Analitical Method to Calculate the Unknown Geometry of Cylindrical Gears

ANALITICAL METHOD TO CALCULATE THE UNKNOWN

GEOMETRY OF CYLINDRICAL GEARS

G. Gonzlez Rey1*, A. Garca Toll2

1
Universidad de Tecnolgica de Aguascalientes, Blvd. Juan Pablo II, No.
1302, Fracc. Exhacienda, La Cantera, Ags. C.P. 20200. Mxico
2,
Instituto Superior Politcnico Jos Antonio Echeverra, Cujae. Marianao 15.
La Habana. Cuba

ABSTRACT

A procedure of reverse engineering to determine the basic geometry for

manufacturing of external parallel-axis cylindrical involute gears by means
of workshop measurement tools is presented. This procedure proposes a
practical method to obtain the fundamental gear parameters in order to
have a reference for calculating the load capacity of cylindrical gears or
when a copy of an external parallel-axis cylindrical involute gear is
necessary for recreating other new gear according to ISO standards by
generation cutting.

KEYWORDS: Cylindrical gear, unknown geometry, inverse engineering

1.0 INTRODUCTION
Gear engineering requires of professional skills in several action fields
like design, production, operation, maintenance, repair and recycled.
Generally, the main action fields are established by the industry profile.
Industries and companies with actions in the maintenance and repair
of gear usually ask for professionals with skill in the recovery of these
elements.

In general, the repair of gear implies bigger challenge to the gear

engineers, because the problems and solutions involve already
manufactured gears whose geometry is generally unknown. In this
situation, the engineer needs to know the previous basic geometry
of the gears in order to have a reference for the recovering or re-
manufacturing.

Actually, there are a wide variety of CNC generative gear testers and
coordinate measuring machines (CMM) destined for inspection and

Corresponding author e-mail: gonzalo.gonzalez@utags.edu.mx

ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 57

Journal of Mechanical Engineering and Technology

control of spur and helical gears with fully automatic measuring cycle
and extremely short measuring times combined with high measuring
accuracies. In this advanced gear measuring machines, the profile
of the tooth can be checked and compared with a flank topography
reference and by means of a trial and error procedure it is possible to
obtain an approximate geometry of the analyzed gears (Kumar, 2014).
Moreover, some advanced measurement machine have incorporated
special program for measuring gears with unknown parameters and
determining some important data of the gear basic geometry (Grimsley,
2003). Unfortunately, the price lists of these machines are very high,
somewhere in the $300,000 to $500,000 range, and not often accessible
to the company or factory involves with gear remanufacturing.
Concerning with this situation, gear specialists (Gonzlez Rey, 1999),
(Innocenti, 2007), (Belarifi et al., (2008), (Schultz, 2010) involved with
recreating replacement gears are considered alternative procedures to
determine the unknown gear geometry using more simple measurement
tools.

Consequently, this paper presents a method of reverse engineering to

determine the unknown gear geometry in order to have a reference
for the design or manufacturing. This method, based on authors
experiences in the analysis, recovery and conversion of helical and
spur gears, proposes a practical procedure with results not too exact,
but practically acceptable, to obtain the fundamental parameters by
means of conventional measurement tools. This method is useful for
the recreating of new external parallelaxis cylindrical involute gears
according to ISO standards by a generation cutting process.

2.0 BASIC GEAR DATA TO DETERMINE THE UNKNOWN

EXTERNAL CYLINDRICAL INVOLUTE GEAR GEOMETRY
It is known that the question of what data is required to specify an
external parallel-axis cylindrical involute gear can be answered
perfectly by means of the theory associated with the involute helicoids
surface of the flank of a helical gear (Maag, 1990). In this case, it is
necessary to know number of teeth, tip diameter, root diameter, base
diameter, base helix angle and base tooth thickness. The three first data
can be determined easily by measurement but the data associated with
the base cylinder can be determined only by special gear measuring
equipment. Thus, where only a sample of a gear but not complete
gear data is available initially, the specification for generating the
gear can be calculated. Main formulas involved with the theory of the
involute helicoids surface of the flank of a helical gear are summarized

58 ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015

cylindrical involute gear can be answered perfectly by means of the theory associated
with the involute helicoids surface of the flank of a helical gear (Maag, 1990). In this
case, it is necessary to know number of teeth, tip diameter, root diameter, base diameter,
base helix angle and base tooth thickness. The three first data can be determined easily
by measurement Analitical
but the data associated
Method with the
to Calculate the Unknown
base cylinder can be
Geometry of determined only
Cylindrical Gears
by special gear measuring equipment. Thus, where only a sample of a gear but not
complete gear data is available initially, the specification for generating the gear can be
calculated. Main formulas involved with the theory of the involute helicoids surface of
below (Equations (1) (8)). Some of them are fundamentals in the
the flank of a helical gear are summarized below (Equations (1) (8)). Some of them are
determination
fundamentals in the of determination
the gear geometry
of the gearthat fulfillsthat
geometry thefulfills
datathe requested
data requested
as reference
as reference forfor
the the design
design or manufacturing.
or manufacturing.

df
m z
cos
*

2 m ha c * x (1)

d a1, 2 2 aw d f2,1 2 c* m (2)

m z
db cos t (3)
cos
tan
t tan 1 (4)
cos

sn m 2 x tan (5)
2
s
sbn z m cos n inv t (6)
zm


d tan
b tan 1 b (7)
m z
cos

p bn m cos (8)
2

Where:
Where:
z : number of teeth sn : normal tooth thickness on reference
m: normal module (mm) cylinder (mm)
z : number of teeth sn : normal tooth thickness on reference
x: addendum modification coefficient sbn : normal base tooth thickness (mm)
m::normal module
helix angle at a (mm)
reference diameter () cylinder (mm)
pbn : normal base pitch (mm)
: tip
x:daddendum
a diameter (mm)
modification coefficient sbn : : pressure
normal angle thickness
base tooth () (mm)
d : root diameter (mm)
: helix angle at a reference diameter ()
f : transverse pressure
pbn : normal base pitch (mm)
t angle ()
aw: centre distance (mm) ha* : factor of addendum
dad: tip diameter (mm) : pressure angle ()
b: base diameter (mm) c* : factor of radial clearance
df: root
b: base diameter (mm)
helix angle () t : transverse pressure angle ()
aw: centre distance (mm) ha* : factor of addendum
db: base diameter (mm) c* : factor of radial clearance
Moreover, standards (Norma NC 02-04-04, 1978; ISO Standard 1340, 1976; AGMA
b: base helix angle ()
Standard 910-C90; 1990) with guidelines about the complete information to be given to
the manufacturer in order to obtain the gear required give you an idea about the proper
Moreover, standards
data to be placed (Norma
on drawings of gearsNC
for 02-04-04, 1978; purposes.
general or special ISO Standard 1340,
The mentioned
1976; AGMA
information Standard
includes details of910-C90; 1990)thewith
the gear body, guidelines
mounting about the
design, facewidth, and
fundamentalinformation
complete gear data for to
manufacturing,
be given toinspection and reference.
the manufacturer Usually,
in order to the gear
obtain
data can be efficiently and consistently specified on the gear drawing in a standardized
the gear required give you an idea about the proper data to be placed
block format. Figure 1 shows the typical gear data block and information required on
on drawings of gears
drawings for standard for
helical general
gears or to
according special purposes.
Cuban Standard NC The mentioned
02-04-04:1998.
information includes details of the gear body, the mounting design,
facewidth, and fundamental gear data for manufacturing, inspection
and reference. Usually, the gear data can be efficiently and consistently
specified on the gear drawing in a standardized block format. Figure

ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 59

 Moreover, standards (Norma NC 02-04-04, 1978; ISO Standard 1340, 1976; AGMA
Standard 910-C90; 1990) with guidelines about the complete information to be given to
the manufacturer in order to obtain the gear required give you an idea about the proper
Journal of Mechanical Engineering and Technology
data to be placed on drawings of gears for general or special purposes. The mentioned
information includes details of the gear body, the mounting design, facewidth, and
fundamental gear data for manufacturing, inspection and reference. Usually, the gear
1data
shows
can be the typical
efficiently gear dataspecified
and consistently block and
on theinformation
gear drawing inrequired on
a standardized
drawings
block format.for standard
Figure 1 showshelical gears
the typical according
gear data block to
andCuban Standard
information requiredNC
on
02-04-04:1998.
drawings for standard helical gears according to Cuban Standard NC 02-04-04:1998.

