Beruflich Dokumente
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
Contents
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Symbols and corresponding terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 Extent of gear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 Identification of deviation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6 Measurement of pitch deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7 Measurement of profile deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Measurement of helix deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Measurement of single flank composite deviations . . . . . . . . . . . . . . . . . . . . . . 26
10 Contact pattern checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figures
1 Notation and numbering for external gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Notation and numbering for internal gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Schematic of single probe measuring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Single pitch deviation, single probe device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Pitch measurement with a pitch comparator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Circular pitch measurement, two probe device . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Single pitch deviation, two probe device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Sample table with hypothetical deviation values obtained by pitch
comparator (two probe) device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9 Sample table with hypothetical deviation values obtained by indexing
(single probe) device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 Sample graphic representation of single pitch deviations, fpt . . . . . . . . . . . . . . 10
11 Sample graphic representation of index deviations . . . . . . . . . . . . . . . . . . . . . . 10
12 Base pitch measurement, two probe device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13 Schematic of involute inspection device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14 Profile measuring method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15 Profile inspection by coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16 Typical tooth profile measurement charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
17 Tooth profile and profile diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
18 Mean profile slope deviation, fHαm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
19 Profile inspection by optical projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
20 Profile inspection by gear tooth caliper method . . . . . . . . . . . . . . . . . . . . . . . . . 18
21 Profile inspection by measurement over pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Helix deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
23 Graphic charting of helix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
24 Helix diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
25 Traces generated from four tooth flanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
26 Helix of right hand helical gear with short lead (+ helix angle) . . . . . . . . . . . . . 23
27 Helix of right hand helical gear with long lead (-- helix angle) . . . . . . . . . . . . . 23
28 Helix of left hand helical gear with long lead (-- helix angle) . . . . . . . . . . . . . . . 24
29 Helix of left hand helical gear with short lead (+ helix angle) . . . . . . . . . . . . . . 24
30 Principle of undulation inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
31 Composite gear testing, double and single flank . . . . . . . . . . . . . . . . . . . . . . . . 26
32 Schematic of a single flank measuring device . . . . . . . . . . . . . . . . . . . . . . . . . . 27
33 Individual tooth deviations revealed by single flank testing . . . . . . . . . . . . . . . 27
34 Filtered signal from figure 33 (eccentricity removed) . . . . . . . . . . . . . . . . . . . . 28
35 Angular motion curves from tooth modification . . . . . . . . . . . . . . . . . . . . . . . . . 29
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
Foreword
This Information Sheet, AGMA 915--1--A02, Inspection Practices -- Part 1: Cylindrical
Gears -- Tangential Measurements is provided for informational purposes and is intended
for use with the Standard ANSI/AGMA 2015--1--A01, Accuracy Classification System --
Tangential Measurements for Cylindrical Gears.
AGMA 915--1--A02 replaces AGMA ISO 10064--1, Cylindrical Gears -- Code of Inspection
Practice -- Part 1: Inspection of Corresponding Flanks of Gear Teeth. and the information on
similar subjects as covered in ANSI/AGMA 2000--A88, Gear Classification and Inspection
Handbook -- Tolerances and Measuring Methods for Unassembled Spur and Helical Gears.
The user of this Information Sheet is alerted that differences exist between it and
ANSI/AGMA 2000--A88 and AGMA ISO 10064--1. These include, but are not limited to:
-- Measuring methods refer to an accuracy grade numbering system that is reversed,
such that the smallest number represents the smallest tolerance;
-- Probe direction and measurement requirements for elemental and composite
tolerances may differ from ANSI/AGMA 2000--A88 or AGMA ISO 10064--1;
-- The measurement “profile evaluation range” and “helix evaluation range”, where
the tolerances are applied, are defined for different area than in ANSI/AGMA 2000--A88
or AGMA ISO 10064--1;
-- The measurement of undulations is included;
-- Concepts of “mean measurement trace”, “design trace”, “slope deviation”, “form
deviation”, “gear form filter cutoff”, “tolerance diameter” and “data density” are defined.
Therefore, the user of this information sheet must be very careful when comparing
measurement methods formerly specified using ANSI/AGMA 2000--A88 or AGMA ISO
10064--1.
The first draft of AGMA 915--1--A02 was made in May, 1998. This document was approved
by the Inspection Handbook Committee on January 31, 2002. It was approved by the
Technical Division Executive Committee as an AGMA Information Sheet on April 16, 2002.
Suggestions for improvement of this document will be welcome. They should be sent to the
American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria,
Virginia 22314.
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
ACTIVE MEMBERS
ASSOCIATE MEMBERS
M. Antosiewicz . . The Falk Corporation W.E. Lake . . . . . . Mitsubishi Gear Technology Ctr.
M.J. Barron . . . . . Gear Motions, Inc. A.J. Lemanski . . . Penn State University
D. Behling . . . . . . Hamilton Sundstrand Aero. G.A. Luetkemeier Rockwell Automation/Dodge
M.K. Considine . . Considine Associates D. Matzo . . . . . . . Northwest Gears, Inc.
R. Considine . . . . Considine Associates P.A. McNamara . Caterpillar, Inc.
J.S. Cowan . . . . . Eaton Corporation W.J. Michaels . . . Sundstrand Corporation
M.E. Cowan . . . . Process Equipment Company M. Milam . . . . . . . Amarillo Gear Company
B. Cowley . . . . . . Mahr Corporation T. Miller . . . . . . . . The Cincinnati Gear Company
C. Dick . . . . . . . . . The Horsburgh & Scott Co.
M. Nanlawala . . . IIT Research Institute/INFAC
H.D. Dodd . . . . . . Caterpillar, Inc.
M. Octrue . . . . . . Centre Technique Des Ind. Mec.
R. Green . . . . . . . R7 Group, Gear Consultants
T. Okamoto . . . . . Nippon Gear Company, Ltd.
D. Gregory . . . . . Gear Products, Inc.
J.A. Pennell . . . . . Univ. of Newcastle--Upon--Tyne
B. Gudates . . . . . Fairfield Manufacturing Co., Inc.
J.S. Hamilton . . . Regal--Beloit Corporation K.R. Price . . . . . . Eastman Kodak Company
H. Harary . . . . . . . NIST R.S. Ramberg . . . The Gear Works -- Seattle, Inc.
D. Heinrich . . . . . Xtek, Incorporated V.Z. Rychlinski . . Brad Foote Gear Works, Inc.
G. Henriot . . . . . . Consultant D.H. Senkfor . . . . Precision Gear Company
J. Horwell . . . . . . Brown & Sharpe S. Shariff . . . . . . . PMI Food Equipment Group
S. Johnson . . . . . The Gear Works -- Seattle, Inc. E. Storm . . . . . . . Consultant
T. Klemm . . . . . . . Liebherr R.F. Wasilewski . Arrow Gear Company
D.E. Kosal . . . . . . National Broach & Machine Co. F.M. Young . . . . . Forest City Gear Company
