝 𝐷𝑝 |𝒗12
12
𝑝 |𝒗𝒑 |+𝐽𝑝1 𝐴𝑝𝑚 +𝐽𝑝2 𝐵𝑝𝑚 +𝐽𝑝3 𝐶𝑝𝑚
(𝐷𝑝2 +𝐸𝑝2 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏 (𝐷𝑝2 +𝐸𝑝2 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏
𝐺1𝜏 = 𝐺1 − =− (4.5.6-5)
𝐷𝑝 |𝒗12
𝒑 |+𝑱𝑝 ∙𝑵1𝑝 𝐷𝑝 |𝒗12
= −𝐷 12 𝑞 𝑞 𝑞 .
𝑝 |𝒗𝒑 |+𝐽𝑝1 𝐴𝑝𝑚 +𝐽𝑝2 𝐵𝑝𝑚 +𝐽𝑝3 𝐶𝑝𝑚 }
Where: 𝜃𝑒𝜏 is rotating angle of 𝒆 about 𝑵1𝑝 to 𝝉. 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚𝑞 𝑞

and 𝐶𝑝𝑚 are decided by expression
(4.5.4-5). 𝐽𝑝1 , 𝐽𝑝2 and 𝐽𝑝3 are calculated by expression (4.5.6-2). 𝐷𝑝 and 𝐸𝑝 are determined by
formular (4.5.6-3).
2 Curvature of Workpiece 2
In manufacturing process of workpiece 2, surface of cutter is treated as first conjugate surface
and tooth surface of workpiece 2 is used as second conjugate surface.
2.1 Calculation of Some Parameters

A. Calculation of 𝑱𝑝
Conjugate motion of workpiece 2 with respect to cutter are given as follow:

𝑞 𝑞 𝑞 𝑞
𝑀 = 𝑀2𝑞 = (𝑑𝜀2) = , = =
,
𝑑𝜎1 𝑑𝜎
𝑓 = 𝑓2𝑞 , = (𝑑𝜀 0 ) = −𝑓2𝑞 tan 𝛼𝑚
𝑞
,
𝑑𝜀1 0 𝑞 (4.5.6-6)
ℎ = 𝑑𝜀 = 𝑑𝜀 = = = 0, = = = 0,
1 1 𝑑𝜀12 𝑑𝜀12 𝑑𝜀1 𝑑𝜀12 𝑑𝜀12
𝝎1 = 𝒌𝑚 , 𝝎2 = − sin(𝛼𝑚 + 𝛼) 𝒋𝑚 − cos(𝛼𝑚 + 𝛼) 𝒌𝑚 . }
Then, application of expression (1.5.2-7) results in
𝑱𝑝 = 𝐽𝑝1 𝒊 + 𝐽𝑝2 𝒋 + 𝐽𝑝3 𝒌 (4.5.6-7)

𝑞 𝑞 𝑞
Here: 𝑥𝑝𝑚 , 𝑦𝑝𝑚 and 𝑧𝑝𝑚 are calculated by expression (4.5.4-5) and
𝑑𝜎
𝑀2𝑞 [𝑓2𝑞 cos(𝛼𝑚 + 𝛼) − (𝑑𝜀 0 ) sin(𝛼𝑚 + 𝛼)]
0 𝑞
𝐽𝑝1 = { },
𝑑𝑀2 𝑞 𝑞
+ 𝑑𝜀 [𝑦𝑝𝑚 cos 𝛼(𝛼𝑚 + 𝛼) − 𝑧𝑝𝑚 sin(𝛼𝑚 + 𝛼)]
0
𝑑𝑀2
𝑞 𝑞
𝐽𝑝2 = sin(𝛼𝑚 + 𝛼) − (𝑥𝑝𝑚 − 𝑓2𝑞 ) cos(𝛼𝑚 + 𝛼) ,
𝑑𝜀0
𝑑𝑀2
𝑞 𝑞
sin(𝛼𝑚 + 𝛼) + (𝑥𝑝𝑚 − 𝑓2𝑞 ) sin(𝛼𝑚 + 𝛼) .}
𝑑𝜀0
~ 402 ~
B. Relative Velocity of Cutter with Respect to Workpiece 2
Velocity of point 𝑃′ on workpiece 2 is as follow:

