Gear tooth measurement

Gears are mainly used for transmission of motion &

power and must be of accurate profile to obtain exact
velocity ratio.

Two commonly used profiles of gear teeth are the

Involute profile & the Cycloidal profile

Involute is defined as the path described by a point

on an inextensible cord which is unwound from a
stationary cylinder.
Cycloid is defined as the curve traced by a point on
the rim of a circle which rolls without slipping on a
fixed straight line.
 Types of gear
Spur Gear - The edge of each tooth is
straight and aligned parallel to the axis of
rotation.

Helical Gear - The leading edges

of the teeth are not parallel to the
axis of rotation, but are set at an
angle. The angled teeth engage
more gradually than do spur gear
teeth. This causes
helical gears to run more
smoothly and quietly than spur
gears.
 Types of gear
Bevel gear - The angle between the shafts of
mating gears can be anything except zero or
180 degrees. Bevel gears with equal numbers
of teeth and shaft axes at 90 degrees are called
miter gears..

Worm gear – Type of helical gear,

but its helix angle is usually
somewhat large and its body is
usually fairly long in the axial
direction; and it is these
attributes which give it screw like
qualities
Gear Tooth Nomenclature
 Gear Tooth Nomenclature
 Base circle: It is the circle from which gear teeth
profiles are generated.
 Pitch circle: It is an imaginary circle which by pure
rolling action, would produce the same motion as the
toothed wheel. The size of the gear is usually
specified by the pitch circle diameter.
 Pitch point: It is a common point of contact between
two pitch circles of two meshing gear wheels.
 Pressure angle: It is the angle between the common
normal to two gear teeth at the point of contact and
the common tangent at the pitch point.
Gear Tooth Nomenclature
 Addendum: It is the radial distance from the pitch
circle to the tip of the tooth.
 Dedendum: It is the radial distance from the pitch
circle to the root of the tooth.
 Face : It is the part of the tooth surface which is
above the pitch surface.
 Flank : It is the part of the tooth surface which is
below the pitch surface.
 Circular pitch : It is the distance measured on the
circumference of the pitch circle from a point on one
tooth to the corresponding point on the adjacent
tooth.
 Module: It is the ratio of the pitch circle diameter in
millimeters to the number of teeth.
 Face width: It is the width of the gear tooth
measured parallel to its axis.
 Gear errors
1. Profile error: - The maximum distance of any point on the tooth profile form to the
design profile.
2. Pitch error: - Difference between actual and design pitch
3. Cyclic error: - Error occurs in each revolution of gear
4. Run out: - Total range of reading of a fixed indicator with the contact points
applied to a surface rotated, without axial movement, about a fixed axis.
5. Eccentricity: - Half the radial run out
6. Wobble: - Run out measured parallel to. the axis of rotation at a specified distance
from the axis
7. Radial run out: - Run out measured along a perpendicular to the axis of rotation.
8. Undulation: - Periodical departure of the actual tooth surface from the design
surface.
9. Axial run out: - Run out measured parallel to the axis of rotation at a speed.
10. Periodic error: -Error occurring at regular intervals
 Following Elements are to be checked while
carrying out gear measurement
Geometrical Parameters
 Tooth Thickness
 Addendum Depth
 Tooth Spacing Over ‘X’ Number of teeth

Functional Parameters
 Pitch Variation
 Involute profile

Functional Parameters while meshing

 Runout
 Backlash
 Contact Area
 Noise
 Gear Measurement element
The Inspection of the gears consists of determine the following
elements in which manufacturing error may be present.
 1. Runout.
 2. Pitch
 3. Profile
 4. Lead
 5. Back lash
 6. Tooth thickness
 7. Concentricity
 8. Alignment
 Runout testing
 It means eccentricity in the pitch circle.
 It will give periodic vibration during each revolution of the gear.
 This will give the tooth failure in gears.

The run out is measured by means of eccentricity testers.

 In this testing process, the gears are placed in the mandrel and
the dial indicator of the tester posses special tip depending upon
the module of the gear and the tips inserted between the tooth
spaces and the gears are rotated tooth by tooth and the variation
is noted from the dial indicator.
Runout testing
 Pitch Measurement

There are two ways for measuring the pitch

varriation .
 1. Point to point measurement (i.e. One tooth
point to next toot point)
 2. Direct angular measurement
Pitch measurement-
Point to point Measurement
 Pitch measurement-
Point to point Measurement
 The instrument has three tips.