J. Koshiol . . . . . . Columbia Gear Corporation P. Zwart . . . . . . . . Caterpillar, Inc.
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
American Gear Manufacturers At the time of publication, the editions indicated were
valid. All standards are subject to revision, and
Association -- parties to agreements based on this document are
encouraged to investigate the possibility of applying
Where
Symbols Definition1) Units first used
b Facewidth mm Figure 24
D Design pitch diameter mm Eq 4
Db Design base diameter mm Eq 3
d Reference diameter mm Eq 24
db eff Effective base diameter mm 6.5.3
dT Tolerance diameter mm 6.2
Fβ Total helix deviation mm Figure 22
(continued)
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
Table 1 (continued)
Where
Symbols Definition1) Units first used
Fis Total single flank composite deviation mm 9.1
Fp Total cumulative pitch deviation mm 6.1
Fps/8 Sector pitch deviation2) mm 6.2
Fr Radial runout mm 9.3.6
Fα Total profile deviation mm Figure 17
fdbm Mean base diameter difference2) mm 6.5.3
fe Eccentricity between gear axis and axis of gear teeth mm Figure 18
ffα Profile form deviation mm Figure 17
ffβ Helix form deviation mm Figure 24
fHα Profile slope deviation2) mm Figure 17
fHαm Mean profile slope deviation2) mm 7.6
fHβ Helix slope deviation2) mm Figure 24
fHβm Mean helix slope deviation2) mm 8.6
fHβmt Mean helix slope deviation, in the transverse plane and tangent to the mm Eq 18
tolerance diameter2)
fid Tooth--to--tooth double flank composite deviation mm 9.3.6
fis Tooth--to--tooth single flank composite deviation mm 9.1
fLm Mean lead difference2) mm 8.7
fpbm Mean normal base pitch deviation2) mm 6.5.3
fpbn Normal base pitch deviation2) mm 6.5
fpt Single pitch deviation2) mm 6.1
fwβ Undulation height (along helix) mm Figure 24
f1, f2 Reading head frequency pulses/sec Figure 32
fα Pressure angle deviation2) degrees 7.5
fαmn Mean normal pressure angle deviation2) degrees 6.5.3
fαmt Mean transverse pressure angle deviation2) degrees 6.5.3
fβ Helix angle deviation2) degrees 8.5
fβm Mean helix angle deviation2) degrees 8.7
gα Length of path of contact mm Figure 36
k Number of pitches in a sector -- -- 5.6
L Left flank -- -- 5.2
L Lead of the design helix mm Eq 17
Leff Effective lead mm 8.7
Lα Profile evaluation range mm Figure 17
Lαc Functional profile length mm Eq 9
Lβ Helix evaluation range mm Figure 24
Lε Base tangent length to start of active profile mm Figure 17
l Left hand helix -- -- 5.3
mn Normal module mm Eq 1
N Pitch number -- -- 5.5
n Number of deviation values included in the mean -- -- Eq 8
pb Base pitch mm Figure 36
pbn Theoretical normal base pitch mm 6.5
pm True position pitch2) mm 6.3.2
(continued)
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
Table 1 (concluded)
Where
Symbols Definition1) Units first used
R Right flank -- -- 5.2
r Right hand helix -- -- 5.3
s Undulation measurement bar length mm Figure 30
z Number of teeth -- -- Eq 2
zM Number of teeth in master indexing worm wheel -- -- Eq 24
z1 Driving gear -- -- Figure 32
z2 Driven gear -- -- Figure 32
αTt Transverse pressure angle at the tolerance diameter degrees 6.5.2
αn Normal pressure angle degrees Eq 1
αn eff Effective normal pressure angle degrees 6.5.3
αt Design transverse pressure angle degrees Eq 6
αt eff Effective transverse pressure angle degrees 6.5.3
β Helix angle degrees Eq 5
βb Design base helix angle degrees Eq 2
βeff Effective helix angle at the standard pitch diameter degrees 8.7
βT eff Effective helix angle at the tolerance diameter degrees 8.7
εγ Total contact ratio -- -- 9.3.5
λβ Undulation wave length mm Eq 24
λβx Axial wavelength of undulation mm Figure 24
ξ Involute roll angle degrees Figure 17
I Reference face -- -- 5.2
II Non--reference face -- -- 5.2
NOTE:
1) Symbols used for deviations of individual element measurements from specified values are composed of lower case
letters “f” with subscripts (exceptions include fe, f1 and f2) whereas symbols used for “cumulative” or “total” deviations,
which represent combinations of several individual element deviations,are composed of capital letters “F” also with sub-
scripts. It is necessary to qualify some deviations with an algebraic sign. A deviation is positive when e.g., a dimension
is larger than optimum and negative when smaller than optimum.
2) These deviations can be + (plus) or -- (minus).
4 Extent of gear inspection processes require basic gear and blank data,
number of teeth, pitch, pressure angle, helix angle,
tooth size, outside diameter, root diameter, face
It is rarely necessary or economical to measure all
width, design profile, design helix, etc. Certain
possible deviations on all gears manufactured.
measuring tasks require additional information. For
Certain elements may not significantly influence the
example, to measure profile, the profile control
function of the gear under consideration. Some
diameter and start of tip break must be provided.
measurements can be substituted for others. Stable
manufacturing processes allow a relatively small With mechanical measuring equipment, additional
number of samples to be measured and still ensure information may be required: base circle diameter
that the required quality level is maintained. It is (radius), base helix angle, sine bar setting, etc.
recommended that specific measuring plans be The design engineer or engineering department
negotiated between purchaser and supplier. should be responsible for supplying this minimum
4.1 Required inspection information required inspection information to those performing
the measurements.
Certain necessary information should be provided to
4.2 Measurement selection
the operator(s) of the measuring equipment. The
information required will vary depending on the type Inspection may be carried out using a number of
of measurement(s) required. Most measurement alternate methods. Some measurements may be
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
substituted for others. For example single flank Ideally the surfaces used to construct the datum
composite measurement may be substituted for axis, the surfaces used to locate the gear for
pitch measurement, or radial composite measure- manufacturing, and the functional surfaces that
ment may replace runout measurement. define the gear axis of rotation in its final assembly
would all be the same. In practice this is often not the
A number of factors should be considered when
case. For example, shaft type parts are often
selecting the measurements, including the quality
manufactured and inspected using female centers to
level required, size of the gear, manufacturing cost
define the datum axis. In cases where the inspec-
and most important the application of the product
tion, manufacturing, and/or functional datum sur-
gear.
faces are different, these surfaces must be
4.2.1 Sampling coincident with each other to a level of accuracy
sufficient to assure the final quality of the gear is
Gears, like other parts, are manufactured to a certain adequately represented during measurement.
level of accuracy dependant on the production
process used. When the process used is proven The gear being measured should be oriented so that
capable of producing the required accuracy level its datum axis is coincident with the axis of rotation of
using statistical methods, sampling inspection may the measuring instrument. In the case of mounting
be utilized. Many factors may influence the sample the gear between centers, care must be taken to
size and frequency, foremost among these should assure that the mounting arbor, if used, is in good
be the assurance that the required accuracy level of condition, and the female centers are clean and
the parts is met. concentric with the datum surfaces of the gear. In the
case of computer controlled measuring instruments,
4.2.2 First piece inspection it may be possible to mount the gear with significant
It may be possible to inspect only the first piece of a deviation to the instrument’s axis of rotation. In that
batch to verify that the setup is correct, allowing the case, the measuring program must be capable of
inherent accuracy of the process to assure the mathematically correcting the errors resulting from
quality of subsequent parts. this off axis mounting condition.
5.2 Right or left flank
It is convenient to choose one face of the gear as the
5 Identification of deviation position reference face and to mark it with the letter “I”. The
other non--reference face might be termed face “II”.