Figure 1. Typical data for gear drawings to be given by the gear designer for
the gear manufacturer, according to NC 02-04-04: 78
Figure 1. Typical data for gear drawings to be given by the gear designer for the gear
manufacturer, according to NC 02-04-04: 78
3
3.0 INITIAL DATA AND MEASUREMENTS
In the proposed procedure, to calculate the fundamental gear tooth
data of an external parallel-axis cylindrical involute gear, it is necessary
to know the following parameters:

Number of teeth on pinion and gear (z1, z2)

Tip diameters on pinion and gear (da1, da2) in mm
Facewidth on pinion and gear (b1, b2) in mm
Base tangent length spanned in k teeth on pinion and gear (Wk1,
Wk2) in mm
Number of teeth spanned for the base tangent length on pinion
and gear (k1, k2)
Tooth depth on pinion and gear (h1, h2) in mm
Centre distance (aw) in mm
Helix angle at tip diameter (a) in degree

Number of teeth (z): Special care should be had counting the quantity
of teeth in the gears. It is a good practice to make some mark with chalk
in the tooth where the count begins to assure that the number of teeth
was correctly determined. An incorrect specification of the number of
teeth on gears will be catastrophic in the next calculation.

60 ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015

In the proposed procedure, to calculate the fundamental gear tooth data of an external
parallel-axis cylindrical involute gear, it is necessary to know the following parameters:
Number of teeth on pinion and gear (z1, z2)
Analitical
Tip diameters Method
on pinion andtogear
Calculate
(da1, the
da2Unknown
) in mm Geometry of Cylindrical Gears
Facewidth on pinion and gear (b1, b2) in mm
Base tangent length spanned in k teeth on pinion and gear (Wk1, Wk2) in mm
Tipdiameters
Number of(da):
teeth A conventional
spanned for the basevernier caliper
tangent length of suitable
on pinion and gearsize
(k1, kcan
2)
be use to determine
Tooth the and
depth on pinion distance
gear (h1between
, h2) in mmthe two outer extremities of
external geardistance
Centre teeth in(awposition
) in mm diametrically opposed. The measure will
always be more
Helix angle ataccurate in (gears
tip diameter with even number of teeth, but it is
a) in degree
also practically applicable in gears with odd quantity of teeth, always
Number of teeth (z): Special care should be had counting the quantity of teeth in the
better in gears with large number of teeth.
gears. It is a good practice to make some mark with chalk in the tooth where the count
begins to assure that the number of teeth was correctly determined. An incorrect
Facewidth (b):theItnumber
specification of is the of
width over
teeth on the
gears toothed
will part ofinathe
be catastrophic gear,
next measured
calculation.
along a generator of the reference cylinder. The measurement can be
Tip diameters
made using a(da): A conventional
vernier vernier caliper
caliper, although it canofbesuitable
enough sizea can be use
simple to
rule
determine the distance between the two outer extremities of external gear teeth in
with precision of millimetres.
position diametrically opposed. The measure will always be more accurate in gears with
even number of teeth, but it is also practically applicable in gears with odd quantity of
Base tangent
teeth, always length
better (Wk):
in gears with The measurement
large number of teeth. is made over a group of
teeth using a conventional vernier calliper or plate micrometer. For a
Facewidth
good (b): is
results It is the widththat
required overthe
thecontrolled
toothed partflanks
of a gear,
are measured
perfectlyalong cleana
generator of the reference cylinder. The measurement can be made using a vernier
and without appreciable wear. Moreover, the calliper jaws must
caliper, although it can be enough a simple rule with precision of millimetres.
penetrate sufficiently into two tooth spaces to make tangent contact
with the tooth
Base tangent lengthsurfaces
(Wk): Thewithout interfering
measurement is made with
over a thegroupteeth adjoining
of teeth using a
the span measurement.
conventional Thus,
vernier calliper or plate the measurement
micrometer. For a good results ofis required
the distance that the
controlled two
between flanksparallel
are perfectly
planes clean and without
tangent to theappreciable
outer flanks wear. of Moreover,
a number the
calliper jaws must penetrate sufficiently into two tooth spaces
of consecutive teeth, along a line tangent to the base cylinder, is taken. to make tangent contact
with the tooth surfaces without interfering with the teeth adjoining the span
In case of not
measurement. considering
Thus, the measurementspaceofbetween non-working
the distance between two flanks
parallel of the
planes
mating
tangent togears when
the outer flanksthe
of working
a number offlanks are in
consecutive contact
teeth, along a(zero backlash),
line tangent to the
the
basedistance
cylinder, ismeasured
taken. In case is of
equal to the normal
not considering thickness
space between of one tooth
non-working flanks at
of
the mating
the gears when
base cylinder sbntheplus
working
the flanks
productare in
ofcontact (zero backlash),
the number of teeththe distance
spanned
measured
less one (kis equal
-1) andto thethenormal
normal thickness
base of onepbn
pith tooth, at
seetheEquation
base cylinder(9).sbnSuffixes
plus the
product of the number of teeth spanned less one (k -1) and the normal base pith pbn , see
k1 (for pinion)
Equation andkk2(for
(9). Suffixes (for gear)and
pinion) afterk2 the
(for letter W specifies
gear) after the letter W the number
specifies the
1
of teeth between the flanks measured. Figures 2 and
number of teeth between the flanks measured. Figures 2 and 3 illustrate the span 3 illustrate the
span measurement
measurement applied to applied to spur
spur and helical and helical gears.
gears.

Wtk sbn pbn (k 1) (9)

Figure 2. Measurement of base tangent length over 3 teeth in spur gear

Figure 2. Measurement of base tangent length over 3 teeth in spur gear

ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 61

Journal of Mechanical Engineering and Technology
Figure 2. Measurement of base tangent length over 3 teeth in spur gear

Figure 2. Measurement of base tangent length over 3 teeth in spur gear

Figure 3. Measurement of base tangent length over 3 teeth in helical gear

(toplength
Figure 3. Measurement of base tangent view)over 3 teeth in helical gear (top view)

On external parallel-axis cylindrical involute gear, the actual base tangent lengths (Wk1
Onand external parallel-axis
Wk2) are less cylindrical
than the theoretical involute
dimensions for zerogear,
backlashthebyactual base
the necessary
tangent
amount of lengths (Wk1backlash
the normal and Wk2allowance,
) are lessbut
than
thisthefacttheoretical
doesn't affect dimensions
the practical
results
for zero because standard
backlash byvalues
the of gear backlash
necessary (ISO/TRof10064-2,
amount the normal 1996) are relatively
backlash
small (not bigger than 3 or 7 % of module) for industrial drives with typical commercial
allowance, but this fact doesnt affect the practical results because
manufacturing tolerances.
standard
Figurevalues of gear
3. Measurement backlash
of base (ISO/TR
tangent length over 310064-2, 1996)
teeth in helical gearare
(toprelatively
view)
small (not bigger than 3 or 7 % of module) for industrial
In gear with profile or helix modifications, the span measurement should be carrieddrives without
On external parallel-axis cylindrical involute gear, the actual base tangent lengths (Wk1
typical
on the commercial
un-modified partmanufacturing
of the tooth flank.tolerances.
Moreover, in some case, span
and W ) are less than the theoretical dimensions for zero backlash by the necessary
measurement
cannotk2be applied when a combination of high helix angle and narrow facewidth prevent
amount of the normal backlash allowance, but this fact doesn't affect the practical
the caliper from spanning a sufficient number of teeth, see Equation (10). In this
In gear
results withstandard
because profilevalues
or helix
of gearmodifications,
backlash (ISO/TR the span1996)
10064-2, measurement
are relatively
situation should be considered other alternative procedures to determine the unknown
should
small (notbe carried
bigger than 3 out
or 7 %on of the
module)un-modified
for industrial part
drives of
withthe
gear geometry using conventional measurement tools (Regalado, 2000) or exhaustive tooth
typical flank.
commercial
manufacturing
Moreover, tolerances.
inwith
some case, spanprocedure
measurement
search method a trial and error to obtain cannot be applied
an approximate geometry when
of the
aanalyzed
combination
gears. of high helix angle and narrow facewidth prevent the
In gear with profile or helix modifications, the span measurement should be carried out
caliper from spanning
on the un-modified a sufficient
part of the tooth flank. number
Moreover,of in teeth, see span
some case, Equation (10).
measurement
In thisbesituation
cannot applied when should b 1 ,015 W
be considered
a combination
min sin
of high helixother
k b alternative
angle and procedures
narrow facewidth
(10)
prevent
toWhere:
the determine the unknown
caliper from spanning a sufficientgearnumbergeometryof teeth, seeusing conventional
Equation (10). In this
situation bmin:
measurement shouldminimum
be
tools
value other
considered
(Regalado,
for facewidth
alternative
2000)
in mm.
or
There istoandetermine
procedures
exhaustive
additionalthe
search
value
method
of
unknown
with
1,5% to
gear geometry makeconventional
using an stable span measurement.
measurement tools (Regalado, 2000) or exhaustive
a trial and error procedure to obtain an approximate geometry of the
search method with a trial and error procedure to obtain an approximate geometry of the
analyzed gears.
analyzed gears. 5

