Racks

Gears
Spur
Helical
Gears
MRGF/MRGFD KRGF-H/KRGFD-H KRG/KRGF/KRGD SRG/SRGF/SRGFD/SRGFK KRF-H/KRFD-H SRF-H/SRFD-H
Hardened Ground Racks Hardened Ground Racks Thermal Refined Ground Racks Hardened Ground Racks Hardened Racks Hardened Racks

Internal
Gears
Series Series Series Series Series

Precision: KHK 1 Precision: KHK 1 Precision: KHK 1 Precision: KHK 3 Precision: KHK 5 Precision: KHK 5
Material: SCM415 Material: SCM440 Material: SCM440 Material: S45C Material: SCM440 Material: S45C
Heat Treatment: Tooth area carburized Heat Treatment: Thermal refined / gear teeth induction hardened Heat Treatment: Thermal refined Heat Treatment: Gear teeth induction hardened Heat Treatment: Thermal refined / gear teeth induction hardened Heat Treatment: Gear teeth induction hardened
m 1.5 ～ 3 Page 198 m 1.5 ～ 3 Page 200 m1 ～ 3 Page 202 m0.5 ～ 6 Page 204 m 1.5 ～ 5 Page 206 m 1.5 ～ 6 Page 208

Racks
SRF-HL/SRFD-HL KRF/KRFD SRAF/SRAFD/SRAFK SR SRF SRFD/SRFK
Laser Hardened Racks Thermal Refined Racks Racks Racks Steel Racks with Machined Ends Steel Racks with Bolt Holes
Series Series Series Series

CP Racks
& Pinions
Precision: KHK 4 Precision: KHK 4
Material: S45C Material: SCM440 Precision: KHK 4 Precision: KHK 4 Precision: KHK 4 Precision: KHK 4
Heat Treatment: Gear teeth laser hardened Heat Treatment: Thermal refined Material: S45C Material: S45C Material: S45C Material: S45C
m 1.5 ～ 6 Page 210 m 1.5 ～ 5 Page 212 m 1.5 ～ 4 Page 214 m 0.5 ～ 10 Page 216 m 0.5 ～ 10 Page 217 m 0.5 ～ 6 Page 218

SUR/SURF/SURFD DRF/DRFD/DRFK PR/PRF BSR SRO/SROS SURO

Stainless Steel Racks Plastic Racks Plastic Racks Racks Round Racks Stainless Steel Round Racks

Gears
Miter
Series

Precision: KHK 5
Material: SUS304 Precision: KHK 5 Precision: KHK 5 Precision: KHK 4 Precision: KHK 4 Precision: KHK 5
Heat Treatment: Solution treated Material: Polyacetal Material: MC901 Material: Free cutting brass (C3604) Material: S45C Material: SUS303
m1 ～ 4 Page 220 m1 ～ 3 Page 222 m1 ～ 3 Page 224 m 0.5 ～ 1 Page 225 m1 ～ 6 Page 226 m1 ～ 3 Page 227

Gears
Bevel
DR SSDR/ARL/SRS KRHG/KRHGF/KRHGFD SRH/SRHF/SRHFD SRHEF SHE
Pinions/Rack Guide Rails
Molded Flexible Racks Rack Clamps
Ground Helical Racks Helical Racks Helical Racks Helical Gears
For Molded Flexible Racks Series New New

Screw
Gears
Precision: KHK 1
Precision: KHK 8 Precision: N8 Material: SCM440 Precision: KHK 5 Precision: KHK 4 Precision: N8
Material: Duracon (M25-44) Material: S45C Heat Treatment: Thermal refined Material: S45C Material: S45C Material: S45C
m 0.8 ～ 2 Page 228 Page 228 m1 ～ 3 Page 230 m 2, 3 Page 232 m 1.5 ～ 6 Page 234 m 1.5 ～ 6 Page 234

Products Gearboxes Gear Pairs

Catalog Number of KHK Stock Gears Worm
The Catalog Number for KHK stock gears is based on the simple formula listed below. Please order KHK gears by specifying the Catalog Numbers.
(Example) Racks Material Other Information
Bevel

M SCM415
K R G F 2 - 500 H K
S
SCM440
S45C
F
D
Racks with Machined Ends
Racks with Bolt Holes
Gear teeth induction hardened SU Stainless Steel K Racks with Drill Holes
Total Length (500mm) BS Brass G Ground Gears
Other

P MC901 H Gear teeth induction hardened

Module (2)
D Polyacetal
Other Products (End Machined)
Type
Other Products (Ground Gears)
R Racks
Type (Rack)
RH Helical Racks
Material (SCM440) RO Round Racks
S Spur Gears

187
 Racks Racks KHK
KHKTechnical
TechnicalInformation
Information

Features Application Examples

KHK stock racks are made for high precision linear motion applications. We offer a large selection of racks ranging from module KHK stock racks & pinions are adopted in driving devices for all kinds of linear motion systems, including transport devices.
0.5 to 10 and lengths from 100 to 2000 mm. The following table lists the main features.