It is convenient to identify deviations associated with For an observer looking at the reference face, so that
measurements of gear teeth by specific reference to the tooth is seen with its tip uppermost, the right flank
individual right flanks, left flanks, pitches or groups of is on the right and the left flank is on the left.
these. Right and left flanks are denoted by the letters “R”
and “L” respectively.
In the following, conventions are described which
enable positive determination of the location of 5.3 Right hand or left hand helical gears
deviations.
The helix of an external or internal helical gear is
5.1 Datum axis referred to as being right hand or left hand. The hand
of helix is denoted by the letters “r” and “l”
Specification of the design profile, design helix, and respectively.
design pitch requires definition of an appropriate
reference axis of rotation, called the datum axis. It is The helix is right hand (left hand) if, when looking
defined by specification of datum surfaces. See from one face, the transverse profiles show succes-
AGMA 915--3--A99. sive clockwise (counter--clockwise) displacement
with increasing distance from an observer.
The datum axis determines tooth geometry, thereby
5.4 Numbering of teeth and flanks
being the reference for measurements and associat-
ed tolerances. The location and orientation of the Looking at the reference face of a gear, the teeth are
tolerance diameter circle are determined by the numbered sequentially in the clockwise direction.
datum axis. The tooth number is followed by the letter R or L,
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
30R 2L
tip
left right
flank flank
30 1
29 2
30R
1L
tip
2
29
1 30
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
Measurements made at different diameters or in between an initial reference pair of adjacent tooth
other directions must be adjusted so that they are flanks.
equivalent to measurements at the tolerance diame-
ter and in the tolerance direction. This adjustment The various pitch parameters can all be determined
must be made before comparison of test results to by either measuring device with the application of
tolerances. suitable calculations. The indexing method is
usually preferred because of its accuracy and
Sector pitch deviation (Fps/8) is an optional parame- simplicity. However, for large diameter gears, use of
ter described in Annex E of ANSI/AGMA the pitch comparator method may be preferable.
2015--1--A01. Measurements of sector pitch devi-
ation are also expected to conform to the above Coordinate measuring machines without a rotating
specified requirements. table can also be used for measurements of pitch
parameters by probe movements that correspond to
Pitch should be measured on both left and right
the principle of the indexing method.
flanks. However, if the specific operating direction of
the gear is known, only the loaded flanks need to be 6.3.1 Indexing pitch measurement method
measured.
The indexing (single probe) device uses an angular
6.3 Pitch deviation measurement methods
indexing apparatus such as an index plate, circle
Pitch parameters can be measured by either of two divider, optical or electronic encoder, or polygon and
types of device. The indexing (single probe) device auto collimator to precisely rotate the gear by an
determines the location of each tooth around a gear, angular increment equal to its pitch, or 360°/z (see
relative to a datum tooth (the index). The pitch figure 3). The degree of its precision must be
comparator (two probe) device compares the dis- consistent with the quality grade and diameter of the
tances between adjacent tooth flanks to the distance gear.
Index mechanism
5
4 Tolerance
diameter, dT
-- Index 2
deviation 1
Index readings
Dash lines represent + Index
theoretical location deviation
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
The single probe should be oriented to contact the pitch deviation value is equal to the index value of the
tooth flanks at the tolerance diameter, dT, and to first tooth subtracted from the index value of the
gather measurements in the specified measurement second tooth. Since the index value of the first tooth
direction. The single probe is adjusted to indicate is set to zero, the number 2 single pitch deviation
zero while the device is contacting the randomly value is equal to the index value of the second tooth.
selected initial test tooth flank. As the gear is The number 3 single pitch deviation value is equal to
incrementally rotated around its datum axis, the the index value of the second tooth subtracted from
single probe moves in and out on a precision slide the index value of the third tooth, and so on.
and stop, measuring each successive tooth flank
position, relative to the indexing mechanism. This
process is repeated until every tooth has been +
Index deviation
measured. --fpt
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
spring
loaded
Tolerance
diameter,
dT
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
are shown as the deviations of individual pitch 6.3.2.4 Calculation of total cumulative pitch
comparator measurement values to the true position deviation, Fp
pitch, pm.
The total cumulative pitch deviation, Fp, is equal to
the difference between the most positive index value
and the most negative index value for the complete
gear.
+ Fps/8
+fpt
Calculation of the sector pitch deviation, Fps/8, is
0 presented in Annex E of ANSI/AGMA 2015--1--A01.
pm pm
6.4 Relationships of pitch parameters and
-- --fpt measuring methods
Figure 7 -- Single pitch deviation, two probe 6.5 Base pitch measurement
device
The normal base pitch measurement device is a two
probe instrument of similar construction to the
hand--held pitch comparator. However, its measur-
6.3.2.3 Calculation of index ing principles are substantially different from those
described under 6.3.2:
The plus and minus index values for each tooth of the
gear can be produced by successive summation of -- Rather than measuring the relative normal
the single pitch deviation values. See clause 5 for pitch at a given measurement (tolerance) diame-
specified tooth numbering, pitch numbering, and ter, it measures the normal base pitch, pbn, which
flank naming conventions. is the shortest distance between adjacent tooth
flanks (see figure 12).
In all cases, the number one (first) tooth shall be the
datum tooth and its index value set to zero -- This method cannot directly or indirectly
accordingly. reference the datum axis of the gear. The tooth
flank features themselves become the reference.
The index value of the second tooth is equal to the Therefore, observations of index and total cumu-
index value of the first tooth plus the number 2 single lative pitch, Fp, can not be properly made with this
pitch deviation value. Since the index value of the device.
first tooth is set to zero, the index value of the second
-- If the instrument is adjusted to the specified
tooth is equal to number 2 single pitch deviation normal base pitch of a gear prior to commencing
value. The index value of the third tooth is equal to measurements, it can provide an observation of
the index value of the second tooth plus the number normal base pitch deviation, fpbn.
3 single pitch deviation value, and so on.
The normal base pitch parameter provides a local-
At the end of this process, the index value of the first ized composite observation of gear tooth flank
tooth will be found by adding the number 1 single accuracy. It is localized, in that the observation is
pitch deviation value to the index value of the last made only at a single point on the tooth flank. It is
tooth. Ideally, this would produce a second index composite in that it combines the effects of involute
value of zero for the first tooth. Excessive deviation profile, helix, and pitch into a single observation that
from zero, of this calculated index value, for the first directly relates to the gear’s ability to achieve
tooth indicates a problem with the measurement. smooth, conjugate meshing action with its mate.
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
Tooth numbers of pitches 18:1 1:2 2:3 3:4 4:5 5:6 6:7 7:8 8:9 9:10 10:11 11:12 12:13 13:14 14:15 15:16 16:17 17:18
Pitch number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
2--probe pitch
0 1 --1 1 --1 --3 --5 --4 --4 --5 --6 --4 --3 --3 --1 1 1 0
comparator readings
True position pitch pm
--2
(mean of readings)
Single pitch deviations fpt
2 3 1 3 1 --1 --3 --2 --2 --3 --4 --2 --1 --1 1 3 3 2
(readings -- pm)
Tooth numbers for Index
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
values
Index deviations (calcu-
0 3 4 7 8 7 4 2 0 --3 --7 --9 --10 --11 --10 --7 --4 --2
lated)
Figure 8 -- Sample table with hypothetical deviation values obtained by pitch comparator
(two probe) device
(In practice, integer values are seldom encountered. Maximum value of fpt and minimum and maximum
values for index deviations are shaded.)