bmin 1,015 Wk sin b (10)

Where:
bmin: minimum value for facewidth in mm. There is an additional value of
Where: 1,5% to make an stable span measurement.
bmin: minimum value for facewidth in mm. There is an
additional value of 1,5% to make an stable span measurement.5

62 ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015

 Analitical Method to Calculate the Unknown Geometry of Cylindrical Gears

Number of teeth spanned for the base tangent length (k): In case of
gears with tooth data specified, the number of teeth spanned for the
base tangent length can be calculated (Maag, 1990), but for gears with
unknown geometry, the number of teeth between the measuring surfaces
can be established so that the points of contact with vernier caliper or
plate micrometer are roughly at mid tooth height. The number of teeth
Number of teeth spanned for the base tangent length (k): In case of gears with tooth data
to be spanned will be larger for gears with larger numbers of teeth and
specified, the number of teeth spanned for the base tangent length can be calculated
for gears
(Maag, with
1990), but higher
for gearshelix angle. Recommendations
with unknown geometry, the numberon of Table 1, based
teeth between the
on authors
measuring experiences
surfaces and calculation
can be established so that the of the of
points base tangent
contact length,caliper
with vernier can
orbeplate
used as guideline
micrometer values
are roughly of number
at mid of teeth
tooth height. for span
The number measurement.
of teeth to be spanned
will
Forbemorelargerdetailed
for gears information
with larger numbers
aboutof values
teeth andoffor
thegears with higher
number helix
of teeth
angle.
spanned for the base tangent length from the helix angle, the numberof
Recommendations on Table 1, based on author's experiences and calculation
the base tangent length, can be used as guideline values of number of teeth for span
of teeth, pressure angle and the addendum modification coefficient can
measurement. For more detailed information about values of the number of teeth
be obtained
spanned for the in MAAG
base tangentGear
lengthBook.
from the helix angle, the number of teeth, pressure
angle and the addendum modification coefficient can be obtained in MAAG Gear Book.
Table 1. Guideline for the number of teeth spanned for the base tangent
Table 1. Guideline for the number of teeth spanned for the base tangent length
length
Number of teeth between the measuring surfaces so that the points of
Helix angle at a tip contact are roughly at mid tooth height (k).
diameter (a) 2 3 4 5 6 7 8 9 10 11 12 13
Number of teeth (z)
11 18 28 36 44 55 65 75 85 95 100 110
0
18 28 36 44 55 65 75 85 95 100 110 120
10 16 24 30 42 48 55 65 75 85 95 100
20
16 24 30 42 48 55 65 75 85 95 100 110
6 9 14 18 24 28 32 36 42 46 50 54
40
9 14 18 24 28 32 36 42 46 50 54 60

Tooth depth (h): This magnitude is usually specified as the radial distance between the
Tooth
tip depth
and root (h): This
diameters. Tooth magnitude is usually
depth may be measured specified
by means as the
of a gear toothradial
vernier
distance
caliper between
or in the tip
tooth space usingand root diameters.
a simple Tooth
vernier caliper withdepth
blade may be
for depth
measurements. The calliper blade must penetrate sufficiently and
measured by means of a gear tooth vernier caliper or in tooth space to make contact with
the surface at the bottom of a tooth space without interfering with adjacent teeth flanks.
using a simple vernier caliper with blade for depth measurements. The
calliper
Centre blade(amust
distance penetrate sufficiently and to make contact with the
w): Involute gears can operate correctly with small change of centre
surfaceaccording
distance at the bottom
with theofproper
a tooth space without
tolerances interfering
for deviations, with adjacent
but assembled gears with
teeth flanks.
incorrect operating centre distance will not operating properly, for that reason, the
centre distance should be determined with a good precision. This magnitude is accepted
asCentre
the shortest distance
distance (aw):between
Involutethe axes
gearsof can
a gear pair andcorrectly
operate this is alsowith
the distance
small
between the axes of shafts that are carrying the gears.
change of centre distance according with the proper tolerances for
deviations, but assembled gears with incorrect operating centre distance
A common method to determine the gear centre distance is the measurement in parallel
will not
planes operating
of the properly,
center holes distancefor that in
located reason, the centre
their functional distance
shafts, should
but taking into
be determined
account the accuracywith a good precision.
of cylindrical Thisonmagnitude
bearing seatings shafts and inishousing
accepted asa
bores,
the shortest
more distance
satisfactory method between
is considerthe
theaxes of a centre
nominal gear pair andas
distance this
theissum
alsoofthe
the
housing
distancebores radii (or the
between outeraxes
radiiof
ofshafts
bearings) plus
that thecarrying
are distance between them. Figure 4
the gears.
and Equation (11) show this idea. Usually, speed reducers and enclosed gear units boxes
have specified the nominal centre distance based on series of preferred numbers (IS0
Standard 3, 1973) and checking it may provide clues to nominal value of the centre
distance.
ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 63
aw R1 R2 T (11)

6
 caliper or in tooth space using a simple vernier caliper with blade for depth
measurements. The calliper blade must penetrate sufficiently and to make contact with
the surface at the bottom of a tooth space without interfering with adjacent teeth flanks.
Journal
Centreofdistance
Mechanical Engineering
(aw): and Technology
Involute gears can operate correctly with small change of centre
distance according with the proper tolerances for deviations, but assembled gears with
incorrect operating centre distance will not operating properly, for that reason, the
A common
centre method
distance should to determine
be determined the precision.
with a good gear centre distance
This magnitude is the
is accepted
measurement in parallel
as the shortest distance betweenplanes
the axesofofthe center
a gear holes
pair and this distance
is also thelocated
distance
between
in theirthefunctional
axes of shaftsshafts,
that are carrying the gears.
but taking into account the accuracy of
cylindrical bearing seatings on shafts and in housing bores, a more
A common method to determine the gear centre distance is the measurement in parallel
satisfactory method
planes of the center holesisdistance
consider theinnominal
located centre
their functional distance
shafts, as the
but taking into
sum ofthe
account theaccuracy
housing bores radii
of cylindrical (or seatings
bearing outer radii of and
on shafts bearings)
in housing plus thea
bores,
distance between
more satisfactory them.
method Figurethe
is consider 4 and Equation
nominal (11) show
centre distance as the this
sum ofidea.
the
Usually, speed
housing bores radiireducers andof enclosed
(or outer radii gear
bearings) plus theunits boxes
distance have
between specified
them. Figure 4
and Equation
the nominal(11) show distance
centre this idea. Usually,
based speed reducers
on series of and enclosednumbers
preferred gear units boxes
(IS0
have specified the nominal centre distance based on series of preferred numbers (IS0
Standard 3, 1973) and checking it may provide clues to nominal
Standard 3, 1973) and checking it may provide clues to nominal value of the centre
value
of the centre distance.
distance.

aw R1 R2 T (11)