𝑞
𝒗𝑝′ = 𝑀2𝑞 𝝎2 × (𝑹𝑞𝑝 − 𝑓𝒊𝑚 )
(𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝 sin 𝛼)𝒊𝑚 (4.5.6-8)
= 𝑀2𝑞 { }
−(𝑥𝑝𝑞 − 𝑓) cos(𝛼𝑚 + 𝛼) 𝒋𝑚 + (𝑥𝑝𝑞 − 𝑓) sin(𝛼𝑚 + 𝛼) 𝒌𝑚
Combination of expressions (4.5.4-9) and (4.5.6-8) generates relative velocity of cutter with
respect to workpiece 2, that is,
𝑞 𝑞 𝑞 𝑞
𝒗𝑐 − 𝒗𝑝′ = 𝑣𝑐𝑝′ 𝑥 𝒊𝑚 + 𝑣𝑐𝑝′ 𝑦 𝒋𝑚 + 𝑣𝑐𝑝′ 𝑧 𝒌𝑚
[−(𝑦𝑝𝑞 cos 𝛼𝑚
𝑞 𝑞
+ 𝑧𝑝 sin 𝛼𝑚 ) − 𝑀2𝑞 (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝 sin 𝛼)]𝒊𝑚
+[𝑥𝑝𝑞 + 𝑓1𝑞 + 𝑀2𝑞 (𝑥𝑝𝑞 − 𝑓) cos(𝛼𝑚 + 𝛼)]𝒋𝑚 (4.5.6-9)
=
𝑑𝜎
+ [( 𝑑𝜀 0) − 𝑀2𝑞 (𝑥𝑝𝑞 − 𝑓) sin(𝛼𝑚 + 𝛼)] 𝒌𝑚
{ 0 𝑞 }
Where:
𝑞
𝑣𝑐𝑝′ 𝑥 = −(𝑦𝑝𝑞 cos 𝛼𝑚
𝑞 𝑞
+ 𝑧𝑝 sin 𝛼𝑚 ) − 𝑀2𝑞 (𝑦𝑝𝑞 cos 𝛼 − 𝑧𝑝 sin 𝛼),
𝑞
𝑣𝑐𝑝′ 𝑦 = 𝑥𝑝𝑞 + 𝑓1𝑞 + 𝑀2𝑞 (𝑥𝑝𝑞 − 𝑓) cos(𝛼𝑚 + 𝛼) ,
𝑞 𝑑𝜎 𝑞 𝑞
𝑣𝑐𝑝′ 𝑧 = ( 𝑑𝜀 0 ) − 𝑀2 (𝑥𝑝 − 𝑓) sin(𝛼𝑚 + 𝛼) .
0 𝑞 }
C. Calculation of 𝐷𝑝 and 𝐸𝑝
𝒗12
𝑝
Let 𝝀 = |𝒗12 | be relative velocity of cutter with respect to workpiece 2 as defined in expression
𝑝
(4.5.6-9), due to surface of cutter being a plane, curvature of cutter surface in tangent direction
𝝀 are zero, that is, 𝐾𝜆 = 𝐺𝜆 = 0.
Unit normal to circular plane of cutter is 𝑵𝑐𝑝 , that is,
𝑵𝑐𝑝 = −𝐴𝑞𝑝𝑚 𝒊𝑚 − 𝐵𝑝𝑚

𝑞 𝑞
𝒋𝑚 − 𝐶𝑝𝑚 𝒌𝑚 (4.5.6-10)