■ Racks
■ Automatic packaging machine manufactured by Toyota Machinery Co., Ltd. ■ Dremax Long Strip Cutter
Total length mm Tooth Gear accuracy
Catalog Number Heat KHK R 001 Note 3
Note 1
Module Parentheses Material Surface Parentheses Features
Treatment show
show no. of teeth Finish JIS B 1702-1
A ground rack made of carburized chromoly steel.
Tooth area
MRGF/MRGFD 1.5 to 3 500 SCM415 Ground 1 Our highest-performance rack, with accumulated pitch
carburized
error of 10μm or less. J Series products are also available.
KRGF-H Thermal refined, Heat treated ground gears with high precision and strength has ex-
1.5 to 3 500, 1000 SCM440 gear teeth induc- Ground 1
KRGFD-H tion hardened cellent cost-performance ratio. J Series products are also available.
KRG/KRGF 100, 500, Thermal High strength and abrasion-resistant for precision
1 to 3 SCM440 Ground 1
KRGD 1000 refined linear motion.
SRG/SRGF 100, 300, Gear teeth induction Reasonably priced ground racks with abrasion-resistant
0.5 to 6 S45C Ground 3
SRGFD/SRGFK 500, 1000 hardened NOTE 2 characteristics. J Series products are also available.
Thermal refined, A high-strength, long-life, tough hardened rack suitable SUR stainless steel rack used for film winding tension part PR plastic rack used for feeding Long Strip Cutter
KRF-H/KRFD-H 1.5 to 5 1000 SCM440 gear teeth induc- Cut 5
tion hardened for compact designs. J Series products are also available.
■ Lathe Auto Loader ■ Lathe Gantry Loader
SRF-H Gear teeth induction Stable hardened racks with high strength, long life span
1.5 to 6 1000 S45C Cut 5
SRFD-H hardened are reasonably priced. J Series products are also available.
SRF-HL 1000, 1500, Gear teeth laser Hardened racks with high strength due to the laser hardened tooth
1.5 to 6 S45C Cut 4
SRFD-HL 2000 hardened surfaces and with a low price tag. J Series products are also available.
Thermal Increased strength with SCM440 material which is
KRF/KRFD 1.5 to 5 500, 1000 SCM440 Cut 4
refined thermal refined. J Series products are also available.
This gear rack has the same tooth height and face width
SRAF/SRAFD 1.5 to 4 1000 S45C — Cut 4 sizes, more compact and reasonably priced in compari-
SRAFK son to SRF Racks J Series products are also available.
SR/SRF 100, 300, 500, Low cost, large selections of modules and number
0.5 to 10 S45C — Cut 4
SRFD/SRFK 1000, 1500, 2000 of teeth. J Series products are also available.
SUR/SURF Solution Suitable for food machinery due to SUS304’s rust
1 to 4 500, 1000 SUS304 Cut 5
SURFD treated resistant qualities.
DRF/DRFD Plastic racks with little dimensional change, absorb lesser wa- SRO Round Rack used as a workpiece storage device (lifting/lowering table) KRG Ground Rack used as a workpiece conveying device
1 to 3 500, 1000 Polyacetal — Cut 5
DRFK ter than MC Nylon racks. J Series products are also available.
Light-weight products made of MC Nylon can be ■ Packaging Machine ■ Extruder (design example)
PR/PRF 1 to 3 500, 1000 MC901 — Cut 5
used without lubrication. * Not a design for machinery or a device in actual use.
Free cutting Small pitch racks made of free-cutting brass (C3604),
BSR 0.5 to 1 300 brass — Cut 4 Motor
(C3604) excellent workability and high rust resistance.
Convenient in applications where the rack has the
SRO/SROS 1 to 6 500, 1000 S45C — Cut 4
reciprocal motion. S Type is easy to install.
Same dimensions as SRO racks, except in stainless
SURO 1 to 3 500, 1000 SUS303 — Cut 5
steel. Use where rust-resistance is required.
Duracon Injection Used in applications due to its flexibility, where metal racks do Sintered Metal Sintered Metal
DR 0.8 to 2 2000 — 8 Bushings Bushings

Extrusion
(M25-44) Molded not have this attribute. Pinions and accessories are also available. Base Base
Pinions
100, 500, Thermal Excellent products with high precision and strength, and low noise
KRHG/KRHGF 1 to 3 SCM440 Ground 1
1000 refined and abrasion characteristics. J Series products are also available.
Round Rack
SRH/SRHF 100, 500, Effective in reducing noise and vibration due to larg-
2 to 3 S45C — Cut 5
SRHFD 1000 er contact ratio of helical gears.
General-purpose helical racks with product dimensions and
SRHEF 1.5 to 6 1000 S45C — Cut 4
helix angle (19°31’ 41”) according to EU specifications. SR Rack used for label feeding SRO Round Rack used for extruders (can also become a lifting/lowering device by setting up vertically)