1--probe readings, 0 3 4 7 8 7 4 2 0 --3 --7 --9 --10 --11 --10 --7 --4 --2
right flanks
Index deviations 0 3 4 7 8 7 4 2 0 --3 --7 --9 --10 --11 --10 --7 --4 --2
Single pitch deviations 2 3 1 3 1 --1 --3 --2 --2 --3 --4 --2 --1 --1 1 3 3 2
fpt (calculated)
Figure 9 -- Sample table with hypothetical deviation values obtained by indexing
(single probe) device
(In practice, integer values are seldom encountered. Maximum value of fpt and minimum and maximum
values for index deviations are shaded.)
0
--2
--4
--6
--8
--10
--12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Pitch number
Figure 10 -- Sample graphic representation of single pitch deviations, fpt
Index deviations
12
10
8
6
4
2
0.001 mm
0
--2
--4
--6
--8
--10
--12
1 2 3 4 5 8 6 7
9 10 11 12 13 14 15 16 17 18
Flank number
Figure 11 -- Sample graphic representation of index deviations
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the gear with its datum axis perpendicular to the X--Y known distance from, and in alignment with, the gear
plane. Three--dimensional systems require align- axis. This requires care in design and manufacture
ment of the gear datum axis parallel to one of the of the gear blank.
three instrument axes. This may be accomplished
7.3 The profile diagram
by accurate mounting of the part, or mathematically
adjusting the instrument axes to coincide with the Amplified traces of the profile inspection test results
gear axis. Coordinate measurement inspection should be presented on charts that are graduated for
instruments may use spherical measurement probe rolling path length or degrees of roll. They should
tips, which require correction for shifting of the probe also be labeled for magnification and evaluation
contact vector. points in conformance with the specification.
An unmodified involute profile with no deviations will
be charted as a straight line. Deviations of the curve
X1 from a straight line represent, in magnified form,
deviations of the actual profile from an unmodified
X2 involute. Profile modifications introduced by the
designer also appear as departures from the straight
X3 line, but they are not considered to be deviations
Y1 from the “design profile”.
Y2
Y3 Excess material on the profile is considered a plus
deviation, while insufficient material is considered a
minus deviation. In addition to identifying the
Figure 15 -- Profile inspection by coordinates location and magnitude of the highest point on the
profile or the maximum profile deviation, these
7.2.3 Portable involute measurement charts are valuable for determining profile character-
istics such as tip break, undercut, and tip or root relief
instruments
(see figure 16).
Profile measuring instruments are generally fixed
Any point along the profile diagram can be related to
type machines. Gears to be tested must be brought
a diameter (radius), a base tangent length and an
to the instrument and accurately mounted, typically
involute roll angle.
on--axis, between centers or on a table. For very
large gears it may be necessary to employ a portable Figure 17 shows a sample tooth profile and the
involute measuring instrument that can be taken to relation to the corresponding profile trace, together
the gear. Such instruments may operate on a variety with the appropriate terms. Details of terms,
of generative or non--generative principles. The definitions and concepts concerning the profile
portable instrument must be accurately mounted at a trace, are provided in ANSI/AGMA 2015--1--A01.
Tip break
Undercut
True
involute Tip break
Profile control
diameter Undercut
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fHα
ffα
A
B
C
Lαc
2
3
D
E
+
Fα
Lαc
Lε
A
A
B
tip circle of mating gear
2 1
Q
tip circle C
E
reference circle D F
E ξC
F
root circle
base circle
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7.4 Evaluation of profile diagrams 7.6 Mean profile slope deviation, fHαm
Slope deviations of individual profiles can be caused
Depending on accuracy class specified, it may only
by eccentricity due to inaccuracies of manufacturing
be necessary to measure total profile deviation, Fα.
or inspection set--up. Such deviations will vary
See ANSI/AGMA 2015--1--A01, clause 4. around the gear. The use of mean profile slope
deviations cancels out the influence of eccentricity
It may also be necessary to determine the profile on individual profile traces.
slope deviation, fHα, and the profile form deviation,
ffα. For this it is necessary to superpose the mean The effect of eccentricity on profile slope, and the
profile line onto the diagram as shown in figure 17, determination of mean profile slope deviation, are
illustrated in figure 18.
also in figure 2 of ANSI/AGMA 2015--1--A01. Allow-
able values of fHα and ffα can be calculated in accor- Calculating the mean profile slope deviation is a step
dance with ANSI/AGMA 2015--1--A01, clause 7. towards the correction of manufacturing processes
or other suitable action.
7.5 Algebraic signs of fHα and fα For all practical purposes, it is usually sufficient to
calculate the arithmetic mean of the profile slope
The profile slope deviation, fHα, is termed positive deviations by calculating the average of the devi-
and the corresponding pressure angle deviation, fα, ations measured on three or more corresponding
is termed negative when the mean profile line rises flanks of equally spaced teeth around the gear
towards the tooth--tip end A of the diagram, as shown circumference according to the following equation:
in figure 17. In figure 18, both positive and negative
f Hαm = 1
n f Hα1 + f Hα2 + + f Hαn
(8)
slopes, caused by eccentricity of mounting on the
gear generating machine, are shown. where:
fHαm is the mean profile slope deviation, mm;
If the slopes seen in the profile diagrams of mating
gears are equal and have the same sign, the fHαn is the individual profile slope deviations, mm;
deviations are mutually compensating. This applies n is the number of profile slope deviation
to both external and internal gears. values included in the mean.
A B + E
1 3
--11.1
--
M
+ C
fe
2
--6.6
I φ
-- 2
+ 1
5.7
3
--
fHα
Lαc
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The mean profile slope deviation, fHαm, can be used Effective transverse pressure angle, αt eff, can be
to calculate a variety of parameters that are useful for calculated as follows:
controlling the quality of gear involute profiles.
Included in these calculated parameters are: α t eff = acos
d b eff
D
(11)
Effective base diameter, db eff, can be calculated as 7.7.6 Calculation of mean normal pressure
follows: angle deviation, fαmn
Mean normal pressure angle deviation, fαmn, can be
d b eff = D b + f dbm × 10 −3 (10)
calculated as follows:
where: f αmn = α n eff − α n (15)
db eff is the effective base diameter, mm. where:
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fαmn is the mean normal pressure angle an indication of profile accuracy (see figure 20).
deviation, degrees; However, readings give no indication as to which
profile may have an error, since two flanks of a
αn eff is the effective normal pressure angle,
measured tooth are contacted at the same time.
degrees;
This method will not reveal deviations that cancel
αn is the design normal pressure angle, each other, such as those caused by a form cutter,
degrees. which has been offset from a true radial position.
A positive mean profile slope deviation (profile trace
rising towards its tooth tip end) implies that the
effective pressure angle is too small, and visa versa.
when fHαm > 0, then fαmn < 0
7.8 Other profile measuring methods
While not commonly used or recommended, the
following profile measuring methods may prove
valuable when more conventional methods are not
practical or available.
7.8.1 Projection
A shadow of the gear tooth under inspection may be
optically magnified and directly or reflex projected to
permit comparison of the profile to a large scale
layout of a specified profile (see figure 19). This
method is normally applied only to fine pitch gears.
