The paper presents the process of preparing gear models with an original profile for numerical analyses. We used solid modeling reflecting the gear cutting using the enveloping generation method. A script was prepared in AutoCAD to enable automatic simulation of the material removal process and obtain precise gear models. The analyzed gears had geometry based on Novikov's engagement; however, during the tool design, the tooth profile was adjusted due to the incorrect values of certain parameters present in the standards. Gears models with a circular-arc tooth profile created in this process were used for finite element method (FEM) calculations in ANSYS. An analysis of the contact pattern for the loaded gearbox was conducted. The stress state for the analyzed gear transmission with the adjusted tooth profile was also determined.
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