A mathematical model of a modified helical gear train (MHGT), manufactured with a practical hobbing machine using a curved-template guide, and which takes considerations of center-distance variation and axial misalignment into account, is developed. Tooth contact analysis (TCA) and kinematic errors of a MHGT due to mis-assembly are investigated. A multiple optimization method is applied to reduce the level of MHGT kinematic errors, and to investigate optimal gear tooth modifications. Computer simulation programs for TCA and optimization are also developed. Two numerical examples are presented to illustrate the kinematic optimization of the proposed helical gear train. The results of this study are most helpful in designing and analyzing a MHGT.

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