■ Pinion ■ Rack Drive Linear Guide ■ Film Sealer

A product designed so that the helix angle is 19°31’ 41” and the
SHE 1.5 to 6 (18 to 30) S45C — Cut (N8)
distance of the pinion traveled in one turn is an integer (mm).
[NOTE 1] The catalog numbers in the above tables with a suffix of F have both ends machined so that they can be butted against each other to make any desired
length. The items with (D) and (K) have mounting screw holes for easier assembly.
[NOTE 2] Products with module less than 0.8 are thermal refined, without their gear teeth being induction hardened.
[NOTE 3] Precision grade standard of racks are set by KHK. Please see "Precision of Racks" in Selection Hints section for details.

● For safe handling and to prevent damage such as deformation, KHK stock racks have round chamfering at the corners of the top
land of the gear tooth.
This rounded chamfered shape is patented by KHK. It is also effective for reducing noise.
● Black products are KHK stock gears that have an applied black oxide coating for rust resistance;
this “blackness” is a product characteristic of KHK stock gears.

Example of table moving device that uses rack & pinion SR rack used for positioning

188 189
 Racks Racks KHK Technical Information

Selection Hints
Please select the most suitable products by carefully considering the characteristics of items and contents of the product ta- The most important factor in selecting gears is the
bles. It is also important to read all applicable "CAUTION" notes shown below before the final selection.

1. Caution in Selecting the Mating Gears ■ Mating Helical Gear Selection Chart ( ○ Allowable × Not allowable) gear strength.
① With the exception of helical racks, KHK stock racks can Catalog Number KRHG
SRHEF
SRH/SRHF
Step 1 Determine the actual load torque applied to the gear and the gear type suitable for
mate with any spur gears of the same module. Products and Direction of KRHGF SRHFD
Helix the purpose.
with different tooth width can also be mated as a pinion.
RH LH RH RH LH
○ × × × ×
② T here are limited choices of mating gears for KRHG/
LH
KHG
× ○ × × × ■ Definition of Bending Strength of Gears ■ Definition of Surface Durability
KRHGF, SRHEF, and SRH Ground Helical Racks and Helical RH

Racks. Be sure to check the helix direction (right or left) SHE LH × × ○ × × The allowable bending strength The surface durability of a gear
when selecting. LH × × × ○ × of a gear is defined as the al- is defined as the allowable tan-
SH
RH × × × × ○ lowable tangential force at the gential force at the pitch circle,
2. Caution in Selecting Gears Based on Gear Strength pitch circle based on the mutu- which permits the force to
Allowable bending strength and surface durability values shown in ally allowable root stress of two be transmitted safely without
product tables were computed by assuming a certain application en- incurring surface failure. The
meshing gears under load.
allowable gear tooth load of a
vironment. They should be used as reference only. We recommend Pinion (L) & Rack (R) gear is defined as the allowable
that each user computes their own values by applying the actual Example of failure due to Example of wear due to
insufficient bending strength
tangential force at the pitch insufficient surface durability
usage conditions. The table below contains the assumptions estab- circle based on the mutual gear
lished for various products in order to compute gear strengths. Pinion (R) & Rack (L) tooth strength of two meshing
■ Calculation of Bending Strength of Gears KRG・KRGF・KRGD Module 1 ～ 3 gears under load.
Racks Pinions Racks Thermal Refined Ground Racks
KRG/KRGF SRAF/SRAFD Step 2 Select provisionally from the allowable torque table of the Master Catalog based on the
KRGF-H SUR
Specifications

KRGD/KRHG SRG/SRGF SRAFK/SR/SRF DRF

Precision grade KHK R 001 grade 1

Catalog Number
MRGF KRGFD-H SRF-HL SURF PR
Gear teeth load torque.
Standard full depth A

KRHGF/ SRGFD/SRGFK SRFD/SRFK/SRO BSR SHE DRFD DR

B

SW
SW

G
G G

MRGFD KRF-H SRFD-HL SURFD PRF

Gears
Pressure angle 20°

Spur
KRHGFD SRF-H/SRFD-H SROS/SRH/SRHF DRFK ■ For provisional selection from the Master Catalog

C
D
Material SCM440
Item
KRFD-H SURO
G

KRF/KRFD SRHFD/SRHEF
Heat treatment Thermal refining only
SW: Sawing surface R1
Tooth hardness 225 ～ 285HB

Helical
Gears
Formula NOTE 1 Formula of spur and helical gears on bending strength (JGMA401-01) The Lewis formula Catalog No. Module
Effective
no. of teeth
Shape
Total length Face width Height Height to pitch line Allowable force (N) Allowable force (kgf) Weight
A B C D Bending strength Surface durability Bending strength Surface durability (kg)

