Gear Metrology2

BY V.N.
PRASAD
GEAR METROLOGY
Gears are very important transmission elements

 These are toothed wheels commonly used to transmit power or motion from one shaft to
another shaft without slip.
 These are positive drives and transmission efficiency is 99%
WHY TOOTHED WHEELS?
Assume that there are two friction

pulleys in contact whose diameters
are equal to the reference or pitch
circle diameters. As the surfaces are
smooth, the rotation will not go
properly when great force is
applied.
This problem will be solved if there

are teeth on the periphery of the
friction pulley. And this is the
concept of gearing.
Need to test and measure the gears
• The errors present in the gears can interfere with the efficient operations of the equipment
using them, e.g., machine tools, vehicles etc.
• The accuracy of gears, both as to their geometrical forms, size has a considerable effect
on smoothness of operation, freedom from noise and length of working life.
• In addition to this for higher efficiency the gears should be perfectly mounted on perfect
shaft running in perfect bearings.
FORMS OF TEETHS
The most commonly used forms of gear teeth are:
1) Cycloidal and
2) Involute
The cycloidal gears are not generally used in modern engineering, but
used for some crude purposes where heavy and impact loads come on
the machine.
Involute gears are now almost entirely used for general purpose in
precision engineering.
1. Cycloidal teeth
A cycloid is curve traced by a point on the circumference of a
circle which rolls without slipping on a fixed straight line.
Epi cycloid and Hypo cycloid?
Involute Profile
Formed by unwrapping a tangent chord
from the base circle
The involute gears also called as straight tooth or spur gears.
Advantages of involute gears over the cycloidal gears are:

• The variations in the center distance between two gears have
no effect on the velocity ratio between a pair of involute gears.
• The pressure angle is constant
• The involute rack has straight teeth. Thus the complex
involute form can be generated by using a relatively simple
cutter.
• All the gears having the same pitch and pressure angle work
correctly together.
• The face and flank of a tooth forms a continuous curve.
TYPES OF GEARS
SPUR GEARS
• These are the most common type of gear
having radial teeth parallel to the axis.
• They have straight teeth and are mounted

on parallel shafts.
• Used in electrical screwdriver, washing

machine.
HELICAL GEARS
The teeth on the helical
gears are cut at an angle
to the face of the gear.
BEVEL GEARS
Bevel gears are used to connect
shafts which intersect usually
but not necessarily at 900.
RACK AND PINION
• A toothed bar into which a
"pinion" meshes.
• Rack and pinion gears are
used to convert rotation into
linear moment.
WORM GEARS
• A worm drive is a gear
arrangement in which a worm
(one which looks like a screw)
meshes with other wheel (worm
wheel).
• Worm drive reduces rotational

speed and allows higher torque to
be transmitted.
Gear Nomenclature
Pitch point
• Pitch Point: The pitch point is the point where gear teeth actually make
contact with each other as they rotate.
Line of action or Force line
• Two involute gears, the left driving the right:

