Gear-loaded tooth contact analysis is an important tool for the design and analysis of gear performance within transmission and driveline systems. Methods for the calculation of tooth contact conditions have been discussed in the literature for many years. It's possible the method you've been using is underestimating transmission error in helical gears. Here's why.
While designing gear and spline teeth, the root fillet area and the corresponding maximum tensile stress are primary design considerations for the gear designer. Root fillet tensile stress may be calculated using macro-geometry values such as module,
minor diameter, effective fillet radius, face width, etc.
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