ADVANCED ENGINEERING

3(2009)1, ISSN 1846-5900

TOOTHING WITH HARMONIC BASIC PROFILE

Obsieger, B.
Abstract: The paper elaborates the geometry, condition of meshing, undercut and sliding
velocities of gears with harmonic basic profile. The calculation show that in the such kind of
gearing the contact pressure on the beginning and at the end of meshing can be neglected
because of convex-concave contact between top and root of teeth. In the middle area of meshing
the contact pressure increase, but is always lesser than in the gears with involute toothing. The
stress on the root fillet of toothing with harmonic basic profile is considerably less than in
involute toothing because of larger cross section and larger curvature radii of the root fillet. Due
to convex-concave contact, the elastohydrodynamic oil film are thicker, and has no tendency to
be lost, as it is case with involute gears with inadequate shift coefficients.

Keywords: gear, toothing, undercut, convex-concave contact, contact pressure.

1 INTRODUCTION
The disadvantage of involute toothing is convex-convex contact at the beginning and at
the end of meshing, which causes the excessive contact stress on these regions. This
fact combined with high sliding velocity and relatively pure tribological properties can
result in intolerable local wear and surfaces destruction.
To avoid this disadvantage a special non-involute toothing with harmonic basic
profile is proposed (Fig. 1). This basic profile consists of a sinus curve [1,2]. The sinus
curve is practically straight in the middle and identical to the involute basic rack. That
will preserve good characteristic of involute toothing (low sensitivity to the variation of
gears distance).

Pt

0n
t
Y

xmn

C0

Pt
p

Pt
p

mn / cos
Fig. 1. Basic profile in transverse section [1]
67

On the other hand, gradually increased curvature on both ends of the basic profile
provide convex-concave contact on top and root of teeth, larger cross section and larger
profile radii on the root of teeth and smaller sliding velocity at the beginning and at the
end of meshing. That will result in reduced contact stress, reduced stress at root of
teeth and better lubricating conditions.

2 BASIC PROFILE
Basic profile of harmonic toothing is defined in co-ordinate system 0 n 0 n in normal
section with expression1
2
0n = ha0 cos 0n .
(1)
mn
Co-ordinates of point Y on profile in the transverse section (Fig. 1 and 2) are

Pt =

0n
,
cos
Pt = 0n + xm n .

(2)

Fig. 2. Co-ordinate systems in transverse section [1]

1

The standardised symbols (such as normal module mn, etc.) that are consistent with ISO
recommendations related to gearing are not declared separately.

68

Angle Pt of the tangent t on point Y is defined with

2ha0 2 0n
cos .
tan Pt = Pt =
sin
Pt
mn
mn

(3)

3 PATH OF CONTACT
For arbitrary point Y(Pt,Pt) on the basic profile and known angle Pt=Pt(Y) of the
tangent t, the rolling arc s can be found:
(4)
s = Pt Pt tan Pt .
Path of contact can be than expressed in co-ordinate system p with equations
p = Pt + s = Pt tan Pt ,
(5)
= Pt .
On the Fig. 3 and 4, the paths of contact for different profile shift coefficients x are
presented. Since, the sinus curve is practically straight in the middle and identical to
the involute basic rack, paths of contact are also almost linear in the middle, preserving
good characteristic of involute toothing (low sensitivity to the variation of axis's
distance). Curved ends of paths of contact will result in convex-concave contact in this
region as it is shown on Fig. 3.

Rack

Gear
Double contact
Convex-concave contact
Fig. 3. Path of contact between gear and basic rack for ha0=1,25mn, = 0 , x=0 and z=10 [1]

4 PROFILE OF HARMONIC TOOTHING

For the arbitrary point Y(p,) on path of contact and corresponding rolling angle
t = s / r , the point Y(xt, yt) on the generated gear (Fig. 5) can be found by
transformation of co-ordinate systems:
x t = p cos t ( + r ) sin t ,
(6)
y t = p sin t + ( + r ) cos t r.
Angle t of the tangent t is defined with t = Pt + t .
69


mn

gY
mn

p
mn

gY
mn

Fig. 4. Paths of contact of toothing with harmonic basic profile, ha0=1,25mn and = 0 [1]

yt

xt
C0

x=1
0,5
0

0,5
1

ha 0 = 1,25mn , z = 20, = 0

Fig. 5. Teeth generated with harmonic basic profile for z = 20 [1]

70

For the illustration, the profiles of teeth generated with harmonic basic profile are
presented on the Fig. 5, 6 and 7.
A free choice of teeth number and basic profile shift combination are limited with
the minimally required teeth top land and with the appearing of undercutting
phenomena.

