You have created your gears with the Gear Generator module from the menu Design, Power Transmission, without problems or errors.
By the way, in the model you notice some small interference.
And also, creating a drawing with the view of the Gear teeth, you notice that this is a simplified representation.
This behavior is as designed.
To get accurate model, you need to do the following.
- Right-click the gear subassembly in the browser and select to Export tooth shape.
- In the following dialog select if you want to export the Gear or Pinion tooth shape.
You can find more details for the other settings and in general for this command in the help, under “Export tooth shape”.
- Then, in the resulting model, extrude the profile.
- Finally, use circular pattern to get amount of teeth you need.
Creating the view of the teeth of this model you can notice the better accuracy.
This process is shown in the first 2-3 minutes of this video, created by my friend Anton Fedoseyev.
Audio is in Russian, but you can watch the steps anyway.