Figure 4. Parameters for calculation of centre distance (aw) by means of

Figure 4. Parameters for calculation of centre distance (aw) by means of center holes distance or
centerbearing
holeshousing
distance or radii
bores bearing
(R1 +housing bores
R2) plus the radii
distance (T)(R1 + R2)them
between plus the
distance (T) between them
Helix angle at tip diameter (a): For spur gears = a =0, because the helix is a
straight line parallel to its rotating axis, but in case of helical gears the measuring of the
Helix angle
helix angle at tip diameter
at reference diameter is(a):
one ofFor
the spur gears of=specifying
most difficult a =0, because
and shouldthebe
helix is aan
done with straight line parallel
special helix to When
angle tester. its rotating axis, measuring
a helix angle but in case of possible
is not helical
gears thespecial
with these measuring of the
equipments, the helix angle
helix angle at reference
at reference diameter
diameter can get byis aone of
simple
the most
method difficult
based of specifying
in the approximate and should
measured be done
of the helix angle with an special
at tip diameter (a)helix
with
results not
angle too exact,
tester. When butapractically acceptable.
helix angle For this,isit not
measuring is necessary
possible apply
witha marking
these
compound to the tip surface of external gear teeth and roll the helical gear in straight
special equipments, the helix angle at reference
line on a white paper to collect their generated trace (see Figure 5).
diameter can get by a
simple method based in the approximate measured of the helix angle at
tip diameter (a) with results not too exact, but practically acceptable.
For this, it is necessary apply a marking compound to the tip surface of
external gear teeth and roll the helical gear in straight line on a white
paper to collect their generated trace (see Figure 5).

64 Figure
ISSN:5.2180-1053
Measuring of outer
Vol. helix
7 No. 2 aJuly
angle by their generated2015
- December trace
done with an special helix angle tester. When a helix angle measuring is not possible
with these special equipments, the helix angle at reference diameter can get by a simple
method based in the approximate measured of the helix angle at tip diameter (a) with
results not too exact, but practically acceptable. For this, it is necessary apply a marking
compound to theAnalitical Method
tip surface to Calculate
of external gear the Unknown
teeth and rollGeometry of Cylindrical
the helical Gears
gear in straight
line on a white paper to collect their generated trace (see Figure 5).

Figure 5. Measuring of outer helix angle a by their generated trace

Figure 5. Measuring of outer helix angle a by their generated trace

4.0 DETERMINATION OF THE UNKNOWN GEAR GEOMETRY

The output results of the unknown gear have strong relation with the
measured values and depending of uncertainty of the measuring and
including all manufacturing errors, wear and deformation on flanks in
the gear itself. It is important understand this concept because modules,
pressure angles, helix angles, addendum modification coefficient and
4.0
other DETERMINATION
gear geometry featuresOF THE UNKNOWN
are GEAR GEOMETRY
given at calculated values and they
are not necessarily the values used in the initial manufacturing of the
The output results of the unknown gear have strong relation with the measured values
gears, but they
and depending of are very useful
uncertainty as reference
of the measuring and to establish
including the fundamental
all manufacturing errors,
7
parameters for reproduction
wear and deformation on flanks in theof new
gear gears
itself. or evaluation
It is important ofthis
understand theconcept
load
capacity of gears.
because modules, pressure angles, helix angles, addendum modification coefficient and
other gear geometry features are given at calculated values and they are not necessarily
the values used in the initial manufacturing of the gears, but they are very useful as
With the initial data and measurements above mentioned, fundamental
reference to establish the fundamental parameters for reproduction of new gears or
gear geometry parameters
evaluation of the load capacity of according
gears. to ISO standards can be obtained
applying the following calculations.
With the initial data and measurements above mentioned, fundamental gear geometry
parametersmodule
Normal according(m)to ISO standards can be obtained applying the following
calculations.
The module m in the normal section of the gear is the same module m
of the standard
Normal module (m) basic rack tooth profile (IS0 Standard 53, 1998) and is
defined
The moduleas mthe quotient
in the of theofpitch
normal section pis (distance
the gear measured
the same module over
m of the the
standard
reference circleprofile
basic rack tooth from(IS0
a point on one
Standard tooth and
53, 1998) to the corresponding
is defined point
as the quotient of on
the
pitch p (distance measured over the reference circle from a point
the adjacent tooth of the gear), expressed in millimetres, to the number on one tooth to the
corresponding point on the adjacent tooth of the gear), expressed in millimetres, to the
.
number .
p
m (12)
m

The module
The module is a is
commonly referencedreferenced
a commonly gear parameter in the
gear ISO gear system
parameter in theand ISO
very
important to defined the size of gear tooth. The module cannot be measured directly
gear
from asystem and
gear; yet, it isvery important
a common to defined
referenced the size
value. Tooling of gear tooth.
for commercially The
available
module cannot be measured directly from a gear; yet, it
cylindrical gears are stocked in standardized modules (ISO Standard 54, 1996) is a common
referenced
(ANSI/AGMAvalue.1102-A03, Tooling
2003).for commercially
Generally, when gearavailable
generationcylindrical gears
has ended a perfect
engagement between gear and its generating hob occurs. Thus,
are stocked in standardized modules (ISO Standard 54, 1996) (ANSI/ the normal module in the
unknown gear geometry may be determined by a simple
AGMA 1102-A03, 2003). Generally, when gear generation has ended search of gear generating hob
with known module which has a perfect mating with the analyzed gear, but this
aprocedure
perfectrequires
engagement between
of a complete set of gear and hob
generating its togenerating
give solutionshob and occurs.
it is not
economically desirable, especially when the measurement has to be done in the field.
Moreover, the normal module could be determined using a more practical procedure
based on theISSN: 2180-1053
difference between Vol. 7 of
values No.base
2 July - December
tangent 2015 a consecutive
lengths over 65
number of teeth spanned and their relations with the normal base pitch. Once the base
tangent lengths have been measured, the value for reference of the normal module may
be calculated applying Equations (13) and (14) for pinion and gear respectively. Since
 pitch p (distance measured over the reference circle from a point on one tooth to the
corresponding point on the adjacent tooth of the gear), expressed in millimetres, to the
number .
p
m
Journal of Mechanical Engineering and Technology (12)
m

The module is a commonly referenced gear parameter in the ISO gear system and very
Thus, the normal module in the unknown gear geometry may be
important to defined the size of gear tooth. The module cannot be measured directly
determined byit ais simple
from a gear; yet, a common search of gear
referenced value. generating hob with available
Tooling for commercially known
module
cylindricalwhich
gears has a perfect
are stocked mating with
in standardized the analyzed
modules gear, 54,
(ISO Standard but1996)
this
procedure
(ANSI/AGMA requires
1102-A03, of a2003).
complete set of
Generally, generating
when hob to
gear generation hasgive
endedsolutions
a perfect
engagement
and between
it is not gear and itsdesirable,
economically generating hob occurs. Thus,
especially when thethe
normal module in the
measurement
unknown gear geometry may be determined by a simple search of gear generating hob
has to be done in the field. Moreover, the normal module could be
with known module which has a perfect mating with the analyzed gear, but this
determined using
procedure requires of aa complete
more practical procedure
set of generating hob tobased on the difference
give solutions and it is not
between
economically desirable, especially when the measurement has to be donenumber
values of base tangent lengths over a consecutive of
in the field.
teeth spanned and their relations with the normal base pitch. Once the
Moreover, the normal module could be determined using a more practical procedure
basedtangent
base on the difference between
lengths have beenvalues of base tangent
measured, the valuelengths
for over a consecutive
reference of the
number of teeth spanned and their relations with the normal base pitch. Once the base
normal module may be calculated applying Equations (13) and (14) for
tangent lengths have been measured, the value for reference of the normal module may
pinion and applying
be calculated gear respectively.
Equations (13) Since the for
and (14) values
pinionm1andandgear m2 need not
respectively. be
Since
exactly
the valuesprecise can
m1 and m be taken
2 need for calculation
not be exactly precise can propose
be taken for a value 20.a
of propose
calculation
value of 20.
Wk1 Wk11
m1 (13)
cos