Fig. 6. Teeth generated with harmonic basic profile for x = 0,5 [1]
71

yt
mn

mn

Fig. 7. Teeth generated with harmonic basic profile for x = 0 [1]

Comparing the limits of sinusoidal an involute toothing, it is visible that, although

insufficient top land on sinusoidal gearing exposes with the slightly greater teeth
number then on the involute gear, undercutting on sinusoidal gearing appears on the
lower teeth number then on the involute gearing (Fig. 8).
72

san
< 0,25
mn

= 0

= 30
= 0

= 30
Harmonic
toothing

Involute
toothing

Undercutting

Fig. 8. A comparison of application limits for n = 20 , ha0=1,25mn and a0=0,38mn [1]

5 CURVATURE RADIUS OF TOOTH PROFILE

According to [1,2], curvature radius of tooth profile in transverse section can be
calculated from
B2

1
= cos 3 Pt
A ,
t
B + r

A = 4ha0 cos 2 cos Pt cos ,

mn

(7)

B = 1 + tan 2 Pt + A .
73

In the analyses of meshing of two gears it has to be kept in mind that the pair of
non-involute gears can be coupled properly only if condition x = 0 is satisfied. Thus,
for the variables r and x have to be set r = r1 = z1m t / 2 and x = x1 for gear 1, or
r = r2 = z 2 m t / 2 and x = x 2 = x1 for gear 2.
Reduced curvature radius t red at meshing point can be than calculated from
expression
1
1
1
=

.
(8)

t red

t 2

t1

As it is shown on Fig. 9, reduced curvature radius of tooth profile at the beginning

and at the end of meshing can arise to infinity. The opposite situation characterises
involute toothing, for which reduced curvature radius at the beginning and at the end of
meshing tends to zero.
1

mn

mn

t red

0,6

=0

0,4

x =0
0,2

z 1 =10

x =0

20

10

z 2 =20

0
0,2

m n / t red

0,4
0,6

mn

t red

=0

0,8
1

0,8

0,6

0,4

0,2

mn

0,4

0,6

0,8

Fig. 9. Curvature radius of tooth profile for x=0, ha0=1,25mn and = 0 [1]
74

6 VELOCITIES
Tangential velocity v1 and v2 can be calculated by using the expression [1]:

v t
cos Pt
v t = 1 r1 ,
v=

1 1

+ ,
B r

(9)

where B and r are those defined for calculation of curvature radius of tooth profile.
Sliding velocity

v g = v 2 v1 = 2

g Y
mn

1 1
+ v t .
z1 z 2

(10)

Herein
g Y =

cos Pt

(11)

represent distance from kinematic pole C to meshing point Y on path of contact (as
shown on Fig. 4).

7 CONTACT STRESS
Hertzian contact stress is usually calculated by using the following formula
H =

E
F 1
,
2
2 (1 ) b red

(12)

where E is module of elasticity, while denotes Poisson's number.

To determine load at the beginning and at the and of tooth meshing, it is necessary
to determine teeth load-sharing that depends on teeth stiffness, (i.e., force Ft1 loading
one pair of teeth in the relation to entire force Ft , Fig. 2) [2,3].
7.1 Teeth deflection and teeth load-sharing
The provided analyses of teeth deflection
= H + f + U
(13)
was based on formulas in [2, 3]. Herein H represents deformation of surface, f influence of stiffness of root, while U represents influence of stiffness of the gear
body. Components f and U are proportional to normal force, while component of
teeth deflection H is logarithmic function of normal force. Consequently, stiffness of
tooth and teeth load-sharing depends on applied force also.
Since teeth deflection is function of the force, the force applied to one pair of teeth
is inverse function of deflection. By applying compatibility conditions, as described in
[2], the teeth load-sharing factor Ft1 / Ft (i.e. force Ft1 loading one pair of teeth in the
relation to entire force Ft ) can be easily calculated for each meshing position.
The example of calculated teeth load-sharing for Harmonic toothing is presented
on Fig. 10.
75