When gears are too large to be mounted in the
projector, a thin wafer (manufactured simultaneous-
ly with the gear), or a mold of a gear tooth form may
be used for projection. This method requires two
known reference surfaces to locate the image both Figure 20 -- Profile inspection by gear--tooth
radially and angularly. caliper method
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7.8.3 Profile measuring with master gear 8.2 Helix inspection methods
Contact pattern checking with a master gear may be The standard methods of helix measurement are
used to check the profile deviation of gears in place with generative, coordinate, or portable helix
or when gears are too large to be accommodated by measuring instruments.
a profile measuring instrument. The axis of the gear 8.2.1 Generative helix measuring instruments
and master must be parallel. Refer to clause 10 for
The most common instruments used for measure-
more information concerning this method.
ment of helix are generative helix measurement
instruments. Such instruments measure the devi-
ation of the actual helix from a nominal helix, which is
generated by the instrument. Generation of the
8 Measurement of helix deviations
nominal helix requires the axial movement of a
measurement probe together with a rotational move-
8.1 Helix ment of the gear mounted on the instrument spindle.
These movements must be synchronized according
Helix is the lengthwise shape of the tooth flank to the specified lead of the gear (see figure 23).
across the face from one end to the other. The When measuring spur gears, the rotational move-
theoretical helix of a helical gear is contained on the ment is eliminated.
surface of a cylinder, which is concentric with the
datum axis of rotation of the gear, at the intersection Total helix deviation, Fβ
of that cylinder with the tooth flank. The theoretical
helix of a spur gear is a straight line parallel to its
rotating axis. Helix is restricted to the operating
portion, which is intended to be in contact during Reference
loaded operation, and does not include edge rounds zero
0
or chamfers.
Total helix
Measured deviation, Fβ
helix
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straight edge is translated into axial movement of the 8.2.3 Portable helix measuring instruments
probe by a ratio mechanism. Combination instru-
ments also capable of measuring involute profile Helix measuring instruments are generally fixed type
often utilize their master base circle mechanisms in machines, which require that gears to be tested must
this manner. be brought to the instrument and accurately
mounted, typically on--axis between centers or on a
Other configurations include master lead bar and table. However, for very large gears it may be
follower mechanisms, and master lead screw and preferable to employ a portable helix measuring
change gearing mechanisms. Newer generative instrument, which can be taken to the gear. The
helix measuring instruments typically use a comput- portable instrument must be accurately mounted at a
er numeric control drive system to generate the known distance from, and in alignment with, the gear
nominal helix. axis. This often requires extra care in design and
manufacture of the gear blank.
Helix measurements must be made relative to the
datum axis of rotation of the gear. Refer to 5.1 for 8.3 The helix diagram
more information concerning the datum axis of
rotation. Amplified traces of helix inspection test results
should be presented on charts that are calibrated for
Probe tips most commonly used are spherical or
axial probe travel as well as magnification of
disk--shaped. The probe tip must be positioned to
measured deviation. Sometimes trace lengths are
contact the tooth surface at the specified tolerance
magnified representations of small facewidths, or
diameter, dT.
reduced representation of large facewidths.
It is often desirable to orient the measurement probe
path of motion normal to the tooth surface. An unmodified helix with no deviations will be
ANSI/AGMA 2015--1--A01 specifies helix tolerances charted as a straight line. Deviations of the curve
in the transverse plane. If measurements are made from a straight line represent, in magnified form,
normal to the tooth surface, all values must be deviations of the actual helix from an unmodified
corrected by dividing by the cosine of the base helix helix. Helix modifications introduced by the designer
angle, cos βb, before comparison against the also appear as departures from the straight line, but
tolerances. they are not considered to be deviations from the
design helix.
8.2.2 Coordinate measurement inspection
instruments Excess material on the helix is considered a plus
deviation while insufficient material is considered a
Helix can be inspected by non--generative, coordi- minus deviation. In addition to identifying the
nate measurement instruments. Such instruments location and magnitude of the helix deviation, these
probe the tooth lengthwise at a series of points, charts are valuable for determining helix characteris-
storing the coordinates of each point. The deviation tics such as edge rounds, crowning, and end relief.
of the actual helix from the nominal is then deter-
mined by comparison of the stored test point Relevance to right hand and left hand helices can be
coordinates against calculated coordinates of the indicated by means of the letters “r” and “l”,
theoretical nominal helix. respectively, used either as symbols or as sub-
scripts.
Coordinate measurement inspection instruments
operate in three dimensions (X, Y, and Z coordi- In figure 24, a typical example of a helix diagram
nates) to measure helix. The gear axis must be shows the helix deviations of a tooth flank of which
aligned parallel with one of the three instrument the design helix is an unmodified helix. Had the
axes. This may be accomplished by accurate design helix been crowned, end relieved or other-
mounting of the part, or mathematically adjusting wise modified, traces representing it would be
instrument axes to coincide with the gear axis. appropriately formed curves.
Coordinate measurement inspection instruments
commonly use spherical measurement probe tips, Details of terms, definitions and concepts concern-
which require correction for shifting of the probe ing the helix trace are provided in ANSI/AGMA
contact vector. 2015--1--A01.
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
λβx λβx able values of fHβ and ffβ can be calculated in accor-
dance with ANSI/AGMA 2015--1--A01, clause 7.
fwβ
2 3 8.5 Algebraic signs of fHβ and Fβ
Helix slope deviation, fHβ, and the total helix devi-
ation, Fβ, are to be reported with an algebraic sign.
fHβ
Fβ
For purpose of gear quality classification, it may be If the helix slope deviations are either random or are
necessary to measure only “total helix deviation”, Fβ. fairly consistent, then the mean helix slope deviation
See ANSI/AGMA 2015--1--A01, clause 4. may be used to correct the helix setting of the
machine used to manufacture the gear. In the case
It may also be necessary to determine the “helix of a matched set of mating gears where one has
slope deviation”, fHβ, and the “helix form deviation”, been manufactured and inspected, then the mean
ffβ. For this it is necessary to superpose the “mean helix slope deviation may be used to adjust the
helix line” onto the diagram as shown in figure 24 manufacture of the other gear in the set. This will
(also in ANSI/AGMA 2015--1--A01, figure 1). Allow- result in improved contact between the gears without
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
the need to make corrections to the previously controlling the quality of gear helices. Included in
finished gear. these calculated parameters are:
If the helix slope deviation, fHβ, varies in a regular -- effective helix angle at the tolerance
pattern around the circumference of a helical gear, diameter, βT eff;
then the datum axis of the gear was probably tilted, -- effective lead, Leff;
offset, or mis--orientated relative to the machine axis
-- effective helix angle at the standard pitch
during either manufacture or inspection. See figure diameter, βeff;
25. Tilting affects spur gears in the same manner,
but offset (eccentricity) does not. -- mean lead difference, fLm;
-- mean helix angle deviation, fβm.
-- Eccentricity: The variation of helix slope
deviation caused by eccentricity (if within speci- All of the following equations are based upon the
fied limits) is not normally detrimental to the mean helix slope deviation, fHβm. Alternatively, the
operation of the gear. same formulas could be applied to the case of
individual tooth data. The calculation sequence
-- Tilting: Variation of helix slope deviation
would then commence with the entry of the individual
caused by mis--orientation of the gear teeth
relative to the datum axis may affect the proper helix slope deviation, fHβ.
functioning of the gear. The helix slope deviations 8.7.1 Required preliminary data
will cause the center of contact pressure to shift
axially back and forth with each revolution. This The following data is required for the additional
may in turn cause premature gear tooth failure calculations for helix measurements.
and/or bearing problems. Therefore, attention
should be drawn to this condition even if the Lead, L, can be calculated as follows:
deviations are within tolerance.