• Blue arrows show the contact forces between them.
• The force line (or line of action) runs along a tangent common to
both base circles.
Pressure angle or angle of obliquity:
• Pressure angle (ø) is the angle between the common normal to the
contacting teeth (line of action) and the common tangent to the pitch
circles of meshing gears .
• The relationship between radii of base (rb) and pitch circles (r) and the
pressure angle (ø ) is:
𝑟𝑏 = 𝑟 𝑐𝑜𝑠∅
• The standard proportions adopted by the Indian
standard system of the elements of an involute
spur gear are :
• The recommended series of modules adopted by the Indian Standard
System are 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16 and 20.
• The modules 1.125, 1.375, 1.75, 2.25, 3.5, 4.5, 5.5, 7, 9, 11, 14 and 18
are of second choice.
• The recommended series of Diametral pitches are 20, 16, 12, 10, 8, 7,
6, 5, 4, 3, 2 ½, 2, 1 ½, 1 ¼ and 1.
Spur Gear Measurement
The analytical inspection of the gears consists in determining the
following teeth elements in which manufacturing errors may be
present.
1. Runout
2. Pitch
3. Profile
4. Lead
5. Back Lash
6. Tooth thickness
7. Concentricity
8. Alignment
9. Composite errors
Tooth Thickness Measurement
Since the Tooth thickness is defined as the length of an arc, it is not possible to measure it
directly. It is generally measured at pitch circle and is, therefore, the pitch line thickness of the
tooth.
In most of the cases, it is sufficient to measure the chordal thickness i.e., the chord joining the
intersection of the tooth profile with the pitch circle.
There are various methods of measuring the gear tooth thickness
1.Chordal thickness method (measurement of tooth thickness by gear tooth Vernier caliper)
2. Constant chord method
3. Base tangent method
4.Measurement over rollers
Gear Tooth Vernier Caliper
Digital Gear Tooth Vernier Caliper
Constant chord method
• Constant chord (AB) is the chord between the points
at which the gear tooth profile touches the flank of
the basic rack of the system.
Derivation for calculating the chord length AB:
Base tangent method
• It is the most commonly used method for checking the tooth thickness of gear.
• The advantage of this method is that, it depends only on one reading unlike gear tooth
Vernier Caliper where we require two Vernier readings.
• The base tangent length is the distance between the two parallel planes which are
tangential to the opposing tooth flanks. As shown in Figure. PQ is the base tangent.
• The number of teeth over which the measurement is to be made for a particular gear
is selected from the gear hand book.
There are two methods for determining tooth thickness error:
1) With the help of flanged micrometer
2) David Brown Base Tangent Comparator
In the first method, the base tangent length is measured with the help of a
flanged micrometer. The difference between the actual reading and
theoretical value is the error.
The base tangent length will consists of one base circular thickness of tooth
and number of base pitches.
Flanged micrometer
• Therefore the position of the measuring faces of the
instrument is unimportant as long as they are parallel
and on an opposed pair of true involutes
• In the formulas and in the tables the theoretical
tooth thickness is always indicated.
• The probable backlash should to be deducted from
that value.
• The following formula indicates the theoretical measurement
across a certain number of teeth for the involute spur gear
𝝅 𝝅𝑺
Base tangent length (W) = 𝑵𝒎𝒄𝒐𝒔∅ 𝒕𝒂𝒏∅ − ∅ + +
𝟐𝑵 𝑵
Where, N = No.of teeth,
m = module
∅ = Pressure angle in radians,
S = No.of tooth spaces contained in W.
Derivation of Base tangent length
From Fig: W = arc AB + arc BC
Where, arc AB = Tooth thickness at base circle
• Arc BC = 𝑆 × (the base pitch)
Where S = number of tooth spaces over which
measurement is made
• i.e., arc BC = 𝑆 × 𝜋𝑚𝑐𝑜𝑠 ∅
• Now, we have to determine arc AB.
• The base tangent length will consists of one base circular
thickness of tooth and number of base pitches.
• What is base pitch?
• Base Pitch = 𝝅 𝒎 𝒄𝒐𝒔 ∅
𝑂𝑄
𝐹𝑟𝑜𝑚 ∆𝑙𝑒, 𝑃OQ cos ∅ =
𝑂𝑃
𝑅𝐵
• cos ∅ =
𝑅
• ∴ 𝐵𝑎𝑠𝑒 𝑐𝑖𝑟𝑐𝑙𝑒 𝑅𝑎𝑑𝑖𝑢𝑠 𝑅𝐵 = 𝑅 𝑐𝑜𝑠∅
2𝜋𝑅 𝑐𝑜𝑠∅
𝐵𝑎𝑠𝑒 𝑐𝑖𝑟𝑐𝑙𝑒 𝑃𝑖𝑡𝑐ℎ =
𝑁
𝜋𝑑𝑐𝑜𝑠∅
=
𝑁
Where d = 2R = Pitch circle diameter
Base Pitch = 𝝅 𝒎 𝒄𝒐𝒔 ∅