0,8

Ft1
Ft

0,6
0,4
0,2
0
3

s /1mn

Fig. 10. Teeth load-sharing for harmonic toothing for z1 = 12 , z2 = 28 .

x = 0,25 , ha0 / m = 1,25 , = 0 and Ft /(bmn E ) = 1 [2]

The load-sharing for involute gears was applied considering ISO DTR 13989.
7.2 Local stress factor
Due to validation of numerical results, it is convenient to introduce local stress factor
YH =

Ft1 F mn
1
,

2
2 (1 ) Ft Ft1 red

(14)

which can also be easily calculated from results obtained by measurements on photoelastic model as [2,4,5]
bmn
.
(15)
YH = H
Ft

E (model)

In that case, the Hertzian contact stress can be calculated by using the following
formula
H = E

Ft
YH .
bmn

(16)

7.3 Measurements on photoelastic model

For the purpose to verify the theoretical results, the measurements were done on
photoelastic model of two gears with teeth numbers z1 = 12 and z2 = 28 , profile shift
coefficient x = 0,25 and ha0 = 1,25mn , which were cut by using NTC machine. Each
measurement consist on positioning and fixing of gear 2 to chosen position, applying
the load to gear 1 and photographing the model. The special device that was used for
loading the model in arbitrary meshing position of gears is presented on Fig. 11.
76

gear 2

gear 1

Fig. 11. Device for loading photoelastic model of gear pair [2]

The detail of one photograph is shown as an example on the Fig. 12. The black and
white fields on photograph, i.e. photoelastic stress patterns, represent places of equal
difference of principal stresses. By counting photoelastic stress patterns, as described
in various literatures [4], the fillet and contact stress can be easily determined.

Fig. 12. Detail of photograph (rotated clockwise for 90 ) [2]

77

7.4 Comparison of theoretical and experimental results

Local stress factor YH obtained by measurements for different meshing positions and its
correlation with theoretical results are presented on Fig. 13. and 14. Very good
correlation between theoretical and experimental results, together with small
dissipation of experimental results indicates that used numerical methods for
calculation of tooth deflection and load-sharing is enough precise for further analyses.
It is evident that harmonic gearing is characterised with very small contact stress at
the beginning and at the end of teeth mesh, as it was expecting due to large red . It is
also evident that maximal values of contact stress at the region of kinematic pole C is
comparable with the value of lowest contact stress of standard involute toothing.
0,5
Numerical results
Experimental results
0,4
YH
0,3

0,2

0,1

0
3

s /m
1n

Fig. 13. Local stress factor YH for s harmonic toothing for

z1=12, z2=28, x=0,25, ha0=1,25mn and = 0 [2]

By analysing factor
2

Y (involute)
f H = (involute) 100% = Hmax 100% ,
Ft max
YHmax
Ft max

(17)

it can be found (Fig. 15) that Harmonic toothing has approximately up to 25% higher
carrying capacity than involute toothing.
78

0,5
YH

Experimental results.

0,4

0,3

0,2

0,1

0
0

0,1

0,2
0,3
Numerical results.

0,4

0,5
YH

Fig. 14. Correlation of factors YH obtained by experimental and numerical methods

for s harmonic toothing for z1=12, z2=28, x=0,25, ha0=1,25mn and = 0 [2]