L= Dπ (17)
tan β
The mean helix slope deviation, fHβm, is calculated
by averaging the helix slope deviation, fHβ, observed where:
on the corresponding flanks of three or more teeth
L is the lead of the design helix, mm;
equally spaced around the circumference of the
gear. D is the standard pitch diameter, mm;
β is the helix angle at the standard pitch diam-
f Hβm = 1
n f Hβ1 + f Hβ2 + + f Hβn (16) eter, degrees.
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8.7.2 Calculation of effective helix angle at the Desired lead Actual lead
tolerance diameter, βT eff of helix of helix
−3 L + d π
Hβmt
f × 10
Lβ T
β T eff = atan Path of contact
L of measuring pointer
(19)
where:
βT eff is the effective helix angle at the tolerance
diameter, degrees;
dT π
L eff = (20)
tan β T eff
Figure 26 -- Helix of right hand helical gear with
where:
short lead (+ helix angle)
Leff is the effective lead.
β eff = atan D π
L eff
(21) Facewidth
f Lm = L eff − L (22)
where:
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
where:
Path of contact fβm is the mean helix angle deviation, degrees.
of measuring pointer
A positive mean helix slope deviation implies that the
effective helix angle is too large, and visa versa.
when fHβm > 0, then fβm > 0
8.8 Undulations
Undulations are helix form deviations having
Facewidth constant wavelength and almost constant height.
Perturbations of gear production machine transmis-
sion elements are their most common cause,
especially those of:
a) the cutter saddle feed--screw drive, and
b) the worm of the indexing wormgear drive.
Figure 28 -- Helix of left hand helical gear with The wavelength of undulations caused by a),
long lead (-- helix angle) measured in direction of helix, is equal to the pitch of
the feed--screw divided by cos β.
Of undulations due to cause b) the wavelength is:
λβ = dπ (24)
Actual lead Desired lead z M sin β
of helix of helix
where:
λβ is the undulation wavelength, mm;
Facewidth d is the reference diameter, mm;
zM is the number of teeth in the master
indexing worm wheel.
Path of contact
The number of undulations generated as a result of
of measuring pointer b), projected into a transverse plane, are equal to the
number of teeth, zM, of the master indexing worm
wheel. These can be sources of objectionable
pure--tone components of noise spectra, also known
as ghost harmonics, at frequencies corresponding to
the rotational speed (revolutions) of the affected
gear multiplied by zM.
Facewidth
The method of application of the undulation measur-
ing attachment of a helix measuring apparatus is
shown in the diagram in figure 30. This is discussed
in the following.
When undulations due to the cause a) or b)
Figure 29 -- Helix of left hand helical gear with mentioned above are to be measured, the appropri-
short lead (+ helix angle) ate wavelength is calculated and the spherical
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
location feet of the attachment are set at an odd outlined in 8.2 are impractical, these indirect meth-
number of wavelengths distant from each other. ods may prove valuable.
The amount of the undulations is indicated by a 8.9.1 Helix indication using axial pitch
probe situated midway between the feet as the latter
An indication of helix accuracy may be derived from
are slid along the helix.
inspection of axial pitch on gears with sufficient helix
angle and face width to have multiple axial overlaps.
It can be seen in the figure that the displacement of
The measurement must be made parallel to the gear
the probe, when a peak and next a trough are sensed
axis at increments equal to the axial pitch. The
by the probe, is equal to twice the height of the
deviation in resulting measurement values is indica-
undulation as shown in figure 30. This feature
tive of deviation of helix. Pitch deviations of the
enhances the sensitivity of the apparatus, which also
measured teeth can affect axial pitch measure-
plots the results in the form of a diagram.
ments, and must be considered. The axial pitch
method of helix inspection is especially attractive for
It should be noted that the undulations would not be
large diameter, wide facewidth gears with large helix
indicated if the feet were spaced at a distance equal
angles.
to an even number of wavelengths as shown in figure
30 with s = 4λβ. 8.9.2 Helix measuring with a master gear
8.9. Indirect helix inspection methods Contact pattern checking with a master gear may be
used to check the helix deviation of gears in place, or
The following indirect methods may be employed for when gears are too large to be accommodated by a
inspection of gear helix. These methods do not helix inspection instrument. The axes of the gear
provide the actual levels of helix deviation. However, and master must be parallel. Refer to clause 10 for
in instances where the measurement methods more information concerning this method.
+fwβ --fwβ
fwβ fwβ
s s
s = λβ
s = 4 λβ
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
9 Measurement of single flank composite measuring angular motion. These are typically
deviations rotary optical encoders (gratings and reader head
assemblies). Rotary accelerometers and velocity
transducers have also been used as sensing de-
9.1 Single flank composite
vices. See figures 31 and 32.
Tangential (single flank) composite measurement
During measurement one gear acts as the driver,
can provide valuable information about the transmis-
rotating the other gear. During rotation, the angular
sion error of a gear, a pair of gears, or an entire gear
positions of the driven gear relative to the driver is
train. Transmission error is the deviation of the
calculated through ratioing of the signals from the
position of a driven gear from the position that the
two sensing devices using analog or digital electron-
driven gear would occupy if all the gears involved in
ics. These relative positions are recorded either on a
the measurement were geometrically perfect.
strip chart or into digital storage on a computer until a
ANSI/AGMA 2015--1--A01 provides tolerances for complete diagram has been generated. To compare
two characteristics of transmission error for individu- these angular readings to the tolerances provided in
al product gears measured with a master gear, total ANSI/AGMA 2015--1--A01 they must first be con-
single flank composite deviation, Fis, and tooth--to-- verted to linear values at the tolerance diameter
tooth single flank composite deviation, fis. specified.
The following is a description of the measuring Single flank composite measurements are per-
methods and a guide to interpretation of the data formed with tooth flank contact maintained, under
generated during single flank measurement of very light load, and with low angular velocities. The
individual gears measured with a master gear. results generated reflect the combined elemental
Single flank measurement of a pair of product gears deviations (profile, helix, pitch) of both gears.
is also described.
Single flank composite deviations of heavily loaded
Single flank measurement of more than a single gears can also be similarly measured. Under these
mated pair of gears is the assessment of the conditions, recorded deviations are influenced by
kinematics of a gear transmission. This is not load induced tooth deformations, by mesh stiffness
considered to be within the scope of this document or variation, and depending on the speed of rotation by
ANSI/AGMA 2015--1--A01. impact effects, as well as by imperfections of tooth
geometry. ANSI/AGMA 2015--1--A01 does not apply
9.2 Single flank composite measurement
to this kind of measurement.
For measurement of single flank composite devi-
9.2.1 Single flank composite deviations
ations, two gears are mounted rotatably in mesh at
an appropriate center distance. The gears are Total single flank composite deviation, Fis, is the
mounted with backlash so that contact occurs only maximum measured transmission error range when
on one set of corresponding flanks. Rotating the gear is moved through one complete revolution.
synchronously with each gear is a device capable of See figure 33.
