I am using the Gear Mate feature in SW 2009. When I rotate the gears, the teeth do not touch/mesh with each other. See screenshots.
All the gear mate does is set the rotation ratios. If you do dynamic interference detection between the gears and have it stop at interference so that the teeth touch each other and then add your gear mate, it will look better.
Here's a simpler way that works for me:
In the drawing tree under Mates, simply right-click the gear mates, then suppress the gear mates. Then line up the teeth of the gears by rotating one of the two gears. Now go back to the gear mates in the tree, right-click them and unsuppress them. The teeth should now stay meshed as long as you have the ratio set correctly for your specific gears.
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