30 Racks (30)
KRG1-100 29 98 0.11
No. of teeth of mating gears

Internal
m1 R1 10 15 14 1530 641 156 65.3

Gears
KRG1-500 159 505 0.55
KRG1.5-100 m1.5 20 R1 101 15 20 18.5 3450 1440 352 147 0.22

100rpm (100 rpm)

KRG1.5-500 105 505 1.10

Rotational speed KRG2-100

KRG2-500 m2 14
79 R1 98
505 20 25 23 6130 2560 625 261 0.35
1.82
KRG2.5-100 11 100 0.54

Over 107cycles Allowable bending stress (kgf/mm2)

KRG2.5-500 m2.5 63 R1 505 25 30 27.5 9580 4010 977 408 2.73

Racks
Design life (durability) KRG3-100
KRG3-500 m3 9
52 R1 101
505 30 35 32 13800 5770 1410 588 0.76
3.81

Uniform load
Total length Face width Height Height to pitch line Allowable force (N) Allowable force (kgf) Weight

Impact from motor Catalog No. Module No. of teeth Shape

m 0.8 4.0
A B C D Bending strength Surface durability Bending strength Surface durability (kg)

CP Racks
& Pinions
KRGF1-1000 m1 318 RF 999.03 10 15 14 1530 641 156 65.3 1.49

Uniform load 1.0 1.15 m 1.0 3.5

KRGF1.5-1000 m1.5 212 RF 999.03 15 20 18.5 3450 1440 352 147 2.18
Impact from load KRGF2-1000
KRGF2.5-1000
m2
m2.5
160
128
RF
RF
1005.31
1005.31
20
25
25
30
23
27.5
6130
9580
2560
4010
625
977
261
408
3.63
5.43

(40℃ (40℃ m 1.5 1.8 NOTE 4

KRGF3-1000 m3 106 RF 999.03 30 35 32 13800 5770 1410 588 7.53

Bidirectional
with No with No m 2.0 1.2
Direction of load
Total length Face width Height Height to pitch line Mounting hole dimensions No. of Mounting
Catalog No. Module No. of teeth Shape mounting
A B C D E F G holes screw size

Gears
Miter
30 Lubrication) Lubrication) (40℃ with Grease
KRGD1-500 m1 159 RD 499.51 10 15 14 6 39.75 140 4 M4

47 32 20 NOTE 3 10.5 4
KRGD1.5-500 m1.5 106 RD 499.51 15 20 18.5 8 39.75 140 4 M5
Allowable bending stress at root σHlim (kgf/mm2) NOTE 2 KRGD2-500 m2 80 RD 502.65 20 25 23 10 41.32 140 4 M6

Lubrication)
KRGD2.5-500 m2.5 64 RD 502.65 25 30 27.5 12 41.32 140 4 M8
KRGD3-500 m3 53 RD 499.51 30 35 32 14 39.75 140 4 M10

1.2
① The allowable forces shown in the table are the calculated values according to the assumed usage conditions. Please see
Safety factor SF [Caution on Product Characteristics]

Gears
Bevel
Page 192 for more details.
② The backlash of racks differ depending on the size of the mating pinion. Please calculate the backlash from the backlash
value of the mating pinion. Also, please refer to the data in the section called 'Backlash of Rack Tooth (Amount of Tooth

■ Calculation of Surface Durability (Except where it is common with bending strength)

Thinning)' on Page 195.
③ After attaching the racks to the base, please fasten with dowel pins. Clamping only with mounting screws could possibly

Step 3 We recommend that each user computes their own values by applying the actual us-
cause the screws to be broken, due to a heavy load. For details, please see the assembly method to the mounting base

Screw
Gears
on Page 197.

Formula NOTE 1 Formula of spur and helical gears on surface durability (JGMA402-01) [Caution on Secondary Operations] age conditions to determine the suitability of the gear strength.
① Please read “Caution on Performing Secondary Operations” (Page 196) when performing modifications and/or second-
ary operations for safety concerns. KHK Quick-Mod Gears, the KHK's system for quick modification of KHK stock gears is

100cSt (50℃)

Products Gearboxes Gear Pairs

also available.
Kinematic viscosity of lubricant

Worm
Calculate the strength formally using the vari- Strength confirmation is simple when using
Gear support Supported on one end.
ous gear strength formulas. the website.
166 112 79 90 NOTE 4 80 52.5 41.3 - 49 112

Bevel
Allowable Hertz stress σHlim (kgf/mm2)
Please see Page 71 of our technical reference
Safety factor SH 1.15 book for more details.

