Geometrical Specification Model for Gear -

Expression, Metrology and Analysis

1 1 1 2
J.Y. Dantan , J. Bruyere , C. Baudouin , L. Mathieu (1),
1
Laboratoire de Génie Industriel et Production Mécanique -
Ecole Nationale Supérieure d’Arts et Métiers, Metz, France
2
Laboratoire Universitaire de Recherche en Production Automatisée
Ecole Normale Supérieure, Cachan, France

Abstract
To ensure the gear precision, industries need a coherent model to express, to analyse and to check
geometrical specifications. Most gear tolerance representations are directly driven by the convenience of
dimensional metrology and not by the convenience of the set of activities of the tolerancing process.
Therefore, to ensure the coherence of all tolerancing process activities, there is a necessity to develop a
complete gear tolerance model which should: represent standard tolerance practices; be integrated in the
Computer-Aided systems of design, manufacturing and metrology; be controlled by CMM; and support
automated tolerance analysis. The proposed model extends capabilities of a vectorial dimensioning &
tolerancing model in order to satisfy the four requirements. This model is based on GeoSpelling [1]. Its
coherence is illustrated by two applications: gear tolerance analysis and gear tolerance verification by CMM.

Keywords:
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Tolerancing Model, Functional Metrology, Gear

1 INTRODUCTION achieve the optimal manufacturing cost. This first

As technology increases and performance requirements approach, however, is not very flexible. A second
continually tighten, the cost and required precision of approach is based on experimentations. In order to
assemblies increase as well. There is a strong need for determine the effects of a tolerance and to understand
increased attention to tolerance design to enable high- the contributions of tolerances on a functional
precision assemblies to be manufactured at lower costs. requirement, it is necessary to identify the relationships
Indeed, tolerance analysis is a key element in industry for between gear tolerances and functional requirements by
improving product quality. a set of experimentations. Effective reuse of experimental
knowledge about the effect between gear tolerances and
Designers want tight tolerances to assure product functional requirements is a key strategic component of
performance; manufacturers prefer loose tolerances to the gear tolerancing process. This second approach is
reduce cost. There is a critical need for a quantitative expensive. There is an important question that requires
design tool for specifying tolerances. Tolerance analysis need to be looked upon: How to determine gear
brings the engineering design requirements and tolerances?
manufacturing capabilities together in a common model,
where the effects of tolerance specifications on both A significant amount of literature is related to tolerance
design and manufacturing requirements can be design. It distinguishes four aspects: tolerance
evaluated quantitatively. representation, tolerance specification, tolerance
analysis, and tolerance synthesis [3] (Figure 1). But,
The inherent imperfections of manufacturing processes
few of this research apply to gear.
(forging, cutting or grinding) involve geometrical
variations and a degradation of product quality. The Tolerance
geometrical variations of each part must be limited by analysis
geometrical specifications (tolerances) to ensure a
certain level of product quality, which is defined by the need a
functional requirements.
In the case of gears, their geometrical variations impact Tolerance need a Tolerance
specification representation
the transmission error, the tooth contact position,
meshing interference, and gap. To ensure a quality level,
need a
designers limit these parameters by requirements.
Tolerancing decisions can profoundly impact the quality Tolerance
and cost of gears. To assess the impact of tolerance on synthesis
gear quality, designers need to simulate the influences of
tolerance with respect to the functional requirements. To Figure 1: Four aspects and their dependences.
do so, they use AGMA [2] or ISO tables. These tables are These four aspects are not at the same level, the first
a set of discrete associations between tolerances and one refers to how tolerances are represented internally
meshing quality. They do not take into account all by the computer, this aspect is indicated directly on the
tolerances, and they focus on the pitch error and the models used for the description of the mechanism
misalignment. In the case of a forged gear or not without and with geometric variations. Tolerance
classical gear like WILDHABER-NOVIKOV, designers specification is an important activity for tolerancing. It
can not use them to allocate the gear tolerances to tries to answer the question: Which tolerance types and

