| In this paper, based on the achievements of our research group on harmonic gear drive, we replaced the addendum and the dedendum of the involute tooth profile with the circle arc. So a kind of new tooth profile was proposed——double-circular-arc tooth profile, and the design method and performance of tooth profile were studied and analyzed.First, this paper presented the design approach of double-circular-arc tooth profile of flexspline, circular spline and their cutters, then wrote corresponding program of tooth profile normal method and envelope method for solving. On the basis of designed program, the tooth profile parameters could be input so as to realize rapid solution of tooth profile of flexspline, circular spline and cutters, which greatly reduced product design and manufacturing cycle of harmonic drive. In the meanwhile, the generality of designed cutters was studied.Second, considering the meshing between flexspline and circular spline influenced by wave generator after the wave generator was put into flexspline, we analyzed the flexspline in the initial deformation, no-load and load in the finite element software Abaqus. The analysis results showed that double-circular-arc tooth profile could significantly improve the meshing condition between flexspine and circular spline under the action of wave generator.Then, we did the research on the control method of tooth thickness of flexspline and circular spline. In order to solve the measured distance over pins M value conveniently, we wrote the corresponding program for solving in Matlab. In addition, we took ultimate load test and backlash test on the prototype of harmonic gear drive.Finally, to avoid the negative effect of variable coefficient on the arc section of double-circular-arc tooth profile, it was found that the cutters of non standard modulus could be designed. Then the complete double-circular-arc tooth profile of flexspline and circular spline can be manufactured.
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