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
z1 z2
Optical gratings
Reading heads
f1 pulses/sec
f2 pulses/sec
Multiplier
z1
z1
z 2 f 1 = f 2 pulses∕sec
30
20
fpt
Amplitude, 0.001 mm
10
Fp
0
Fis
--10
--20
--30
--40
0 1 2 3 4 5 6 7 8 9 10 11 12
Tooth number
Figure 33 -- Individual tooth deviations revealed by single flank testing
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
40
30
20
10
Amplitude, 0.001 mm
0
fis
--10
--20
--30
--40
0 1 2 3 4 5 6 7 8 9 10 11 12
Tooth number
Tooth--to--tooth single flank composite deviation, fis will influence the measurement of product gears. If
is the value of the greatest measured transmission the quality of the master is at least 4 accuracy grades
error over any one pitch (360/z) after removal of the better than the required grade of the product gear,
long term component (sinusoidal effect of eccentrici- inaccuracies of the master are usually ignored. If the
ty) when the gear is moved through one complete quality of the master is less than 4 accuracy grades
revolution. See figure 34. better than the required grade of the product gear,
inaccuracies of the master should be taken into
9.3 Single flank measurement with master
account.
gear
Recorded diagrams of single flank composite mea- 9.3.2 Influence of profile deviations
surements generally include short period compo-
nents corresponding to successive cycles of tooth When using a master gear in the measuring of single
engagement, superposed on long period compo- flank composite deviations, the assumption that the
nents associated with complete revolutions of each master gear is perfectly accurate implies that the
of the meshing gears. generated single flank composite deviation diagram
The diagram in figure 33 represents the record of represents only the combined deviations of the tooth
single flank composite deviations generated during elements of the product gear.
one revolution of a pinion having 12 teeth when
meshed with a master gear. Figure 35 shows schematically, single flank compos-
ite recordings of three consecutive cycles of tooth
9.3.1 Master gear requirements
engagement of a master gear and product gear.
For single flank measurement of individual product Each corresponds to a different tooth profile. The
gears, a master gear of known accuracy (calibrated) first is unmodified and faultless, the second being
and specifically designed to mesh with the product progressively modified from mid--depth towards
gear to be inspected should be used. Attention must each limit of the active profile, and the third with
be paid to the fact that the quality of the master gear negative profile slope deviation.
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
0
It must be noted that diagrams of single flank
angular motion curve composite measurements do not merely reflect
-- influences of profile deviations revealed by mea-
surements made on a few teeth, but may be
B influenced by contact involved in any prominences
tip on the working surfaces of the teeth of the product
master
modified tooth gear.
test shape [profile
gear
barrelling Cα] 9.3.3 Influence of pitch deviations
root
Each single pitch deviation introduces a local
+ 1 pitch 1 pitch 1 pitch tangential component, which will show on the single
displacement
0
diagram.
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
contact location will vary around the gear. This recognized that the maximum length of the single--
condition may adversely effect single flank compos- pair tooth contact path is realized when the contact
ite deviations of both spur and helical gears. ratio, εγ, is equal to one. As the contact ratio
increases, this length reduces and when the contact
Helix form deviations do not substantially influence ratio is equal to or greater than two, there is no
the single flank results of spur gears. Single flank single--pair tooth contact at all.
composite deviations of helical gears, however, may
be adversely effected by helix form deviations. When the total contact ratio, εγ exceeds two, which is
normally the case for helical gears, the short period
9.3.5 Influence of contact ratio components which represent profile irregularities
are smoothed to some extent because in general,
A single flank composite deviation diagram gener-
simultaneous contact takes place on two or more
ated from a master--gear and product--gear
tooth pairs.
combination is composed of successive curves
representing for the most part the profile deviations, Diagrams in figure 37 with the two cases “A”
as shown in figure 36. Single--pair and two--pair (generated from helical gears) and “B” (from spur
tooth engagements and the single flank composite gears) illustrate the difference between the ways in
deviation diagram during a complete cycle of tooth which the influence of the overlapping teeth of the
engagement is clearly illustrated. It can easily be two types combine.
root tip
master gear
tangential composite 1 2 3
deviation
stylus
profile
component
3
product gear
2
1
master gear
pb
pb = base pitch pb
gα = length of path of contact gα
Figure 36 -- Effect of contact transfer on the profile component in a tangential composite deviation
diagram (spur gears)
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
Single flank composite results can be very different tooth composite of both flanks, fid (short term
from what is expected, especially if these expecta- component).
tions are derived from consideration of theoretical
Single flank composite data charts are made up
contact ratio and an assumption that contact is
primarily of information related to cumulative pitch,
perfect over the tooth profiles and facewidth of
Fp (long term component) deviations, and deviations
helical gears.
in tooth form of the single flank in contact, fis (short
Single flank composite deviations can be influenced term component).
by modification of tooth profile and helix (tip relief,
9.3.6.1 Traditional interpretation
crowning, etc.) introduced to accommodate possible
deformations of shafts, housings and teeth under In ANSI/AGMA 2000--A88 and ISO 1328--2, double
load. If under full load the tooth bearing is uniformly flank composite measurements were toleranced for
distributed over the working surfaces of the teeth, total composite variation, and tooth--to--tooth com-
such is not likely to be the case under the light load posite variation. They were interpreted from a
conditions used during single flank composite mea- recorded chart for one revolution of the product gear
surement where the tooth bearing may be localized. as shown in figure 38. The total composite variation
Given these circumstances, the contact ratio during was defined as the difference between the highest to
measurement is likely much less than elementary lowest point on the chart. The tooth--to--tooth
theory would suggest. variation was defined as the greatest change in any
360 degree/z part of the chart. This may be
9.3.6 Interpretation of results acceptable for evaluation of the final gear quality
This section contains information and techniques for relative to the application for some purposes.
interpreting single flank composite results beginning However, traditional double flank testing has some
with a comparison to methods used for traditional limitations. For example, it cannot detect cumulative
pitch deviation that occurs without radial runout
double flank (radial composite) testing.
deviation. Double flank testing is not considered a
Double flank composite data charts are made up reliable method for determining noise potential.
primarily of information related to radial runout, Fr Double flank testing also provides little information
(long term component), and deviations of tooth--to-- for diagnoses of tooth--to--tooth deviations.
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
5.0
4.0
3.0
2.0
1.0
Total
composite
Amplitude
0.0 Unfiltered
tooth--to--
--1.0 tooth
--2.0
--3.0
--4.0
--5.0
0 1 2 3 4 5 6 7 8 9 10 11 12
Tooth number
Figure 38 -- Single flank composite strip chart
The traditional analysis method used for calculation 1/2 of the total composite tolerance. This is partly in
of tooth--to--tooth composite deviation may give a order to accommodate the distortion of tooth--to--
distorted indication of the tooth form that the tooth data, by the long term component, especially
machine and tool is producing. This is due to the for low numbers of teeth.
influence of the long term component on the
In the case of a gear with very little or no runout, there
tooth--to--tooth composite deviation.
should be a greater difference between total and
This distortion is best explained by the case of a gear tooth--to--tooth composite deviation tolerances. In
that had identical tooth form on all teeth being this case the tooth--to--tooth composite tolerance
measured with a perfect master. In this case the should be 0.1 to 0.2 times the total composite
greatest tooth--to--tooth variation will be along the tolerance. This more appropriate tolerance ratio is
part of the long term component curve that has the feasible regardless of the amplitude of the long term
greatest slope. This has the effect of distorting the component if the tooth--to--tooth composite devi-
amplitude of the data relating to that particular tooth. ations are separated from the long term component
For the same quality of tooth form and runout, the prior to analysis.
tooth--to--tooth composite deviation would be great-
er for a gear with a lower number of teeth than it will 9.3.6.3 Separation of tooth -- to -- tooth composite
for higher numbers of teeth. See figures 39 and 40 observations
for a comparison.