Annals of the CIRP Vol. 56/1/2007

 values are needed on features to control functional focuses on three types of gear variations which are
requirements? Tolerance analysis is a method to verify limited by some tolerances: the flank deviations, the
the value of functional requirements after tolerances have deviations between flanks and the deviations between
been specified on each isolated part. This method is teeth and hole.
totally dependent on the models chosen before. To express these tolerances, we use the classical
Tolerance synthesis is regarded as a tolerance allocation standardized language and GeoSpelling which is based
and a tolerance optimization method taking into account on the following basic concept:
manufacturing and inspection aspects.
• a specification is a condition on a characteristic
The tolerancing process is defined through all the defined from geometric features [1], [5],
activities involved by geometric product variations
management. We can propose four classical activities: • these geometric features are features created from
tolerance specification, tolerance analysis, tolerance the model of the real surface of the part (SKIN
synthesis, and tolerance verification. Tolerance model) by different operations.
specification, tolerance analysis and tolerance synthesis A condition defines an interval of IR inside of which the
are sub activities of tolerance design. Tolerance value of a characteristic of geometric features must lie
verification defines inspection planning and metrological [1], [5].
procedures for functional requirements, functional
specifications and manufacturing specifications. It is very 2.1 “Profile or form tolerances”
important to consider tolerance verification early in the In the case of the GD&T standards, the profile deviations
design activities to be able to assess uncertainties. are the deviations normal to the transverse involute
Tolerance verification permits to close the process loop, profiles, measured within the profile evaluation range Lα :
to check the product conformity and to verify Fα, ffα, fHα, [4] … These profile characteristics can easily
assumptions made by the designer. The tolerancing be measured but they are not adapted for tolerance
process depends totally on the models used. The analysis [6]. Therefore, we propose a set of flank form
representation of deviations and tolerances, on parts or specifications like flank topography [4], [1] (Figure 3).
assembly, is the key problem of tolerancing [1] (Figure 2). Like Fα, ffα, fHα, …, we can distinguish different datum
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systems that define the position and the orientation of the

Tolerance Tolerance Tolerance Tolerance tolerance zone.
specification analysis synthesis verification
t1
AA
Tolerance representation / coherent model t2 A
t3 A B
Figure 2: Tolerancing process. t4 C

To be coherent, the tolerancing process has to use the

same language based on a unified mathematical model
to express tolerancing for each person involved during
the process. To ensure this coherence between gear
tolerance design and gear tolerance verification, there is
a necessity of developing a complete gear tolerance
model which should: (i) represent standard tolerance C
practices; (ii) be integrated in the Computer-Aided
systems of design, manufacturing and metrology, (iii) be A
controlled by CMM and (iiii) support automated tolerance
analysis.
Indeed, most gear tolerance representation schemes are
not directly driven by functional requirements, but by the
dimensional metrology pratice. In fact, an amount of
research has been devoted to the development of Gear
Metrology [4].
A A
The paper focuses on the gear tolerance model and its
utilization during the tolerancing process. The proposed B
model extends capabilities of a vectorial dimensioning &
tolerancing model in order to satisfy the four Figure 3: Flank form tolerances.
requirements. It is based on GeoSpelling [1] - the model These specifications of the flank form are defined by a
proposed for rebuilding standards [5] in the fields of tolerance zone in which this flank must be included. The
tolerancing and metrology - GeoSpelling allows to tolerance zone can be generated according to various
express the specification from the function to the methods [7]. The translation of the specification 1 and 2
verification with a common language. This model is (Figure 3) in GeoSpelling language is given in Table 1
based on geometrical operations which are applied not and Table 2. Let us suppose, Sa and Sf (Figure 4)
only to ideal features, but also to the non-ideal features defined by partition operations [5]. Sa is the non ideal
which represent a real part. These operations are feature [8] which is nominally the cylinder A and Sf the
themselves defined by constraints on the form and non ideal feature which is nominally a spherical involute,
relative characteristics of the features. the range of this non ideal feature can be Lα.
The use of the gear tolerance model for gear tolerance With these four specifications, we can explicitly define
analysis and for gear tolerance verification by CMM the datum system which allows to fit the ideal flank and
illustrates its coherence. which locates the tolerance zone. These expressions
2 EXPRESSION OF GEOMETRICAL GEAR make easier the tolerance analysis and the tolerance
SPECIFICATION WITH GEOSPELLING verification. In the case of the conventional profile
evaluation, the result requires some rules to interpret
Obviously, the vast spectrum of gear tolerancing cannot deviations correctly.
be covered within this paper. Therefore, the following
sections will be mainly restricted to the bevel gear and
 bevel gear is caused by the superposition of different
C1 deviations. Therefore, the runout tolerance analysis is
Sf
complex.
F1
Associated Associated
flank flank
C2

