The digital tooth contact analysis (DTCA) of machined gears is an effective way to evaluate both the design and manufacturing before rolling tests. This is very challenging to face gear drives due to two aspects. (1) No measurement standard is available for face gears to obtain an accurate measurement model. (2) The DTCA equation is highly nonlinear related to the complex geometry of face gears. To fulfil those problems, this work presents an accurate measurement model of the face gear tooth surface, wherein the DTCA is implemented with a robust algorithm. An effective measurement strategy based on sensitivity analysis is proposed to establish a measurement coordinate system (MCS), and the relationship between the MCS and the design coordinate system (DCS) is further analyzed to compensate the measurement errors. Subsequently, the B-spline fitting technology is applied to reconstruct the measurement model. Furthermore, the equation of meshing is simplified to reduce its nonlinearity and realize the DTCA. The proposed method is verified by both the finite element analysis (FEA) and a rolling test.

机加工齿轮的数字齿接触分析 (DTCA) 是一种在滚动试验前评估设计和制造的有效方法。由于两个方面，这对于面对齿轮驱动是非常具有挑战性的。(1) 平面齿轮没有测量标准，无法获得准确的测量模型。(2) DTCA 方程是高度非线性的，与面齿轮的复杂几何形状有关。为了解决这些问题，这项工作提出了一个精确的面齿轮齿面测量模型，其中 DTCA 是用稳健的算法实现的。提出一种基于灵敏度分析的有效测量策略，建立测量坐标系(MCS)，并进一步分析MCS与设计坐标系(DCS)的关系，以补偿测量误差。随后，该应用B样条拟合技术重建测量模型。进一步简化了网格划分方程，降低了其非线性，实现了DTCA。通过有限元分析 (FEA) 和滚动试验验证了所提出的方法。