Wk 2 Wk 21
m2 (14)
cos

Although mating gears can have different base tangent lengths and
number of teeth, mating gears must have the same module and pressure8
angle, for that reason the correct normal module for gear m should be
Although mating gears can have different base tangent lengths and number of teeth,
established equal to the nearest standardized module to the values m
mating gears must have the same module and pressure angle, for that reason the correct1
and m2module
normal . Tablefor
2 can
gear be used be
m should as established
guideline equal
for values of standardized
to the nearest standardized
normal
module tomodules.
the values m1 and m2. Table 2 can be used as guideline for values of
standardized normal modules.
Table 2. Standardized normal modules of cylindrical gears for general and
Table 2. Standardized normal modules
heavyof cylindrical
engineeringgears for general and heavy engineering

Series I 1 1,25 1,5 2 2,5 3 4 5 6

II 1,125 1,375 1,75 2,25 2,75 3,5 4,5 5,5 (6,5)
Series I 8 10 12 16 20 25 32 40 50
II 7 9 11 14 18 22 28 36 45
NOTE:
NOTE: Preference
Preference should
should be givenbetogiven
the usetoofthe
the use of the
normal normal
modules modules
as given in seriesas
I. The
given in series
module I.6,5
The module
of series 6,5 ofbeseries
II should avoided.II should be avoided.
These normal modules These
are not normal
necessary
modulesapplicable
are not tonecessary
gears used applicable to gears
in the automotive field. used in the automotive field.

Helix angle at reference diameter ().

Helix
As it isangle
known,atinreference diameter
spur gears the ().at reference diameter is = 0. In case of
helix angle
As it isgears
helical known, in spur
the helix angle gears the helix
at reference angle
diameter canatbereference
calculated diameter is
based in the
= 0. Inofcase
measured of helical
the helix angle atgears the helix
tip diameter (a) as angle
follows:at reference diameter can
be calculated based in the measured of the helix angle at tip diameter
(a) as follows: m z tan a
sen 1 (15)
da

Nominal pressure angle ().

It is an important characteristic of the standard basic rack tooth profile for cylindrical
66involute gearsISSN:
cutting by generating
2180-1053 Vol.tool
7 and
No. constitutes a geometrical
2 July - December 2015 reference for
involute gears in order to fix the sizes and profiles of their teeth. In general, gears are
generating with a cutter normal profile angle chosen from the range between 14.5 and
25. Standard values for nominal pressure angle are 14.5, 17.5, 20, 22.5, and 25.
 applicable to normal
Table 2. Standardized gears used in theof
modules automotive
cylindricalfield.
gears for general and heavy engineering

Helix
Series angle
I at reference
1 1,25 1,5(). 2
diameter 2,5 3 4 5 6
II
As it is known, 1,125
in spur1,375 1,75
gears the 2,25 at reference
helix angle 2,75 3,5 4,5is =5,5
diameter (6,5)of
0. In case
Series gears
helical I 8 Analitical
the helix10angle 12
Methodat to 16 diameter
Calculate
reference the20Unknown25 Geometry
can 32 of Cylindrical
be calculated40based 50inGears
the
measuredII of the7 helix angle
9 11diameter
at tip 14 (a) as18 follows:
22 28 36 45

NOTE: Preference should be given to the use of the normal modules as given in series I. The
module 6,5 of series II should m z tan a normal modules are not necessary
sen 1 be avoided. These (15)
d field.
applicable to gears used in the automotive
a
Helix angle at reference diameter ().
Nominal pressure angle ().
Nominal pressure
As it is known, in spurangle
gears the().helix angle at reference diameter is = 0. In case of
It is an important characteristic of the standard basic rack tooth profile for cylindrical
Ithelical
is an gears the helix
important angle at reference
characteristic
involute gears cutting by generating tool of the diameter can basic
and standard
be calculated
rack tooth
constitutes a geometrical
basedprofile
in the
reference for
measured
for of
cylindricalthe helix angle
involute at tip
gears diameter
cutting ( a)
by as follows:
generating tool and
involute gears in order to fix the sizes and profiles of their teeth. In general, gears are constitutes
agenerating
geometricalwith areference
cutter normal forprofile
involuteangle gears
chosen infrom order to fixbetween
the range the sizes
14.5and
and
25. Standard values for nominal
profiles of their teeth. Ingeneral, m
pressure z tan
angle
are 14.5, 17.5, 20, 22.5, and 25.
sen gears are
1 a
generating with a cutter (15)
Some gear manufacturers use non-standard cutter profile
d a range angles to accomplish specific
normal profile angle chosen from the between 14.5 and 25.
design goals, in these case this method of reverse engineering can give some idea for
Standard values
recreating other new for
gearnominal pressure
with standardized angle
values are 14.5,
of pressure angle.17.5, 20, 22.5,
Nominal
and 25.pressure
Someangle gear ().manufacturers use non-standard cutter profile
It is an into
important characteristic of the standard basic rack toothofprofile for cylindrical
angles
Taking to accomplish
account the sum specific designbase
of theoretical goals, in these
tangent lengths caseboththistoothed
method of
wheels
involute
(wtk = W gears cutting by generating tool and constitutes a geometrical reference for
reverse tk1 + Wtk2) the
engineering can nominal
give pressure
some idea angle
for can be estimated.
recreating other By means
new gearof
involute gearsprocessing
mathematical in order tooffixthe theEquations
sizes and (6),
profiles
(8), of their
(9) and teeth.for
(16) In pinion
general, gears
and gearare
is
with standardized
generating with a cuttervalues
normal of pressure
profile angle.from the range between 14.5 and
angle chosen
possible the determination of Equation (17). In particular, Equation (17) is relevant
25. Standard values for nominal pressure angle are 14.5, 17.5, 20, 22.5, and 25.
because the numerical values obtained are derived directly from the basic gear data
Some gear
Taking manufacturers angles to accomplish specific
specifiedinto account
and the sum
use non-standard
usedofastheoretical base
cutter profile
previously can be important factor in tangent
the decision lengths
makingof both
task.
design goals, in these case this method of reverse engineering can give some idea for
toothed wheels (wtk = Wtk1 + Wtk2) the nominal pressure angle can
recreating other new gear with standardized values of pressure angle.
be estimated. By means inv wt inv t z processing
x1 x2 of mathematical of the Equations
x 1 z2 (16)
(6), (8), (9) and (16) for pinion 2 and
tan gear is possible
Taking into account the sum of theoretical base tangent lengths of both the determination
toothed wheels
of
(wEquation
tk = Wtk1 + (17).
Wtk2In particular,
) the nominal pressure Equation angle(17)can isbe relevant
estimated. because
By meansthe of
wtk wtkof k1 (6),
wtk 2Equations
1 the 1 (9)
k 2 (8), z1 and invthe
z 2 (16) tw pinion gear
m cosand (17)
numerical
mathematicalvalues obtained
processing are derived directly from for basic gear data
is
possible the determination of Equation (17). In particular,
specified previously and can be used as important factor in the decision Equation (17) is relevant
With
because the numerical values obtained are derived directly from the basic gear data
making task.
specified previously and can be used as important factor in the decision making task.
9

x x1 x2
inv wt inv t z z2 (16)
1
2 tan

wtk wtk1 wtk 2 k1 k 2 1 z1 z 2 inv tw m cos (17)

