The diagram below demonstrates the positions along the path of contact.

The position along the path of

contact can be expressed as the roll distance, roll angle and radius to tooth flank demonstrated within
the diagram 1:
Diagram 1

The investigation of your results has led us to believe that you have taken the roll angle incorrectly
within your calculations. We think that you have not taken the roll angle as demonstrated on the
diagram above, instead taking it from the base radius line to the radius line shown on the diagram
above, hence a lower calculated roll angle than that calculated within Romax Designer.
I have calculated the roll angle and can verify the Romax Designer value of 33.640 degrees given.
Please find my calculations as follows:
Calculations 1
The positions along the path of contact can be calculated using the following equations:
Roll Distance = roll angle x base radius
Roll Distance =

radius

up tooth

flank

base radius

From the information you supplied we have calculated the base diameter db to equal:
The equations above require the base radius br, which is:

71.0556

35.5278

The tooth flank diameter as taken from the attachment (GI Gear) sent on the 07/11/05 is 82.4.
The roll distance can therefore be calculated as follows:
Roll Distance =

radius

Roll Distance =

82.4

up tooth

71.0556

flank

base radius

20.8618

It is now possible to calculate the roll angle because we now have the roll distance (calculated) and
base radius from the attachment (GI Gear), by rearranging the following equation:
Roll Distance = roll angle x base radius
Rearranging gives:

Roll Dis tan ce

Base Radius

Roll angle =

20.8618
0.587196 rad
Roll angle = 71.0556

The roll angle is given in radians; this is then converted to degrees as follows:

20.8618

Roll angle =
71.0556

180 33.6438 deg s

This is the same value as that obtained within Romax Designer at 33.640.
As explained above, I think you are taking the roll angle incorrectly within your calculations to achieve
your answer of 30.42. Please see diagram 2 and the explanation below:
Diagram 2

My investigations have demonstrated that you are using the angle between the diameter and base circle
which is the pressure angle at that particular point. However, to calculate the roll angle you need to
take the angle to the involute, the involute angle y + the pressure angle .

Roll angle = y
The following calculations (calculations 2) demonstrate how you have achieved the value of 30.42
degrees.
Calculations 2
You have performed the calculations using the correct values but using the incorrect method. The
values you have used are the EAP (end of active profile) which is the start of the tip chamfer/radius up
to tooth flank, and the base radius.
The EAP = 82.4
The base radius = 71.0556
Base radius

EAP

cos 1

71.0556

1
2
30.4214 deg
= cos
82.4

Conclusion
The value 30.42 degrees you have calculated is therefore the pressure angle at that particular point
and not the roll angle which explains the difference between your calculated value and the roll angle
value achieved in Romax Designer of 33.640 degrees. The Calculations outlined in the calculations 1
section provides the same value as that achieved within Romax Designer of 33.64 degrees for the roll
angle.
As discussed you are using the correct information but performing the calculations incorrectly.