130

fH
[%]
120

z 2=
40
20

110

100

14

17

20

25

30

z1

40

50

70

100

Fig. 15. Carrying capacity of harmonic toothing in the respect to standard

involute toothing, for n = 20 , ha0=1,25mn, x=0 and = 0 [1]
79

8 STRESS OF ROOTH FILET

Nominal tooth-root stress by ISO method C is defined with following equation:
F
F
F0 = t YFaYSaY Y = t YFSY Y ,
(18)
bmn
bmn
when total force is acting at point A on addendum (Fig. 16). ISO standard [6] defines
form factor
6h / mn cos Fan
(19)
YFa = Fa
( s Fn / mn ) 2 cos n
stress correction factor
1 /(1,21 + 2,3hFa / s Fn )
s
(20)
YSa = (1,2 + 0,13s Fn / hFa ) Fn
2 n
and corresponding tip factor YFS = YFaYSa .
Bottom tooth thickness sFn and bending moment arm relevant to load application at
the tooth tip hFa (Fig. 16) depends on critical section at tooth-root fillet. According to
ISO standard, the critical section is defined by the = 30 tangent, but this criterion of
selecting critical section gives non-realistic results when applied to noninvolute
gearings. More realistic results are obtained by determining critical section with MAX
method [7, 8, 9] which defines critical section as those on which tip factor has
maximum value
YFS ( critical ) = (YFaYSa ) max
(21)
Consequently, the value of tooth-root fillet tangent critical depends on gear parameters.
Results of calculation are presented on Fig. 17.

Fig. 16. Transverse section [1]

80

4,1

YFS

-0,5

3,9

0
3,8

3,7
x = 0,5
3,6

1
3,5

3,4
14

17

20

25 30
zn

40

50

70

100

Fig. 17. Factor YFS of harmonic gearing (MAX method) [1]

By analysing factor
YFS
100%
(inv)
YFS

(22)

it can be found (Fig. 18) that Harmonic toothing has approximately 10-30% higher
carrying capacity than involute toothing.
81

140

YFS
[%]
(inv)
YFS

a0 = 0,2

-0,5

x= 0

130
0,5

-0,5

a0 = 0,38

120

x=0

0,5

110

100

14

17

20

25

30

40 50

70100

Fig. 18. Comparison of factor YFS of harmonic and involute gearing (MAX method) [1]

Actual tooth root stress can be expressed by formula

F
F = t YFYS ,
(23)
bm
where
6hF / mn cos Fn
,
(24)
YF =
( s Fn / mn ) 2 cos n
1 /(1,21 + 2,3hF / s Fn )
s
.
(25)
YS = (1,2 + 0,13s Fn / hF ) Fn
2 n
Factor YFYS can be also easily calculated from results obtained by measurements
on elasto-optic model (Fig. 12) as

(bmn )(model)
(26)
Ft
Result and comparison of experimental and theoretical results are presented on the
Fig. 19 and 20. Correlation between theoretical and experimental results is presented
on Fig. 21.
YFYS =

82

Numerical results
Experimental results

Y FY S
3

0
3

s /m n

Fig. 19. Factor YFYS for gear 1, z1 =12, z2 = 28, x1 = 0,25, x2 = 0,25 and ha0* = 1,25 [2]

Numerical results

Y FY S

Experimental results

0
3

s /m n

Fig. 20. Factor YFYS for gear 2, z1 =12, z2 = 28, x1 = 0,25, x2 = 0,25 and ha0* = 1,25 [2]
83

4
Y FY S

Experimental results

0
0

Numerical results

Y FY S

Fig. 21. Correlation of factors YFYS obtained by experimental and numerical

methods for z1 =12, z2 = 28, x1 = 0,25, x2 = 0,25 and ha0* = 1,25 [2]

9 LUBRICATION
In the case of elasto-hydrodynamic lubrication, the thickness of the oil film separating
surfaces at meshing point can be calculated from expression [2, 10]:

0,6 (6M v ) 0,7 E 0,03 t0,43

equ
.
h0 = 0,281
2 0, 03
0,13
(1 ) ( F / b)

(27)

Herein M denotes dynamic viscosity at the initial surface temperature and

environmental pressure, while denote influence of pressure p to dynamic viscosity
= M ep between surfaces.
It is convenient to separate variables characterising local geometry from external
variables, i.e., load, speed and material properties. By introducing factor
0, 7

M v t 1 2 Ft

3 6

X h = 12,17 10

mn

bmn

0,13

1 2

0,1

(28)

which consists on three dimensionless groups, the thickness of the oil film h0 can be
calculated as
0, 7
( t equ / mn ) 0, 43
h0
6 ( v / v t )
= 23,09 10
Xh .
mn
( F / Ft ) 0,13

84

(29)