F2
CYa

Angle around
Sa associated hole axis

Angle around Associated

Figure 4: Features and characteristics. associated hole
Definition of the associated spherical involute F1 teeth cone axis Associated
teeth cone
Association F1, ideal feature, type spherical involute
Objective to minimize : maximum distance (Sf, F1) Figure 5: Pitch deviations.
Definition of the toleranced characteristic C1 We propose to dissociate the cause of the runout and to
limit the situation deviations [5] between the associated
Evaluation C1: maximum distance (Sf, F1) hole and the associated teeth cone (Figure 6).

Definition of the condition Associated

hole
C1 ≤ t1 / 2
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SKIN
model
Table 1: GeoSpelling expression of specification 1.
Definition of the datum A Associated
teeth cone
Association CYa, ideal feature, type Cylinder
Constraints: minimum signed distance (Sa, CYa) ≥ 0
Objective to maximize : diameter of CYa
Definition of the associated spherical involute F2 Situation
deviation
Association F2, ideal feature, type spherical involute
Constraints: coaxiality between CYa and axis of F2
Objective to minimize : maximum distance (Sf, F2) Figure 6: Runout deviation.
Definition of the toleranced characteristic C2 For the functional tolerancing, we advocate to consider
the form tolerance (specification 1 – Figure 3), the form
Evaluation C2: maximum distance (Sf, F2) position tolerances with the hole datum system
(specifications 2 and 3 – Figure 3) and the pitch
Definition of the condition tolerance around the hole datum axis; because the gear
C2 ≤ t2 / 2 revolves around of the hole axis.
For the manufacturing tolerancing, we advocate to
Table 2: GeoSpelling expression of specification 2. consideration the form tolerance (specification 1 – Figure
3), the form position tolerance with the teeth datum
2.2 “Pitch tolerances” and “Runout tolerances” system (specification 4 – Figure 3), the pitch tolerance
In the same way, we can express some specifications around the teeth datum axis and the runout deviation;
which limit the cumulative angular pitch deviation because we can dissociate the cumulative pitch angular
(orientation deviations between flanks) and the runout error around the teeth cone axis and the deviations
(situation deviations between teeth and hole). between the teeth cone axis and the hole axis. This
In the case of the standard [2], the cumulative pitch dissociation is interesting for the simulation of the impact
deviation Fpk over a sector of k pitches is the algebraic of forging and machining variations, because the
difference between the actual length and the theoretical cumulative pitch angular errors around the teeth cone
length of the relevant arc. Bevel gears are being tested axis are due to the forging operation and the deviation
close to the mean pitch cone diameter dM [4], but the between the teeth cone axis and the hole axis are due to
datum in which dM is defined is not clarified. the machining operation.
Therefore, we propose to limit the cumulative angular 3 A COHERENT TOLERANCING PROCESS
pitch deviation which is the difference between the To illustrate the coherence of this proposed geometrical
nominal angle between two flanks and the angle [8] specification model, two examples are shown: Tolerance
around a datum axis between two associated flanks. The analysis and tolerance verification by CMM.
two associated flanks are defined by association
operations [1] with constraints: coaxiality between the 3.1 Gear Tolerance analysis
datum axis and the axis of the involute cone. The datum This example is based on:
axis can be the axis of the associated hole or the
• an analytical definition (parametric model) of tooth
associated teeth cone (Figure 5).
surface in a global coordinate system which includes
In the case of the standard, the runout of teeth [4], Fr, is form deviations, location and orientation deviations
the total variation of the distance between a datum between features and gaps,
surface(s) (hole) and an indicated surface(s) (teeth).
Typical runout types are axial and radial. Runout of a
 • a mathematical representation of the geometrical
specifications which are detailed in section 2, 9,56 evaluation in the datum system based on teeth

Circular thickness (mm)