 One is fixed measuring tip and the second is sensitive

tip, whose position can be adjusted by a screw and the
third tip is adjustable or guide stop.
 The distance between the fixed and sensitive tip is
equivalent to base pitch of the gear.
 All the three tips are contact the tooth by setting the
instrument and the reading on
the dial indicator is the error in the base pitch.
 Profile checking

The methods used for profile checking is

 1. Optical projection method.
 2. Involute measuring machine.

1. Optical projection method:

 The profile of the gear projected on the screen by
optical lens and then projected value is compared
with master profile.
 Lead checking

It is checked by lead checking instruments.

 Actually lead is the axial advance of a helix for
one complete turn.
 The lead checking instruments are advances a
probe along a tooth surface, parallel to the axis
when the gear rotates.
 Backlash measurement
 Backlash is the distance through which a gear can be rotated to
bring its nonworking flank in contact with the teeth of mating gear.

Numerical values of backlash are measured at the tightest point of

mesh on the pitch circle.

There are two types of backlash

 1. Circumferential backlash
 2. Normal backlash

.
 Measurement of tooth thickness

 Measurement of tooth thickness by

 Gear tooth vernier caliper.
 Constant chord method.
 Base tangent method.
 Measurement by dimension over pins
 Gear tooth vernier caliper.

 The tooth thickness can be very conveniently measured by a gear tooth

vernier.

 Since the tooth thickness varies from the tip of the base circle of the tooth,
the instrument must be capable of measuring the tooth thickness at a
specified position on the tooth. Further this is possible only when there is
some arrangement to fix that position where the measurement is to be taken.

 The tooth thickness is generally measured at pitch circle & is, therefore,
referred to as pitch line thickness of tooth.

 The gear tooth in the vernier has two vernier scales & they are set for the
width ‘w’ of the tooth & the depth ‘d’ from the top, at which w occurs.
 Gear tooth vernier caliper.

 Considering one tooth, the theoretical values of w

& d can be found which may be verified by the
instrument.

 Also the depth d adjusted on the instrument is

slightly greater than the addendum CE, & hence
the width w is called chordal thickness & d is
called chordal addendum.
Gear tooth vernier caliper.
 Gear tooth vernier caliper.

From the fig, w=AB=2AD,

Now angle AOD = q = 360/4N
Where N is the number of teeth,
w=2AD=2*AO*sinq
= 2R sin (360/4N) (R=PITCH CIRCLE RADIUS)
Module, m= P.C.D/number of teeth = 2R/N
R=N*m/2
w=(N*m)*sin(360/4N)
Also from fig, d= OC-OD
OC = OE+ addendum = R+m
= (N*m/2)+m
OD = R * cosq
= N*m/2 cos(90/N)
d = (N*m/2)+m-(N*m/2) cos(90/N)
 Why constant cord method

Vernier method like the chordal thicknessand

chordal addendum are dependent upon the
number of teeth.

Due to this for measuring large number of gears

different calculations are to be made for each
gear.
 So these difficulties are avoided by this
constant chord method.
 The Constant Chord Method
 Property : - If an involute tooth is considered
symmetrically in close mesh with basic rack form
, then it is observed that when gear rotates and all
teethes come in mesh with rack , for the given
size of tooth (same module), the contact is
always occur at point two points
 A & F as shown in fig. i.e the distance AF
remains constant and known as constant chord.
 The Constant Chord Method
 Property : - If an involute tooth is considered
symmetrically in close mesh with basic rack form
, then it is observed that when gear rotates and all
teethes come in mesh with rack , for the given
size of tooth (same module), the contact is
always occur at point two points
 A & F as shown in fig. i.e the distance AF
remains constant and known as constant chord.
The Constant Chord Method
Efficient for measuring large no of gears, each having
different no of teeth but same module
 The Constant Chord Method

BD=BE=arc BE =1/4circular pitch

=1/4 X  P.C.D/N = ¼  m
In ∆ ABD, AB=BD cos
=( /4)m cos 
In ∆ BAC,AC=AB cos
=( /4)m Cos2 
C=constant cord =2AC
 W=C = 0.5m Cos2 

Now, BC=AB sin  =( /4)m cos  sin 

h= addendum-BC
 h = m – 0.25mCos Sin

 - pressure angle
 m- module
Base Tangent method
This method uses David brown tangent comparator to measure span of a
Convenient no of teeth

Advantage over gear tooth vernier is:

1)Measurement does not depend on 2 vernier reading, each being
function of other .
2)Measurement not made with an edge of measuring jaw with the face.
 Base Tangent method
  = Pressure angle
 S =Number of tooth spaces contained in W 
 W = arc AB + arc BC
 Base Tangent method