𝑞 𝑞
and 𝐶𝑝𝑚 are calculated by expression (4.5.4-5).
With help of expressions (4.5.6-9) and (4.5.6-10), 𝐷𝑝 and 𝐸𝑝 are calculated by expression (1.5.2-
11), that is,
~ 403 ~
𝒗𝟏𝟐
𝒑
𝐷𝑝 = 𝐾𝜆 |𝒗12
𝑝 | − [(𝝎1 − 𝑀𝝎2 ) × 𝑵𝑐𝑝 ] ∙ |𝒗𝟏𝟐 |
𝒑
𝑞 𝑞 𝑞
1
(𝐶𝑝𝑚 𝑣𝑐𝑝′ 𝑥− 𝐴𝑞𝑝𝑚 𝑣𝑐𝑝′ 𝑧 ) 𝑀2𝑞
sin(𝛼𝑚 + 𝛼)
= |𝒗𝟏𝟐| { 𝑞 𝑞
},
+ (𝐴𝑞𝑝𝑚 𝑣𝑐𝑝′ 𝑦 − 𝐵𝑝𝑚
𝑞
𝒑
𝑣𝑐𝑝′ 𝑥 ) [1 + 𝑀2𝑞 cos(𝛼𝑚 + 𝛼) ] (4.5.6-11)
𝒗12
𝑝
𝐸𝑝 = |𝒗12
𝑝 |𝐺𝜆 + (𝝎1 − 𝑀𝝎2 ) ∙ |𝒗12
𝑝 |
1 𝑞 𝑞
= |𝒗𝟏𝟐 | {𝑀2𝑞 𝑣𝑐𝑝′ 𝑦 sin(𝛼𝑚 + 𝛼) + [1 + 𝑀2𝑞 cos(𝛼𝑚 + 𝛼)]𝑣𝑐𝑝′ 𝑧 } .
𝒑 }
2.2 Curvature of Tooth Profile of Workpiece 2
Curvature of tooth profile 𝐴̅ of workpiece 2 in arbitrary tangent direction 𝝉 is calculated by

application (1.5.4-2) as follow:
(𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏 (𝐷𝑝2 +𝐸𝑝2 ) sin2 𝜃𝑒𝜏

𝐾2𝜏 = − 𝐾𝜏 = 𝐷 𝑞 𝑞 𝑞 ,
𝐷𝑝 |𝒗12
12
𝑝 |𝒗𝒑 |−𝐽𝑝1 𝐴𝑝𝑚 −𝐽𝑝2 𝐵𝑝𝑚 −𝐽𝑝3 𝐶𝑝𝑚
} (4.5.6-12)
(𝐷𝑝2 +𝐸𝑝2 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏 (𝐷𝑝2 +𝐸𝑝2 ) cos 𝜃𝑒𝜏 sin 𝜃𝑒𝜏
𝐺2𝜏 = 𝐺𝜏 − = −𝐷 𝑞 𝑞 𝑞 .
𝐷𝑝 |𝒗12
12
𝑝 |𝒗𝒑 |−𝐽𝑝1 𝐴𝑝𝑚 −𝐽𝑝2 𝐵𝑝𝑚 −𝐽𝑝3 𝐶𝑝𝑚
Where: 𝜃𝑒𝜏 is rotating angle of 𝒆 about 𝑵1𝑝 to 𝝉. 𝒆 is defined in expression (4.5.6-4). 𝐴𝑞𝑝𝑚 , 𝐵𝑝𝑚
𝑞
𝑞
and 𝐶𝑝𝑚 are decided by expression (4.5.4-5). 𝐽𝑝1 , 𝐽𝑝2 and 𝐽𝑝3 are calculated by expression
(4.5.6-7). 𝐷𝑝 and 𝐸𝑝 are determined by formular (4.5.6-11). 𝐾𝜏 = 𝐺𝜏 = 0.
~ 403 ~
References
[1] Chih-Hsin Chen. “Theory of Conjugate Surfaces”, (1) (in Chinese). Beijing: Science Press,
1974.
[2] Chih-Hsin Chen. “Theory of Conjugate Surfaces”, (2) (in Chinese). Beijing: Science Press,
1977.
[3] Chih-Hsin Chen. “Fundamentals of the Theory of Conjugate Surfaces”, (in Chinese). Beijing:
Science Press, 1985.
[4] Chih-Hsin Chen. “Theory of Conjugate Surfaces and Its Applications-----Collected Scientific
Works of Chih-Hsin Chen”, (in Chinese). Beijing: Science Press, 2008.
[5] Stephen P. Radzevich. “Dudley’s Handbook of Practical Gear Design and Manufacture”.
Second Edition. CRC Press Taylor & Francis Group, 2012.
~ 404 ~