With
With

tan 9
t tan 1
cos
m z1 z 2 cos t
tw cos 1
2 aw cos
inv wt tan( wt ) wt
Where:Where:
wtk : sum of theoretical base tangent lengths of mating pinion and gear.
w : sum of theoretical base tangent lengths of mating pinion
wt: pressuretkangle at the pitch cylinder.
and gear.
t: transverse pressure angle
wt : pressure angle at the pitch cylinder.
To determine the t : transverse
nominal pressure
pressure angle in theangle
unknown gear should be compared the
sum of the theoretical base tangent lengths (Wtk = Wtk1 + Wtk2) with the result of the
sum of the measured base tangent lengths (Wk = Wk1 + Wk2). Thus the nominal
pressure angle must be estimated equal to the nearest standard value of pressure angle
with smaller difference between the sum of the theoretical (Wtk) and measured (Wk)
base tangent lengths ISSN:
of both gears. The starting
2180-1053 Vol. 7 value
No.in
2 the search
July should be
- December 20, since
2015 67
the majority of cutting tools use that angle conforming to world-wide acceptance.
Smaller pressure angles can be analyzed for case of gears with higher transverse contact
ratios when lower noise levels are desirable, in this circumstances these gears usually
have high numbers of teeth and lightly loaded. Higher pressure angles are sometimes
 t tan
cos
m z1 z 2 cos t
tw cos 1
2 aw cos
Journal of Mechanical Engineering and Technology
inv wt tan( wt ) wt
Where:
To determinewtk : sum
theofnominal
theoreticalpressure
base tangent lengths
angle in of
themating pinion and
unknown gear gear.
should
: pressure angle at the pitch cylinder.
be compared the sum of the theoretical base tangent lengths (Wtk =
wt
t: transverse pressure angle
Wtk1 + Wtk2 ) with the result of the sum of the measured base tangent
lengths (W
To determine the k = Wk1 +pressure
nominal Wk2). Thus
angle inthethenominal
unknown gear pressure
should angle must
be compared the
be
sum of the theoretical base tangent lengths (Wtk = Wtk1 + Wtk2) with the result angle
estimated equal to the nearest standard value of pressure of the
with
sum ofsmaller difference
the measured between
base tangent the (W
lengths sumk of = Wthek1 +theoretical
Wk2). Thus(W tk) and
the nominal
measured
pressure angle (W k) base
must tangentequal
be estimated lengths
to the of bothstandard
nearest gears.value
The ofstarting
pressurevalue
angle
with
in smaller
the search difference
shouldbetweenbe 20,thesince
sum of themajority
the theoreticalof (W tk) and tools
cutting measured
use(W k)
that
base tangent lengths of both gears. The starting value in
angle conforming to world-wide acceptance. Smaller pressure angles the search should be 20, since
the majority of cutting tools use that angle conforming to world-wide acceptance.
can be pressure
Smaller analyzed forcan
angles case
be of gearsfor
analyzed with
casehigher
of gears transverse contact contact
with higher transverse ratios
when lower noise levels are desirable, in this circumstances
ratios when lower noise levels are desirable, in this circumstances these gears usually these gears
usually
have highhavenumbershigh ofnumbers of teeth
teeth and lightly and Higher
loaded. lightlypressure
loaded.angles
Higher pressure
are sometimes
angles
preferredare
for sometimes
gears with lower preferred
numbers of forteeth
gears
and with
heavily lower
loadednumbers
when toothof teeth
bending
strength is required. Table 3 shows a sample of how to
and heavily loaded when tooth bending strength is required. Table 3 determine a nominal pressure
angle.
shows a sample of how to determine a nominal pressure angle.
Table 3. Sample of the procedure to determine the standardized pressure angle by
Table
means3.ofSample ofbetween
difference the procedure tothe
the sum of determine
theoreticalthe
(Wstandardized pressure
tk) and measured (Wk)
angle
base by means
tangent of difference
lengths of both gearsbetween the sum of the theoretical (Wtk) and
measured (Wk) base tangent lengths of both gears
Basic gear data
Pinion (1):
Number of teeth z1 = 16
Number of teeth between measured flanks k1 = 2
Actual base tangent length (average) w2 = 13,88 mm
Wheel (2):
Number of teeth z2 = 83
Number of teeth between measured flanks k2 = 10
Actual base tangent length (average) w10 = 87,48 mm
Gear:
m = 3 mm
= 8,11
aw = 150 mm

Nominal pressure angle () 14,5 17,5

Pressure angle at the pitch 14,64 17,66
cylinder (tw)
inv tw 0,00571 0,01015
Sum of the theoretical base
102,01 101,75
tangent lengths (Wtk = 10
Wtk1 + Wtk2); mm
Sum of the actual base
tangent lengths (Wk= Wk1 101,36
+ Wk2); mm
Difference between
theoretical (Wtk) and 0,65 0,39
measured (Wk); mm
Estimated value of standardized pressure angle
= 20

Addendum modification coefficient (x1, x2)

68 ISSN:
The profile shift is 2180-1053 Vol.is7 added
the amount that No. to,
2 July - December
or subtracted 2015the gear teeth
from,
addendum to enhance the operational performance of the gear mating or meet fixed
design criteria. For specialists involved with gear design based on ISO standards, its
very familiar that the datum line of the basic rack profile need not necessary be tangent
 tangent lengths (Wtk =
Wtk1 + Wtk2); mm
Sum of the actual base
tangent lengths (WkMethod
Analitical 101,36
= Wk1 to Calculate the Unknown Geometry of Cylindrical Gears
+ Wk2); mm
Difference between
theoretical (Wtk) and 0,65 0,39
Addendum
measuredmodification
(Wk); mm coefficient (x1, x2)
The profile shift is the amount thatvalue
Estimated is added to, orpressure
of standardized subtracted
angle from,
the gear teeth addendum to enhance the operational = 20 performance of
the gear mating or meet fixed design criteria. For specialists involved
with gear design based on ISO standards, its very familiar that the
Addendum modification coefficient (x1, x2)
datum lineshift
The profile of the basic
is the amountrackthatprofile need
is added notsubtracted
to, or necessaryfrom,bethe
tangent to
gear teeth
the reference
addendum diameter
to enhance on gear,performance
the operational thus the tooth
of the profile andorhis
gear mating meetshape
fixed
can becriteria.
design modifiedFor by shifting
specialists the datum
involved linedesign
with gear frombased
the tangential position
on ISO standards, its
very familiar that the datum line of the basic rack profile need
(Gonzlez Rey, G. et al, 2006). The main parameter to evaluate the not necessary be tangent
to the reference diameter on gear, thus the tooth profile and his shape can be modified
addendum modification is the addendum modification coefficient x,
by shifting the datum line from the tangential position (Gonzlez Rey, G. et al, 2006).
also know by
The main parameterAmerican as profile
to evaluate the shift factormodification
addendum or rack shift is coefficient.
the addendum
modification coefficient x, also know by American as profile shift factor or rack shift
The addendum modification coefficients for pinion (x1) and gear (x2)
coefficient.
can be estimated by Equations (18) and (19) obtained by consideration
The addendum modification coefficients for pinion (x1) and gear (x2) can be estimated
of normal backlash and mathematical processing of the Equations (6),
by Equations (18) and (19) obtained by consideration of normal backlash and
(8), (9) and (15)
mathematical processing of the Equations (6), (8), (9) and (15)

1 W j
x1 k1 bn k1 0,5 z1 inv t (18)
2 tan m cos

inv wt inv t
x2 z1 z 2 x1 (19)
2 tan

Where: jbn = Normal backlash (mm).

Where: jbn = Normal backlash (mm).
Normal backlash is the shortest distance between non-working flanks of two gears when
the working
Normal flanks areisinthe
backlash contact. Somedistance
shortest backlash should be present
between in all gear meshes.
non-working flanks
It is required to assure that the non-driving flanks of the
of two gears when the working flanks are in contact. Some backlash teeth do not make contact.
Backlash in a given mesh varies during operation as a result of changes in speed,
should be and
temperature present in amount
load. The all gearof meshes. It is required
backlash required depends on tothe
assure
size of that the
the gears,
non-driving flanks of the teeth do not make contact. Backlash
their accuracy, mounting and the application. For purpose of this procedure, normal in a
given
backlashmesh varies measured
is preferable during operation as a result
with feeler gauges when of changes
gears in speed,
are mounted in the
temperature and conditions.
housing under static load. TheWhen amount of backlash
normal backlash canrequired depends
not be measured can on
be
used Table 4 as guideline of values of minimum backlash (ISO/TR
the size of the gears, their accuracy, mounting and the application. For 10064-2, 1996)
recommended for industrial drives with ferrous gears in ferrous housings, working at
purpose of this procedure, normal backlash is preferable measured
pitchline speeds less than 15 m/s, with typical commercial manufacturing tolerances for
with feeler
housings, gauges
shafts when gears are mounted in the housing under static
and bearings.
conditions. When normal backlash can not be measured can be used
Table 4 as guideline of values of minimum backlash (ISO/TR 10064-
2, 1996) recommended for industrial drives with ferrous gears in 11
ferrous housings, working at pitchline speeds less than 15 m/s, with
typical commercial manufacturing tolerances for housings, shafts and
bearings.

ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 69

Journal of Mechanical Engineering and Technology

Table 4. Recommended values (in mm) for minimum backlash jbn

Table 4. Recommended
Table values
4. Recommended values(in
(in mm) forminimum
mm) for minimum backlash
backlash jbn jbn
Normal Centre distance (aw); mm
module
Table 4. Recommended
Normal 50 values
100 (in(amm)
Centre distance 200 for minimum
400 backlash
800 jbn
w); mm
(m); mm
module 50 100 200 400 800
1,5
(m); mm 0,09 0,11
2Normal
1,5 0,10
Centre 0,12
0,11 (aw0,15
0,09 distance ); mm
3module
2 0,12
50
0,10 0,14
100
0,12 0,17
200
0,15 0,24
400 800
5(m);
3 mm 0,12 0,18
0,14 0,21
0,17 0,28
0,24
81,5
5 0,09 0,24
0,11
0,18 0,27
0,21 0,34
0,28 0,47
12
28 0,10 0,12
0,24 0,35
0,15
0,27 0,42
0,34 0,55
0,47
312 0,12 0,14 0,17
0,35 0,24
0,42 0,55
5 0,18 0,21 0,28
Equations (20)
Equations (20) and8 and
(21),(21), derived
derived thefrom
from0,24 the (5),
0,27
Equation Equation
0,34 (5), give
0,47
give a possible a possible
cross-check for
cross-check for
12 the
the estimated values estimatedmodification
of addendum values
0,35 ofcoefficients
addendum
0,42 if themodification
0,55 normal tooth
Equations (20) and (21), derived from the Equation (5), give a possible cross-check for
coefficients
thicknesses on if
the estimated the normal
reference
values ofcylinder tooth thicknesses
for pinion
addendum modification n1on
andreference
sn2) are
and gear (scoefficients the cylinder
if known. for
normal tooth
pinion and gear (s
thicknesses on reference and s ) are known.
n2 for pinion and gear (sn1 and sn2) are known.
n1 cylinder
Equations (20) and (21), derived froms the Equation (5), give a possible cross-check for
n1
the estimated values of addendum modification coefficients if the normal tooth
m
s 2 (20)
thicknesses on reference cylinderxfor 1 pinionn1
and gear (sn1 and sn2) are known.
2 tan
x1 m 2 (20)
2s tan
sn 2
n 1

x m 22 (20)
x21 2smn2tan

(21)
2m tan 2
x2 (21)
2s tan
Factor of radial clearance (c*) and factor n 2 of addendum (h *)
a
Shape and geometrical parameters x of
m
the 2
basic rack tooth profile for involute gears(21) are
Factor of radial clearance (c*) and2 factor of addendum (ha*)
Factor
setting
Shape and ofspecial
by radialstandards
geometricalclearance (see(c*)
parameters ofand
Table2 tan factor
the5)basic of tooth
in corresponding
rack addendum with for
profile (ha*)
the rack shaped
involute gearstool
are
Shape
(such
settingasbyand
hobs geometrical
or
special rack
standards parameters
type cutters)
(see used 5)
Table in in of the ofbasic
thecorresponding
cutting rack
gearwith
by means tooth
the rack profile
ofshaped
generation
tool
Factor of The
methods. radial clearance (c*) and factor of addendum (ha*)
for as hobsdimensions
(suchinvolute orgears
rack type ofcutters)
are the standard
setting used bybasic therack
in special tooth
cutting ofprofile
standards
gear bygive information
(see
means Table about
5)
of generationin
Shape and
standardized geometrical
values of parameters
radial of
clearance the basic
and rack
addendum tooth profile
as a for involute
multiple of gears
the are
normal
methods. The dimensions
corresponding with of therack
the standardshaped basic rack
tool tooth
(suchprofile
as give information
hobs or rack about
type
setting by special standards (see Table 5) in corresponding with the rack shaped tool
module.
standardized
cutters) used values ofcutting
radial clearance andmeans
addendum as a multiplemethods. of the normal
(such as hobs orinrack
the type cutters) of gear
used in by the cuttingofofgeneration
gear by means of generation The
module.
dimensions
methods. TheTable of 5.the
dimensions
Somestandard
of the standard
standard basic
values rack
ofbasic
basicracktooth
rack toothprofile
tooth profile give
give information
information
profile parameters. about
standardized
about values of radial clearance
standardized and addendum as and a multiple of the normal
Table 5. Some values of radial
standard values of basicclearance addendum
rack tooth profile parameters. as a
module.
multiple of the
normal
ha module.
c * *
F Standard*

20,0 1,00*
5. Somehstandard0,25
* 0,380
cvalues of basic ISO 53:1998
rackStandard
*
Table a F tooth profile parameters.
20,0
Table 5. Some 1,00
20,0 standard 0,25
1,00 values 0,300
0,25 of basic
0,380 rack ISOtooth profile parameters.
53:1998
20,0
20,0 1,00
1,00
*
0,25
0,25
*
0,250
0,300

20,0 ha
1,00 c
0,40 F
0,39
*
Standard
20,0 1,00 0,25 0,250
20,0
20,0 1,00
1,00 0,25
0,25 0,380
0,300 ISO 53:1998
AGMA 201.02-68
20,0 1,00 0,40 0,39
20,0
20,0 1,00
1,00 0,25
0,25 0,300
0,350
20,0 1,00 0,25 0,300 AGMA 201.02-68
20,0
20,0 1,00
0,8 0,25
0,20 0,250
0,3
20,0 1,00 0,25 0,350
20,0
25,0 1,00
1,00 0,40
0,25 0,39
0,300
20,0 0,8 0,20 0,3
20,0
25,0 1,00 0,25 0,300
0,350 AGMA 201.02-68
25,0 1,00 0,25 0,300
20,0
14,5 1,00 0,25
0,157 0,350 -
25,0 1,00 0,25 0,350
20,0 0,8
1,00 0,20
0,25 0,3
20,0
14,5 1,00 0,157 0,375 - JIS B 1701-72
25,0 1,00
1,00 0,25
0,25 0,300
0,400
20,0
20,0 1,00 0,25 0,375 GOST 13755-68
JIS B 1701-72
25,0 1,00 0,25 0,350
20,0 1,00 0,25 0,400 GOST 13755-68 12
14,5 1,00 0,157 -
20,0 1,00 0,25 0,375 JIS B 1701-72 12
20,0 1,00 0,25 0,400 GOST 13755-68
12

70 ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015

 Analitical Method to Calculate the Unknown Geometry of Cylindrical Gears

The factor
The factor of of radial
radial clearance
clearance is the distance,
is the distance, along the linealong the line
of centres, of centres,
between the root
The factor
between of
surface of athe radial
root
gear clearance
and surface is the distance,
of a gear
the tip surface along
of its and
mating the line
thegear of centres,
tipgiven
surface between the
of itstomating
in relation root
normal
surface
module. of a gear
Radial and theistip
clearance thesurface
same of its along
between mating
the gear
root given
surface in relation
and the tip to the
normal
surface for
gear
The
module.
given
factor of in clearance
Radial
relationistothenormal
radial clearance is the module.
distance,
same between
Radial
the
the root
line clearance
of centres,
surface and
is the same
between
the tip surface
root
for
pinion
surface
between and
of gear
a
the with
gear
root the
and same
the
surfacetip tooth depth
surface
anddepth of (see
the tipits Figure
mating
surface 6).
gear given in relation
for pinion and gear withto normal
pinion and gear with the same tooth (see Figure 6).
module. Radial clearance is the same between the root surface and the tip surface for
the same tooth depth (see Figure 6).
pinion and gear with the same tooth depth (see Figure 6).

