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From the Rolls-Royce experimental archive: a quarter of a million communications from Rolls-Royce, 1906 to 1960's. Documents from the Sir Henry Royce Memorial Foundation (SHRMF).
Technical document detailing the calculation of the arc of contact for gear teeth.

Identifier  ExFiles\Box 136\2\  scan0255
Date  15th April 1940 guessed
  
-2-

During the passage of a pair of tooth profiles into and out of contact this length MN is rolled off one base circle and on to an-other.

Therefore the arc of contact measured on the base circle is MN.

Measured on the pitch circle it is (MN / Cos. φ) and the number of teeth in contact is (MN / (Cos. φ pc)) where pc is the circular pitch.

MN = MP + PN{Mr Northey}
PN{Mr Northey} = LN - LP{Mr Lappin}
LN = √(O2N² - O2L²) = √((r2+a2)² - r2²cos²φ)
LP{Mr Lappin} = r2 sin. φ
∴PN{Mr Northey} = √((r2+a2)² - r2²cos²φ) - r2 sin φ
similarly MP = √((r1+a1)² - r1²cos²φ) - r1sin φ
MN = √((r1+a1)² - r1² cos² φ) + √((r2+a2)² - r2²cos² φ) - (r1+r2) sin φ, and number of teeth in contact:
= (1 / (Cos φ pc)) * [√((r1+a1)² - r1²cos²φ) + √((r2+a2)² - r2²cos²φ) - (r1+r2)sinφ]
  
  


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