Other
[NOTE 1] The gear strength formula is based on JGMA (Japanese Gear Manufacturers Association) specifications, "MC Nylon Technical Data" by Nippon Polypenco
Limited and "Duracon Gear Data" by Polyplastic Co. (2) Bending strength formula
The units for the rotational speed (rpm) and the stress (kgf/mm2) are adjusted to the units needed in the formula. In order to satisfy the bending strength, the nominal circum-
[NOTE 2] The allowable bending stress at the root σFlim is calculated from JGMA401-01, and set to 2/3 of the value in the consideration of the use of planetary-, idler-, ferential force Ft on the meshing pitch circle must be less
or other gear systems, loaded in both directions. than or equal to the allowable circumferential force Ftlim on
the meshing pitch circle calculated by the permissible
[NOTE 3] For SRG, or SRGF Ground Racks, with a module less than m 0.8, the allowable bending stress and allowable hertz stress are respectively 24.5 (kgf/mm2) and 62.5 (kgf/mm2).
bending stress at root.
[NOTE 4] The values for DR m 1.5 racks were assumed by KHK. Usage conditions for SSDR (DR Rack Pinion) are the same as for the SSCP Pinion, shown on Page 241.
(10.4)
204
Alternatively, the bending stress at root σF obtained from the
When selecting KHK standard gears, glance over the Cautions on Product Characteristics and Cautions on nominal circumferential force Ft on the meshing pitch circle must
be less than or equal to the permissible bending stress at root σFlim.
Performing Secondary Operations in the respective dimension tables. (10.5)
The permissible circumferential force Ftlim (kgf) on the
① Products not listed in this catalog or materials, modules, number of teeth and the like not listed in the dimensional meshing pitch circle is obtained by the following equation.
tables can be manufactured as custom items. Please see Page 16 for more details about custom-made orders. (10.6)
② The color and shape of the product images listed on the dimension table page of each product may differ from the actual product.
The bending stress at root (kgf/mm2) is obtained by the
Be sure to confirm the shape in the dimension table before selection. following equation.
③ The details (specifications, dimensions, prices, etc.) listed in the catalog may be changed without prior notice. (10.7)
Changes are announced on the KHK website.
Website URL: https://khkgears.net/ (3) Calculating various coefficients

Overseas Sales Department: TEL: 81-48-254-1744 FAX: 81-48-254-1765 E-mail: info@khkgears.net

190 191
 Racks Racks KHK Technical Information

3. Cautions on Selecting Racks By Precision ② Precision of Rack Blanks

The precision standards of KHK stock racks are established by us. ■ Tolerance on Face Width and Height ■ Maximum Curvature Values (Flatness Tolerance L)
The table below indicates the tolerance ranges of our racks.
Face width Less than 0.03mm
Measurement po-
① Pitch Errors of Racks (KHK R 001) sition of extruded
material
Our precision grades for pitch errors are established by referring to JIS Standards. The precision grades are set from 1 to 8, in 1.0mm
accordance with the tolerance of a single pitch error (S.P.E.), adjacent tooth-to-tooth error (T.T.E.), and the total composite Note) Some products use an extruded material and
error (T.C.E.) for each module and length. the center of the 4 surfaces of the material may

■ Precision Grades of Racks (KHK R 001)

be slightly dented.
Unit: μm
Unit: mm Unit: mm
Over m 0.4 to 1 Over m 1 to 1.6 Over m 1.6 to 2.5 Over m 2.5 to 4 Over m 4 to 6 Over m 6 to 10
CP2.5 CP5 － CP10 CP15 CP20 Precision grade Precision Grade
(KHK R 001) (KHK R 001)
Rack Length (nominal) Grade 1 Grade 2 Grades 3 to 5 * Grades 1 & 2 Grade 3 Grades 4 & 5
Pitch Error

Face width Length (nominal)

Grade

1000 or less

1001 up to 2000

1000 or less

1001 up to 2000

1000 or less

1001 up to 2000

1000 or less

1001 up to 2000

1000 or less

1001 up to 2000

1000 or less

1001 up to 2000
0 0
6 or less 500 0.05 0.1 0.2
－ 0.10 － 0.18
0 0
7 to 10 1000 0.1 0.2 0.3
－ 0.10 － 0.22
0 0
11 to 18 1500 － － 0.3
0 － 0.10 － 0.27
S.P.E. 10 － 10 12 11 12 11 13 13 14 14 16
－ 0.05 0 0
19 to 30 2000 － － 0.4
1 T.T.E. 10 － 11 13 12 14 13 15 14 16 16 18 － 0.15 － 0.33
T.C.E. 28 － 29 33 30 35 32 37 35 40 40 45 31 to 50 0 0 [NOTE] The straightness tolerances of round racks are 0.15/500 mm and 0.2/1000 mm.
－ 0.15 － 0.39 Plastic racks change over time so are excluded from this precision standard.
14 － 14 17 15 17 16 18 18 20 20 23
S.P.E.
51 to 90 0 0
2 T.T.E. 16 － 16 19 17 19 18 21 20 24 24 27 － 0.15 － 0.46 ■ Tolerance on Total Length Unit: mm
[NOTE] Dimensional tolerance of hardened products is that prior to hardening.
T.C.E. 39 － 41 48 43 49 46 53 50 57 58 64 Product Type Module Dimensional Tolerance
Dimensional tolerance for plastic racks is the value obtained when ma-