Figure 6. Identification of radial clearances between the teeth of gear meshes

Figure 6. Identification of radial clearances between the teeth of gear meshes

Equations (22)
Figure and (23) can
6. Identification be clearances
of radial used tobetween
determine
the teeththe factor
of gear meshesof radial
clearances. (22) For
EquationsFigure and purpose
(23) can be of
used this
to procedure,
determine the radial
factor of clearances
radial clearances.
6. Identification of radial clearances between the teeth of gear meshes are
For
Equations
purpose of (22) and (23) can
thismeasured
procedure, be used
radial to determine
clearances are the factor
preferable of radial
measured withclearances.
gauges whenFor
preferable
purpose of this procedure,
with
radial
gauges
clearances
when
are
gears
preferable
are
measured
mounted
with
in
gauges
the
when
gears are mounted
Equations
housing (22) andin
under the housing
(23)
static can undertostatic
be used
conditions. conditions.
determine the factor of radial clearances. For
gears are mounted in the housing under static conditions.
purpose of this procedure, radial clearances are preferable measured with gauges when
gears are mounted in the housing under a conditions.
c static 0,5 da da h
c **1 c11 aww 0,5 da11 da22 h22 (22)
c1 m m (22)
cm a 0,5 dam1 da 2 h2
c *1 1 w (22)
c
c **2 cm
aw 0,5 dam1 da2 h1
2

c 2 m2 w
a 0,5 da
m1
da 2 h1 (23)
(23)
*
m
c
c 2 directly
2

a w 0,5 m
da1 da 2 h1
(23)
Equations (24) and (25), derived m from them basic gear are given to estimate
Equations
values (24) of
of factor and (25), derived directly from the basic gear are given to estimate
addendum.
Equations (24) and
values of factor (25), derived directly from the basic gear are given
Equations (24) of
andaddendum.
(25), derived directly from the basic gear are given to estimate
to estimate values of factor of addendum.
values of factor of addendum. m z1
da 2 2 a w m z
1 cos
h **a1 da 2 2 a w cos x1 (24)
h a1 da 2 a 2 mm z1 x1 (24)
2 w 2 m cos
(24)
h * a1 x1
2m m
da1 2 a w m z z2
2 cos

da 2 a w
h **a 2 1 cos x 2 (25)
h a 2 da 2 a 2 mm z 2 x2
(25)
1 w 2m cos
*
h a2 x2 (25)
Since the majority of cutting tools use values 2 of
m ha* = 1 and c* = 0,25, conforming to
Since the majority
world-wide of cutting
acceptance, these tools
valuesuseshould
valuesbe of analysed
ha* = 1 and c* in
firstly = 0,25, conforming
the searching. It to
is
world-wide
possible to acceptance,
found other these values
non-standard should
cutter to be analysed
accomplish firstly
specific
Since the majority of cutting tools use values of ha* = 1 and c* = 0,25, conforming in the
purpose searching.
as ha* = It to
0,75 is
Since
for stubthe
possible
world-widegearsmajority
to found other
or ha* of
= 1,25
acceptance, cutting
non-standard
these gearstools
forvalues cutter
with
should use
to
deepbe values
accomplish
teeth. of
In case
analysed ha*
specific = 1theand
purpose
of non-standard
firstly in asc*
ha*= =0,25,
system
searching. 0,75
It of
is
for stub
conforming
basic gears
rack
possible or
totooth
found ha* = 1,25
toprofile,
world-wide
other for gears
Equations
non-standard with
(22) to deep
acceptance,
cutter (25) teeth.
these
can Invalues
give
to accomplish case
some ofidea
specific non-standard
should
purpose be system
asanalysed
for recreating
ha* =otherof
0,75
basic
firstly
new rack
gear
for stub in tooth
theor
with
gears profile,
searching.
standardizedEquations (22)
It isgears
ha* = 1,25values.
for possibleto (25)
with deep can
to found give some
teeth. Inother idea for
case ofnon-standard recreating
non-standard system other
cutter of
new gear
basic rackwith
toothstandardized values. (22) to (25) can give some idea for recreating other
profile, Equations
to accomplish specific purpose as ha* = 0,75 for stub gears or ha* = 1,25
newgears
for gear with
withstandardized values.
deep teeth. In case of non-standard system of basic rack
tooth profile, Equations (22) to (25) can give some idea for recreating
other new gear with standardized values.
13
13
13

ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 71

Journal of Mechanical Engineering and Technology

5.0 CONCLUSIONS
The theory of the involute surface of the flank of a cylindrical gear can
give information about basic gear tooth data needed to determine the
unknown gear geometry. Based in the mentioned theory, a procedure
of reverse engineering to determine the basic geometry of external
parallel-axis cylindrical involute gears has been presented. The
proposed method can be used as an alternative procedure to determine
the unknown gear geometry using conventional measurement tools.

It is important to highlight that all results, more or less accurate,

represent the estimated values of the gear mating, depending on the
uncertainty of the measurement and including all manufacturing
errors in the gear itself. This is an important concept because modules,
pressure angles, helix angles, addendum modification coefficients and
other gear geometry features determined using this method are given
at estimated values and they are not necessarily the values used in the
initial manufacturing of the gears, but they are very useful as reference
to establish the fundamental parameters for the evaluation of the load
capacity of cylindrical gear or the reproduction of a new gear pair.

The method, based on authors experiences in the analysis, recovery

and conversion of helical and spur gears according to ISO, AGMA and
non-standard gear systems, proposes a practical method with results
not too exact, but practically acceptable, to obtain by calculating and
conventional measurement tools the fundamental parameters needed
for the reproduction of a new cylindrical gears according to ISO
standards.

REFERENCES
AGMA Standard 910-C90. (1990). Formats for fine-pitch gear specification
data. Virginia.USA: American Gear Manufacturers Association,
ANSI/AGMA 1102-A03 (2003). Tolerance specification for gear hobs. Virginia.
USA: American Gear Manufacturers Association,
Belarifi, F., Bayraktar, E., Benamar, A.(2008).The reverse engineering to optimise
the dimensional conical spur gear by CAD. Journal of Achievements in
Materials and Manufacturing Engineering, 31(2), 429-433.
Gonzlez Rey, G. (1999). Procedimiento para la obtencin de los parmetros
geomtricos bsicos de un engranaje cnico de dientes rectos.
Ingeniera Mecnica, 2 (1), 23-31.

72 ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015

 Analitical Method to Calculate the Unknown Geometry of Cylindrical Gears

Gonzlez Rey, G., Frechilla Fernndez, P. and Garca Martin, R. (2006).

Cilindrical Gear Conversions: ISO to AGMA. Gear Solutions, March
2006, 22-29.
Grimsley, P. (2003). Software solutions for unknown gear. Gear Solutions. June
2003, 16-23.
Innocenti, C. (2007). Simple techniques for measuring the base helix angle
of involute gears. Proceedings of the 12th IFToMM World Congress,
Besanon, France, June 18-21, 2007 (pp. 406-412).
IS0 Standard 3. (1973). Preferred numbers. Series of preferred numbers. ISO.
Genve 20, Switzerland.
ISO Standard 1340 (1976). Cylindrical gears. Information to be given to the
manufacturer by the purchaser in order to obtain the gear required. ISO.
Genve 20, Switzerland.
ISO Standard 54. (1996). Cylindrical gears for general and heavy engineering.
Modules. ISO. Genve 20, Switzerland.
ISO/TR 10064-2. (1996). Cylindrical gears. Code of inspection practice. Part 2:
Inspection related to radial composite deviations, runout, tooth thickness and
backlash. ISO. Genve 20, Switzerland.
IS0 Standard 53. (1998). Cylindrical gears for general and heavy engineering.
Standard basic rack tooth profile. ISO. Genve 20, Switzerland.
Kumar, A., Jain, P.K., and Pathak, P.M. (2014). Machine element reconstruction
using integrated reverse engineering and rapid prototyping approach.
Proceedings of the 26th All India Manufacturing Technology, Design and
Research Conference (AIMTDR 2014). IIT Guwahati, Assam, India.
December 12th14th, 2014 (pp. 123-1, 123-5)
Maag (1990). Maag gear book. Zurich-Switzerland: Maag Gear Company Ltd.
Norma NC 02-04-04 (1978). Reglas para elaborar los planos de trabajo de las ruedas
dentadas cilndricas. La Habana. Cuba.
Schultz, C. D. (2010). Reverse Engineering. Proceedings of the AGMA Fall Technical
Meeting. AGMA Technical Paper 10FTM09. Milwaukee, Wisconsin, USA.

ISSN: 2180-1053 Vol. 7 No. 2 July - December 2015 73