Gearing With Varied Transmission Ratio

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Gearing With Varied Transmission Ratio

Uploaded by

Copyright:

Available Formats

GEARING WITH VARIED

Part I Theory of Conjugate Surface 1

Chapter 1 Rotation of Vector 2

1.1.1 Rotation of a Vector about Fixed Oriented Axis 2

1 Expression for Rotation of a Vector 2

2 Expanded Formula for Rotation of a Vector 2

3 Some Properties of Rotation of Vector 3

4 Sequence Reciprocation of Successive Rotations about Two Axes with

5 Resolution of Rotation of a Vector 5

1.1.2 Differential of Rotation of a Vector 7

1 Differential Quantity Caused by Differential Change of Rotating Angle 7

2 Differential Quantity Caused by Differential Change of Rotating Axis 8

3 Differential Quantity Caused by Differential Change of Both Rotating

Angle and Axis 9

Chapter 2 Engineering Differential Geometry 10

1.2.1 Boundary Surface 10

1 Expression of Boundary Surface 10

2 Unit Normal at Ant Point on Boundary Surface 11

1.2.2 Intersection Curve 21

1 Representation of Intersection Curve 21

3 Principal Normal Vector and Curvature at Any Point

4 Unit Binormal Vector to Intersecting Curve at Any Point 25

5 Torsional Curvature of Intersecting Curve at Any Point 25

7 Geometric Angular Velocity of Intersection Curve 27

8 Relative Geometric Angular Velocity of Intersecting Curve

with Respect to Boundary Surface 28

9 Relative Curvature and Relative Torsional Curvature of Intersecting

Curve with Respect to Boundary Surface 29

11 Differential Equation of Geometric Angular Displacement

For Parallel Transport along a Given Curve on Given Surface 30

12 Parallel Transport of a Vector along a Given Curve on Given Surface 31

13 Displacement of a Vector along a Given Curve on Given Surface 32

14 Relationship between Parallel Transport and Displacement of

a Vector along a Given Curve on Given Surface 34

Chapter 3 Conjugate Motion, Conjugate Surface and Requirements of Conjugate Contact 37

1.3.1 Canonical Form of Conjugate Motion 37

1.3.2 Canonical Form of Simple Conjugate Motion 38

1.3.3 Dual Coordinate System for Simple Conjugate Motion 39

1.3.4 Displacement of Any Point on Rigid Body in Simple Conjugate Motion

1 Independent Parameters of Variable 40

2 Displacement of Point on Rigid Body I 40

3 Common Point on Rigid Body II 41

4 Initial Position of Common Point on Rigid Body II 41

1.3.5 Linear Velocity of Point in Simple Conjugate Motion with Single

1 Linear Velocity of Common Point on Rigid Body I 42

2 Linear Velocity of Common Point on Rigid Body II 42

3 Relative Linear Velocity of Common Point on Rigid Body I

with Respect to Rigid Body II 42

1.3.6 Angular Velocity of Simple Conjugate Motion with Single Degree

1.3.7 Conjugate Contact Point and Conjugate Point 43

2 Requirements to be Satisfied by Conjugate Contact Point 43

1.3.8 Instantaneous Contact Line and Contact Line 44

2 Calculation of Instantaneous Contact Line 45

1.3.9 Path of Contact and the Second Conjugate Surface 47

Chapter 4 Pitch Surface and Surface of Screw Axis 48

1.4.1 Definition of Pitch Surface 48

1.4.3 Equation of Pitch Surfaces 48

1 Equation of the First Pitch Surface 48

2 Path of Contact for Pitch Surfaces 48

3 Equation of the Second Pitch Surface 49

1.4.4 Unit Normal to Pitch Surface at Instantaneous Contact Position 49

1.4.5 Rate of Rotating Angular Increment with Respect to Arc-Length, Ratio of