( －－ 0.1
0.3 )
S.P.E. 20 － 20 24 21 25 23 26 25 29 29 32 chining is performed, and may increase slightly due to aging.
* BSR products are not applicable.
m 0.5

( － 0.5 )
3 T.T.E. 22 － 24 28 25 29 27 31 30 34 34 40
－ 0.1
m 0.8 (CP2.5)
T.C.E. 56 － 57 67 60 70 64 74 71 80 81 91

( －－ 0.2
0.6 )
F Type End Machined Product
S.P.E. 28 － 29 33 30 35 32 37 35 40 40 45 m 1 up to 2.5
4 T.T.E. 33 － 34 42 38 43 40 46 44 50 51 57 m 2.5 or more ( － 0.8 )
－ 0.2

T.C.E. 79 － 81 95 85 99 91 105 100 115 115 130

FRCP and DR Flexible Racks Uniform ± 10
S.P.E. 39 － 41 48 43 49 46 53 50 57 58 64
＋3
49 － 51 59 53 62 57 69 66 75 76 85 Products other than the above Uniform
5 T.T.E. －2
T.C.E. 110 － 115 135 120 140 130 145 140 160 160 180 [NOTE] For Type-F racks with machined ends, the dimensional tolerance is a
calculated value according to assumed usage conditions, without con-
S.P.E. 206 206 212 212 219 219 － － － － － － ③ Backlash of Rack Teeth sideration of pitch errors and aged deterioration.

8 T.T.E. 330 330 339 339 350 350 － － － － － － ■ Backlash of Rack Teeth (Amount of Tooth Thinning) Unit: mm
T.C.E. － － － － － － － － － － － －
Precision grade
(KHK R 001) Grade 4 Grade 5
[NOTE] ① Since the pitch accuracy of racks may vary due to humidity, the precision grades are evaluated at the bottom surface of the product, at the temperature of 20℃ . Grade 1 & 2 Grade 3
Module (m )
The dimensions of the KHK PR Plastic Racks may vary widely due to humidity. Therefore, the total composite error is assumed to be excluded from this Pitch (CP)
accuracy standard.
Excludes thermal refined racks Includes thermal refined racks Hardened Products Stainless Steel/Helical Racks Plastic Products
Please refer in our separate technical reference book to "Design of Plastic Gears" (Page 100) for change in dimensions. m 0.5 － 0 to 0.07 0 to 0.08 － － － －
② For the accuracy of CP Rack, convert CP to m (module) when reference is made to the data in the table. (m =CP/ π ).
m 0.8, CP2.5 0 to 0.06 0 to 0.08 0 to 0.09 － － － －
■ Pitch inspection and a sample report using Karl Zeiss UMC-550 Coordinate Measuring Machine. (KHK R 001 Grade 1) m1 0 to 0.06 0 to 0.10 0 to 0.11 － － 0 to 0.13 0 to 0.20
m 1.5, CP5 0 to 0.06 0 to 0.10 0.04 to 0.13 0.04 to 0.15 0.02 to 0.17 0.04 to 0.15 0 to 0.21
m2 0 to 0.06 0 to 0.10 0.05 to 0.14 0.05 to 0.16 0.03 to 0.18 0.05 to 0.16 0 to 0.22
m 2.5 0 to 0.06 0 to 0.10 0.06 to 0.16 0.06 to 0.18 0.04 to 0.20 0.06 to 0.18 0 to 0.24
m 3, CP10 0 to 0.06 0 to 0.10 0.07 to 0.18 0.07 to 0.20 0.05 to 0.22 0.07 to 0.20 0 to 0.27
m4 － 0 to 0.10 0.08 to 0.22 0.08 to 0.24 0.06 to 0.26 0.08 to 0.24 －
m 5, CP15 － 0 to 0.10 0.09 to 0.24 0.09 to 0.26 0.07 to 0.28 0.09 to 0.26 －
m 6, CP20 － 0 to 0.10 0.10 to 0.28 － 0.08 to 0.32 － －
m8 － － 0.13 to 0.32 － － － －
m 10 － － 0.15 to 0.34 － － － －
[NOTE] The values shown in the table are amount of tooth thinning. The theoretical backlash of assembled rack and pinion is given by:

Rack & pinion backlash = Amount of tooth thinning of the rack + Amount of tooth thinning of the pinion
Amount of tooth thinning of the rack : See above table
Amount of tooth thinning of the pinion : Take 1/2 of backlash given in the product table
192 193
 How to mount racks on a mounting base (For SRFD2-1000)