By considering that factor X h has value X h = 1 , we can see at once in Fig. 22 that
the values oil film thickness at the beginning of the meshing of involute toothing is
radically diminished, while the values oil film thickness of harmonic toothing has
highest values. Moreover, the minimal value oil film thickness of harmonic toothing at
the region of kinematic pole C is comparable with the value of highest oil film
thickness of involute toothing.
4

h0 5
10
mn

harmonic toothing

h0 min
2
involute toothing

h0 min

0
3

s /1mn

Fig. 22. Oil film thickness for different meshing points for z1 = 12 , z2 = 25 ,
x1 = 0,25 , x 2 = 0,25 , n = 20 , ha0 = 1,25mn , = 0 and X h = 1 [2]

h0 min 5
10
mn

Harmonic
toothing

50

z 2=25

Involute
toothing

z 2=25
50

0
1

0,5

x1

0,5

Fig. 23. Minimal thickness of oil film for harmonic and involute toothing
for z1 = 25 , n = 20 , ha0 = 1,25mn , = 0 , x = 0 and X h = 1 [2]

85

As it is shown on Fig. 23, the influence of profile shift coefficient x1 and numbers
of teeth z to minimal oil film thickness of harmonic toothing can be neglected in
relation to those of involute toothing. According to that, excellent lubricating
conditions of harmonic toothing for wide range of profile shift coefficient x and
numbers of teeth z can be expected.

10 CONCLUSION
The most important advantage of toothing with harmonic basic profile in relation to
standard involute toothing is convex-concave contact at the beginning and at the end of
meshing path, which result in (a) very low contact stress at these region, (b) excellent
lubricating conditions, i.e., adequate oil film thickness from the beginning to the end of
meshing, and (c) gradual and smooth beginning and end of the tooth meshing.
Consequently, it is possible to avoid the damages of teeth flanks and to increase the
reliability and durability of gearbox.
Larger cross section and larger profile radii on the root of teeth, together with
smaller contact pressure significantly enlarge carrying capacity in comparison to
involute toothing.
The harmonic toothing has some other advantages that are not described in this
paper, such as possibility to cut gear with small tooth number (down to z=5) without
undercutting. Due to better lubrication conditions, the harmonic toothing is also
characterised with lesser friction losses and lesser temperature level on contact area,
which are important conditions required for transmissions that working under high load
and high velocities.
References:
[1]

Obsieger, B. (1986). Some Characteristics of Gears with Sinusoidal Toothing, Magisterium, University in Ljubljana, Technical Faculty, Ljubljana
[2] Obsieger, B. (1993). A Contribution to Research of Carrying Capacity and Tribological
Chara-cteristic of Sinusoidal Toothing, Dissertation, University of Rijeka, Faculty of Engineering, Rijeka
[3] Winter, H. & Podlesnik, B. (1983). Zahnfedersteifigkeit von Stirnradpaaren, Teil 1:
Grundlagen und bisherige Untersuchungen, Antriebstechnik 22(1983) Nr. 3
[4] Frocht, M., M. (1983). Photoelasticity, John Wiley & Sons, London
[5] Obsieger, B. (1999). Researches of Non-Involute Toothing with Harmonic Basic Profile,
4th World Congress on Gearing and Power Transmission, Paris, 1999.
[6] International standard - ISO 6336-1, Part 1 and part 3, 1. Edition, International
Organization for standardization, Switzerland, 1996.
[7] Obsieger, B. & Obsieger, J. (1980). Zahnformfaktoren von Auen- und Innenverzahnungen bei der Herstellung im Abwlzverfahren mit Schneidrdern, Konstruktion
32(1980)H.11, S. 443-447
[8] KISSsoft Manual - Calculation - Programs for machine design, www.KISSsoft.ch
[9] Glaar, V.; Obsieger, B. & Gregov, G. (2008). Comparison of ISO and MAX Method In
Determining Tip Factor Of Involute Gears, Advanced Engineering 2(2008)1, ISSN 18465900
[10] Dowson, D. & Higginson, G.R. (1977). Elasto-Hydrodynamic Lubrication, Oxford, New
York, Toronto, Sydney, Paris, Frankfurt, Pregamon Press Ltd.

Received: 2008-10-16
86