• To determine arc AB,
The tooth thickness at
Base circle, consider the
Fig. as shown.
Arc AB = 2 Arc AD
= 2 (Arc AF + arc FD)
𝑎𝑟𝑐 𝐴𝐹
= 𝑖𝑛𝑣. ∅ 𝑟𝑎𝑑𝑖𝑎𝑛𝑠
𝑅𝑏
𝑁𝑚
𝐴𝑟𝑐 𝐴𝐹 = 𝑐𝑜𝑠∅ 𝑡𝑎𝑛∅ − ∅ (Since 𝑅𝑏 = 𝑅𝑝 𝑐𝑜𝑠∅)
2
𝑎𝑟𝑐 𝐴𝐹 = 𝑅𝑏 𝑡𝑎𝑛∅ − ∅
𝑎𝑟𝑐 𝐺𝐻 𝑎𝑟𝑐 𝐹𝐷
𝜃 𝑟𝑎𝑑𝑖𝑎𝑛𝑠 = = −−−→ 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 (1)
𝑅𝑝 𝑅𝑏
1
𝐵𝑢𝑡, 𝑎𝑟𝑐 𝑮𝑯 = × 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐ℎ
4
𝜋𝑚
=
4
1 𝜋𝑚 𝜋𝑚 2 𝜋
𝜃= × = × = 𝑟𝑎𝑑𝑖𝑎𝑛𝑠
4 𝑅𝑝 4 𝑁𝑚 2𝑁
𝑎𝑟𝑐 𝐹𝐷 = 𝑅𝑏 × 𝜃 𝑓𝑟𝑜𝑚 𝑒𝑞. (1)

• But arc AB = 2( arc AF + arc FD )
𝝅 𝝅𝑺
W= 𝑵𝒎𝒄𝒐𝒔∅ 𝒕𝒂𝒏∅ − ∅ + +
𝟐𝑵 𝑵
• Calculate the setting of David Brown tangent comparator to measure the distance over three of
a spur gear with module of 2.5 mm, 20o pressure angle and 30 teeth, ignoring any backlash
allowance. What will be the size when the backlash allowance on the single gear is 0.1 mm
normal to the tooth flank.
Ans:
• 𝝅 𝝅𝑺
W= 𝑵𝒎𝒄𝒐𝒔∅ 𝒕𝒂𝒏∅ − ∅ + +
𝟐𝑵 𝑵
• T= Number of teeth,
• m = module,
• ∅ = pressure angle in radians.
• S= number of tooth spaces contained in W.
• W = 19.50 mm (ignoring backlash allowance)

• And distance over 3 number of teeth in a gear
• 19.50 – 0.1 = 19.40 mm (Considering backlash)
• In order to avoid calculation of the value of base tangent length (W)
for every case, tables are prepared for all ordinary tooth numbers,
module and for pressure angles 14o30’ and 20o
W = 4.59 mm
Ans: W = 14.01 mm
Ans: W = 4.5415 mm
David brown tangent comparator
Basics of Runout
Digital span micrometer for internal measuring
• A new way to measure
tooth thickness on
internal parts using a
span micrometer.
• The gage is set to a
master and then placed
over several teeth.
• The Gear software will
calculate the tooth
thickness / dimension
under pins.
Measurement With CMM
Basics of Runout

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BY V.N.

Gears are very important transmission elements

Assume that there are two friction

This problem will be solved if there

Advantages of involute gears over the cycloidal gears are:

• They have straight teeth and are mounted

• Used in electrical screwdriver, washing

• Worm drive reduces rotational

• Two involute gears, the left driving the right:

Base Pitch = 𝝅 𝒎 𝒄𝒐𝒔 ∅

𝑎𝑟𝑐 𝐹𝐷 = 𝑅𝑏 × 𝜃 𝑓𝑟𝑜𝑚 𝑒𝑞. (1)

• W = 19.50 mm (ignoring backlash allowance)

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