Racks Racks KHK Technical Information

1. Pitch alignment
Place SRFD2-1000 on the mounting base, align SR2-100 and temporarily tighten the bolt.

SR2-100 (joining rack)

Application Hints SRFD2-1000

0.2 to 0.6
SRFD2-1000
105.3

In order to use KHK stock racks safely, carefully read the Application Hints before proceeding. If there are questions or you re- Mounting base
As an example of Rack Joining, we recommend the following method.
quire clarifications, please contact our technical department or your nearest distributor. Dimensions Table F SRFD2-1000 is designed to have
Value x 2 a gap of 0.2 to 0.6 mm.

▪ TEL: 81-48-254-1744 FAX: 81-48-254-1765 E-mail: info@khkgears.net 2. Securing to the mounting base
Tap with a plastic hammer, bring it into close contact with the mounting base, and
further tighten the bolt.

1. Cautions on Handling 3. Points of Caution during Assembly Joining Rack

(When using a metal hammer, be careful not to damage the gear teeth by using a
stiffening plate, etc.)

① K HK products are packaged one by one to prevent ① KHK stock racks are designed to give the proper normal d
Stiffening

scratches and dents, but if you find issues such as rust, direction backlash when assembled using the mounting Plate

scratches, or dents when the product is removed from distance given by the formula below (mounting dis- [NOTE] J oining gaugeSR2-100
racks(joining
for helical
rack)
racks must have the opposite hand
the box after purchase, please contact the supplier. tance tolerance of H7 to H8 required). The backlash val- from the racks. Please use 100 mm long racks as a joining gauge

② Depending on the handling method, the product may be- ues are given in the table on Page 193. Make sure that rack, or alternatively the rack SRFD2-1000
SRFD2-1000 of the same specifications on hand.

the mounting distance stays constant for the length of

Mounting base

come deformed or damaged. Long racks and resin racks

deform particularly easily, so please handle with care. the rack. How tomount
How to mount
racks on aracks
mounting on a mounting
base (For SRFD2-1000) base (For SRFD2-1000)

2. Cautions on Performing Secondary Operations Mounting distance a = Height of pitch line of rack + Pitch radius of pinion 1. Pitch alignment
Place SRFD2-1000 on the mounting base, align SR2-100 and temporarily tighten the bolt.
3. Run the pinion and check the following
Is there abnormal noise or vibration?
Is the backlash appropriate?

①S  econdary operations can be performed on all KHK stock

Is there poor edge contact of
[NOTE] Pinions are assumed to be stan- gear teeth?

racks except for the racks with their gear teeth induction
SR2-100 (joining rack)
dard stock spur gears (x=0).
hardened. To avoid problems of gear precision, do not
reduce the face width. The precision of ground racks and
SRFD2-1000 SRFD2-1000
0.2 to 0.6
SRFD2-1000 SRFD2-1000

racks with mounting holes may drop if you do not exercise

105.3 Mounting base
Pinion
extreme caution during installation or while modifying.
Mounting base

Dimensions Table F SRFD2-1000 is designed to have 4. Secure fixation to the mounting base

②P  itch lines of racks are controlled by using the bottom sur- Rack
Value x 2 a gap of 0.2 to 0.6 mm. We recommend that you tap the knock pin so that the rack does not shift due to vibration, etc.
Simultaneously machine reamer holes

face as the reference datum and over-pin measurements 2. Securing to the mounting base
Tap with a plastic hammer, bring it into close contact with the mounting base, and
Reamer hole

on tooth thickness. If you machine the bottom surfaces, further tighten the bolt.
(When using a metal hammer, be careful not to damage the gear teeth by using a
Drill

the precision of the racks may be affected. ② KRG type of KHK stock ground racks have four surfaces stiffening plate, etc.)
SRFD2-1000 SRFD2-1000

③ When connecting two racks, the machining of the mat- ground parallel with high precision. To maintain true Stiffening Mounting base
ing ends requires careful consideration in terms of the angle, they should be mounted on high precision bases Plate

pitch (p ) accuracy. The meshing will be poor if the pitch (within 10μm recommended) as shown below. It is even
Drive the knock pin
Knock pin
SR2-100 (joining rack)

straddling the connection has a positive tolerance. We possible to correct for the angular errors of racks by com-
recommend a minus tolerance on pitch of at the con- pensating the mounting base. With recent increases in
SRFD2-1000 SRFD2-1000
SRFD2-1000 SRFD2-1000

nection. the requirement for zero backlash linear drives, such ac- Mounting base Mounting base

The below is an indication of pitch tolerance for each module. curate assembly as shown is becoming more important. Tighten again after tapping the knock pin.
It can be marked with a pen to find looseness.