 And when S tooth spaces are considered,

 arc BC = 2/N x S x NM/2 cos 
 AC =NM/2 cos  (tan - )
  = /2N radians
 Arc CD =Rp cos  /2N = NM/2 cos  /2N
 AB = NM cos  ( tan  – ) + /2N
 Total arc length for S spaces, W = NM
cos ((tan  – )- /2N + S/N)
Base Tangent method

David Brown Tangent Comparator – The distance(w) for S no of teeth

Calculated and set with the help of slip gauges.
The distance w theoretical and actual is verified for any difference.
 Measurement of concentricity
In setting of gears the centre about which the gear is
mounded should be
coincident with the centre from which the gear is
generated.
 It is easy to check the concentricity of the gear by mounting
the gear between
centres and measuring the variation in height of a roller
placed between the
successive teeth.
 Finally the variation in reading will be a function of the
eccentricity present.
Measurement of concentricity
Allignment checking

It is done by placing a parallel bar between the

gear teeth and the gear being mounted between
centres.

Finally the readings are taken at the two ends of

the bar and difference in reading is the
misalignment
Geometric measurement mc
GEOMETRIC MEASUREMENT
POINT MEASUREMENT : 
Free point, peak point, constant
intersection, mid point 
(between elements of measured data)

LINE MEASUREMENT :
Line, Tangent line, Perpendicular line

CIRCLE MEASUREMENT : 
Circle (Multipoint), Centre & radius.
DISTANCE, ANGLE :
Distance, Step, Pitch & angle.
Gear measuring instrument
It can accomplish a variety of gear
measuring tasks including the
inspections of tooth data on cylin- drical
gears ( external spur and helical gears:
standard measuring module ), shaping
and shaving cutters, as well as on gear
and worm hobs (optional). In addition,
the range of application also extends to
inspection of worm and worm gear,
spiral, straight and helical bevel gears
(optional). These gear measuring centres
are widely used in automobile, machine
tool, instrument industries, as well as
inspection laboratory and modern
factory environ- ment.
 Test Plug Method for checking pitch diameter
and tooth spacing
 A roller is placed between a pair of teeth so that the its centre
lies on the pitch circle as shown on slide.
 For a gear with an odd number of teeth a radial measurement
is taken with the gear between centres using a comparator.
Test Plug Method for checking pitch diameter
and tooth spacing
 Test Plug Method for checking pitch diameter
and tooth spacing

 OA = ¼  M cos  (OA= radius of rollers)

 Gauging Radius: Rg = ½ NM + ¼ M cos
 Dimensions over a pair of Rollers in opposite
tooth spaces : Dg = M(N + ½
 cos  )
 Test Plug Method for checking pitch diameter
and tooth spacing

 Procedure
 Two pins of equal dia are placed on either side of
tooth and reading compared with calculated value
of M.
 M=(m X nX Cos )/cos m x cos 90/N + d
 M-Required size over wire
 ‘m – module, d-dia of wire, -pressure angle,
m – pressure angle at centre of pin(m formula
given in book)
PARKINSON GEAR TESTER
 PARKINSON GEAR TESTER
 The master gear is fixed on vertical spindle and the gear to be
tested is fixed on similar spindle which is mounted on a
carriage.

 The carriage which can slide either side and these gears are
maintained in mesh by spring pressure.

 When the gears are rotated, the movement of sliding carriage

is indicated by a dial indicator and these variations arc is
measure of any irregularities in the car under test. Fig

 The variation is recorded in a recorder which is fitted in the

form of a waxed circular chart.
 PARKINSON GEAR TESTER
 In the gears are fitted on the mandrels and are
free to rotate without clearance and the left
mandrel move along the table and the right
mandrel move along the spring-loaded carriage

 The two spindles can be adjusted so that the axial

distance is equal and a scale is attached to one
side and vernier to the other, this enables center
distance to be measured to within 0.025mm
 PARKINSON GEAR TESTER
 If any errors in the tooth form when gears are in close mesh, pitch or
concentricity of pitch line will cause a variation in center distance from this
movement of
carriage as indicated to the dial gauge will show the errors in the gear test.

 The recorder also fitted in the form of circular or rectangular chart and the errors
are recorded.

 Limitations of Parkinson gear tester:

 1. Accuracy±0.001mm
 2. Maximum gear diameter is 300mm
 3. Errors are not clearly identified:
 4. Measurement dependent upon the master gear.
 5. Low friction in the movement of the floating carriage.