• a digital simulation tool based on Tooth Contact
Analysis [9] which enables one to evaluate functional 9,54
characteristics as kinematic error, position of contact
point, , … (the result is similar to the tangential 9,52
composite test [6], but the cost of a digital simulation evaluation in the datum system based
is lower than the cost of an experimental simulation), 9,50 on plane and cylinder

• a tolerance analysis tool by Monte Carlo simulation,

which computes the probability that the product can 9,48
be assembled and will function (respect of
requirements on the kinematic error, …) for given 1 2 3 4 5 6 7 8 9 10 11 12 13 14
individual tolerances. Tooth number
The result of a statistical tolerance analysis [6] is a set of Figure 9: Influence of the datum system on pitch
meshing simulations (Figure 7), the probability deviations.
distribution of each functional characteristics like
kinematic error (Figure 8). 4 CONCLUSION
The important point of the proposed geometrical
specification model for a gear based on GeoSpelling is to
Kinematic error (radian)

0,02
provide an unique solution to express tolerances based
on geometry. This way is based on the characteristic
0
concept. Taken into account directly, in the expression of
-0,02 the specification, the result based on a mathematical
expression is unique and clearly described for everybody.
-0,04 There is no more interpretation for the designer, the
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manufacturer and the metrologist.

-0,06 Indeed, tolerance analysis or tolerance verification are
based on tolerance representation. Given a particular
-0,08 tolerance representation, efficient and accurate
algorithms are needed to actually perform the tolerance
5 10 15 analysis. Unfortunately, as the geometric tolerances are
Rotational angle – φ1 (radian) complex, so too are the algorithms using these
tolerances.
Figure 7: Numerical meshing simulations For managing efficiently geometrical variations along the
160 product life cycle, we propose a geometrical specification
model for gears based on GeoSpelling which is the basis
140
of a complete and coherent tolerancing process.
120
5 REFERENCES
Number

100
80 [1] Mathieu L. and Ballu A, 2003, GeoSpelling: a
common language for Specification and Verification
60 to express Method Uncertainty, Proc. of 8th CIRP
40 Seminar on Computer Aided Tolerancing, North
Carolina, USA.
20
[2] ANSI/AGMA 2009-B01, 2005, Bevel Gear
0 Classification, Tolerances, and Measuring Methods.
2 4 6 8 10 12
0 2 4 6 8 10 12 [3] Salomons O., Van Houten F., Kals H., 1998, Current
Kinematic error (10-3 radian) Status of CAT Systems, Geometric Design
Tolerancing: Theories, Standards and Applications,
Figure 8: Tolerance analysis pp. 438-452, ISBN O-412-83000-0.
3.2 Gear Tolerance verification. [4] Goch G., 2003, Gear Metrology, Annals of CIRP,
52/2:659-695.
Tolerance verification permits one to check the product
conformity and to verify assumptions made by the [5] ISO/TS 17450-1, 2005, Geometric Product
designer. To do so, we develop some metrological Specification (GPS) – General concepts – Part 1:
procedures for adequacy with the GeoSpelling [5] Model for geometrical specification and verification.
expression of each geometrical specification which is [6] Bruyere J., Dantan J.Y., Bigot R., Martin P., 2006,
detailed in section 2. Statistical tolerance analysis of bevel gear by Tooth
Section 2.2 explains the importance of the definition of a Contact Analysis and Monte Carlo simulation, in
datum axis to specify the cumulative angular pitch press, Mechanism and Machine Theory.
deviation. To illustrate this, we evaluate the circular [7] Pasupathy T., Zhao X., Wilhelm R., 2006, Flexible
thickness around two datum systems: the datum system tools for specifying design variation, Int. J. Adv.
based on the teeth (Figure 5) and the datum system Manufacturing Technology, 28:659-664.
based on the hole (Figure 5), we can determine the [8] Ballu A., Mathieu L., Dantan J.Y., 2001, Global view
difference of the values according to the datum systems of geometrical specifications, Proc. of 7th CIRP
(Figure 9). In fact, we can dissociate the impact of the Seminar on Computer Aided Tolerancing, Cachan,
cumulative pitch angular error around the teeth cone axis France.
and the situation deviations between the teeth cone axis
[9] Litvin F.L., 2004, Gear Geometry and Applied
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Theory, PTR Prentice Hall, Englewood Cliffs, NJ.