The separation of eccentricity effects from observa-
9.3.6.2 Relationship between tolerances
tions of tooth--to--tooth composite deviations can be
Because of the relationship between the long term done by different techniques. The preferred method
component and the tooth--to--tooth deviation, toler- is by use of a digital computer program that is
ances have had unrealistic values in some cases. In capable of fitting and extracting a sine wave
previously existing standards, the tooth--to--tooth according to the given test data. This would result in
composite tolerance has been approximately 1/3 to charts as shown in figures 41a, 41b, and 41c.
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
5.0
4.0
3.0
2.0
1.0
Amplitude
0.0
Unfiltered
--1.0 tooth--to--tooth
(12 tooth gear)
--2.0
--3.0
--4.0
--5.0
0 1 2 3 4 5 6 7 8 9 10 11 12
Tooth number
5.0
4.0
3.0
1.0
0.0
--1.0
--2.0
--3.0
--4.0
--5.0
0 5 10 15 20 25 30
Tooth number
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
5.0
4.0
1.0
Amplitude
0.0
--1.0
--2.0
--4.0
--5.0
0 5 10 15 20 25 30
Tooth number
5.0
4.0
3.0
2.0
Long term component
Amplitude
1.0
0.0
--1.0
--2.0
--4.0
--5.0
0 5 10 15 20 25 30
Tooth number
Figure 41b -- Long term component
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
5.0
3.0
2.0
Amplitude
1.0
0.0
--1.0
--2.0
--5.0
0 5 10 15 20 25 30
Tooth number
If this method is not available in the measuring in ring gears where heat treat distortions occur at the
system, an approximation can be done manually. location of each bolt hole in the blank. Even the short
This involves drawing an upper and lower envelope term component can have distortions from variations
of essentially sinusoidal shape enclosing the mea- in the tooth shape.
sured data. The vertical distance between these
Analysis of composite test data can be enhanced by
upper and lower envelope lines is the tooth--to--tooth
the use of analog or digital filters that segregate long
composite error, fis. This is shown in figure 42.
and short term component deviations at a selected
“cutoff” wavelength. Still more comprehensive
9.3.6.4 Additional diagnostics
analysis of higher order deviations is possible by use
These techniques are focused on evaluation of the of Fourier analysis techniques, such as a Fast
final gear quality relative to the given application. Fourier Transform (FFT) analyzer.
However, it may be desirable to carryout additional 9.4 Single flank measurement of product gear
analysis for diagnostic purposes, such as noise pair
potential or manufacturing process monitoring. In
such cases more comprehensive data filtering is The single flank tooth--to--tooth and total composite
appropriate. deviations involving a mated pair of product gears
are termed “transmission deviations of a gear pair”.
Most situations with long term component deviations To fully explore the complete spectrum of the
will be in the sinusoidal form, which is caused by deviations, it is necessary to continue rotation until
eccentricity, as shown in figures 41a, 41b, 41c and the complete meshing period of both gears has been
42. There are cases, however, where long term explored. The number of revolutions required
deviations will show up in higher orders, such as corresponds to the number of teeth in the larger
shown in figures 33 and 34. This can be caused by member divided by the largest factor common to
oval shapes, triangular shapes, etc. This is common both members.
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
5.0
4.0
0.0
--1.0
--2.0
--4.0
--5.0
0 1 2 3 4 5 6 7 8 9 10 11 12
Tooth number
Analysis is similar to that described in 9.3.6 for a tus, in which case the effectiveness of the
product gear with a master gear, except that the adjustments can be verified without delay.
deviations should be calculated based on the
9.4.2 Selective meshing of gears
complete meshing period of both gears rather than
on a single revolution of the product gear. In some exceptional cases, involving mated pairs of
gears with equal numbers of teeth or other integer
9.4.1 Identification and location of defects
ratios, special steps can be taken to ensure that
The measurement of tangential composite devi- optimum performance is realized. Such gears can
ations facilitates the identification and location of be meshed to best advantage by remeshing the
defects (nicks or burrs) which may degrade the gears with a phase shift of ninety degrees to find the
quality of transmission. For example, as indicated in quadrant in which single flank composite deviations
the diagram in figure 43, the presence of a defective are smallest. Following this, the process is repeated
tooth can readily be seen. Furthermore, it is by remeshing the gears with phase shifts less than
sometimes possible to carry out corrective mea- ninety degrees in order to find the optimum meshing
sures while still connected to the measuring appara- phase.
damaged tooth
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
In figure 44 diagrams are shown which were 10.1 Control of test conditions
generated from a pair of gears at the different phases
The reproducibility of contact pattern checks is
of mesh indicated. It is quite evident that the single
dependent upon careful control of the test condi-
flank composite deviation diagrams for the left flanks
tions. A small variation, 0.01 mm, in location of the
and right flanks are not the same. It may be
gears from test to test may have a significant effect
necessary to choose an intermediate meshing
on the results.
position that provides the best compromise solution
if a high degree of transmission accuracy is needed Caution should be used when static contact checks
for both directions of rotation. are performed on gears and shafts mounted in
dynamic bearings. The shafts should be located in a
fixture in such a way that they represent the final
operating conditions.
10 Contact pattern checking
10.1.1 Gear axes parallel
Contact checking is used for the inspection of mating When the gears are tested outside the housing in
gear sets to determine their operational compatibility which they may be used, or if the assembled centers
and for the inspection of gears which will not fit into are adjustable, the gears are normally mounted with
available measuring machines because of size and their axes parallel. This is usually accomplished in
weight limits. This clause explains a quasi--static an adjustable testing frame with the line of centers
method of obtaining and analyzing contact patterns, horizontal, so that a precision level and micrometers
and a method for evaluating the observed deviations can be used to establish parallel axes at the given
from designed contact. Contact checking is com- center distance in a common plane. The absolute
monly used on bevel, mill, marine, and high speed value of center distance is not as important as
gears. maintaining the gear axes parallel.
0°L 0°R
90°L 90°R
180°L 180°R
270°L 270°R
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AGMA 915--1--A02 AMERICAN GEAR MANUFACTURERS ASSOCIATION
If test gears are being compared to a master gear, Typical values for carefully applied marking com-
the master gear must be of known quality, and of pound thickness are from 0.008 mm to 0.012 mm.
sufficient accuracy to assure that errors in the master Figure 45 shows a contact pattern obtained with
gear will not appreciably affect the results. good profile contact, and some tooth alignment
Gears may also be tested as matched pairs. mismatch. If the marking compound thickness is
0.01 mm, the tooth misalignment shown over the
10.1.3 Marking compound length of the contact pattern is also 0.01 mm. An
angular correction in helix angle or mounting of 0.01
Various marking compounds can be used including
mm divided by the length of contact should produce
Prussian blue, dye check developer, and proprietary
full contact.
compounds. It is important that the compound be
controlled carefully, since its viscosity and the
method of application will affect the film thickness, Length
which is critical to the interpretation of results. of contact
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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 915--1--A02
Figure 47 -- Waviness
10.5 Specifications
Contact pattern acceptability is specified by defining
the area in which contact may not occur, the areas in Figure 48 -- Typical specification:
which contact should occur, and the percentage of approximately 75% contact, excluding
contact required in the desired area. Figure 48 extremes of tooth, which are intentionally
illustrates a contact pattern which meets a specifica- relieved
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AMERICAN GEAR MANUFACTURERS ASSOCIATION
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