The double flank gear rolling testing is a method by which a master gear is rolled together, in tight mesh, with a testing gear. As the gears roll, slight variations of center distance are measured and recorded as an indicator of gear quality. The double flank gear rolling testing is easy and low coast, therefore, it is widely used in gear industry. In this study, the mathematical models of standard master gears and testing gears with various errors are carried out first according to the theory of gearing. Then, the process of double flank gear rolling testing is simulated by applying the concept of tooth contact analysis (TCA). Tooth contact types including surface-to-surface contact and tip-to-surface interference are considered, and three possible combinations of these two contact types occurring on each tooth flanks are discussed as well. The results of this study can provide the industry a significant process to establish the analysis and capacities for double flank testing.

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