Turn that problem into an opportunity for excellence. Avoid those troublesome surprises when you can least afford them. Seek out the unknown. Be wary of untested assumptions. Understand the Material Properties Strive to get the most performance out of your material selection.
Improved accuracy has multiple effects on the design.
Insure that the design quality is consistent with the manufactured quality. It is a detriment to assume a lower accuracy level than is actually achieved. This first pass gearset determination is based on the load capacity, desired ratio, material and quality selections. The output will be the basic center distance, pitch, and tooth combination. The gear design must meet all requirements at the extreme conditions that result from the use of dissimilar materials for the housing, pinion, and gear, the operating temperature range, bearing runout and clearance, and gear tooth errors.