Unit: mm
3. Run the pinion and check the following

p
Module Pitch (p ) Tolerance 4. Cautions onnoise
Is there abnormal Starting
or vibration?
－ 0.05 Is the backlash appropriate?
1.57
① Check the following items before starting. For initial operation, the lubricant may deteriorate markedly,
m 0.5 － 0.15 Is there poor edge contact of
gear teeth?
－ 0.05
m 0.8 2.51 － 0.25 • Are the gears installed securely? so check the condition of the lubricant after starting.
m1 3.14 • Is there uneven tooth contact? For more technical information, please see the section "Gear
－ 0.1
m 1.5 4.71
－ 0.3 • Is there adequate backlash?
SRFD2-1000 SRFD2-1000
Lubrication" (Page 112) of our technical reference book.
6.28
Be sure to avoid Mountingzero-backlash. ④ If there is any abnormality such as noise or vibration
m2
base
m 2.5 7.85
m3 9.42 • Has proper lubrication been supplied? during startup, check the gears and assembly condition.
p = π·m ② 4.IfSecure
gears fixationare
to the exposed, be sure to attach a safety cover "High gear accuracy", "smooth gear teeth surface" and
p : Reference pitch m4 12.57 mounting base
－ 0.1
to ensure
Simultaneouslysafety. Also,
holes be careful not to touch rotating "correct tooth contact" are some of the measures against
We recommend that you tap the knock pin so that the rack does not shift due to vibration, etc.
15.71
π : Pi m5 － 0.4 ③ If the racks are not secured properly to the base, they could machine reamer
m6 18.85 gears. Reamer hole
gear noise. For more technical information, please see
m : Module
25.13 shift during operation and cause unexpected problems.
③G ears can be lubricated with the "grease lubrication method", the section "Gear Noise and Countermeasures" (Page
m8 Drill
m 10 31.42 It is very important to insure firm mounting by the use of
dowel pins or similar devices. "splash
SRFD2-1000
lubrication method (oil
SRFD2-1000 bath method)", or "forced 119) of our technical reference book.
④ To use dowel pins to secure racks, attach the racks to the ④ Machined end type racks such as SRF and SRFD series lubrication method (circulation lubrication method)".
Mounting base
base and drill both simultaneously. have the pitch tolerance of -0.05 to -0.4mm at the end
⑤ KHK stock racks made of S45C and SCM440 (except for face. If you try to connect the racks without any space,
Drive the knock pin
KHK considers safety a priority in the use of our products.
Knock pin
ground racks) can be induction hardened. However, the the pitch at the connection will be too small and will
When handling, adding secondary operations, assembling, and operating KHK products, please be aware of the following issues in order
to prevent accidents.
precision of pitch is decreased. cause problems. Please follow the following diagrams SRFD2-1000 SRFD2-1000

⑥ To be able to handle parts safely, all burrs and sharp cor- for assembly. Warning:
Mounting base Precautions for preventing physical and property damage

ners should be removed after the secondary operations ⑤ With SRFD etc., if using more than 10 racks connected 1. When using KHK products, follow relevant safety regulations (Occupational Safety and Health Regulations, etc.).
It can be2. Pay
withattention to the following
items when installing, removing, or performing maintenance and inspection of the product.
Tighten again after tapping the knock pin.

are done. together to form a rack with mounting holes machined

marked a pen to find looseness.
① Turn off the power switch.
⑦ I f you are going to modify the gear by gripping the along a length of 1 meter, the pitch precision and ma- ② Do not reach or crawl under the product.
③ Wear appropriate clothing and protective equipment for the work.
teeth, please exercise caution not to crush the teeth chining precision may cause the rack and base mount-
by applying too much pressure. Any scarring will cause ing holes to deviate, leading to set screw interference Caution Cautions in Preventing Accidents
noise during operation. with the counterbored hole and preventing mounting. 1. Before using a KHK product, read the precautions in the catalog carefully in order to use it correctly.
2. Avoid use in environments that may adversely affect the product.
When using a rack for long lengths such as 10 meters 3. Our products are manufactured under a superior quality control system based on the ISO9000 quality management system; if you
or 20 meters, have the mounting holes additionally ma- notice any malfunctions upon purchasing a product, please contact the supplier.
chined into long holes.
194 195
 Racks Racks KHK Technical Information

Comparison of Racks & Pinions and Ball Screws Rack downsizing

Since racks are a simple mechanism, the material, hardening, strength and precision can be designed ac- The H Series, KHK stock racks with induction hardened gear teeth, and the HL Series, with laser hardening,
cording to the environment. are available.
They are also inexpensive, with parts that can be purchased separately for replacement.
The graph below simulates the downsizing of KHK stock racks. It is possible to reduce the module (size) with equivalent trans-
In the designing process, please refer to Features of Racks & Pinions and Ball Screws in the table below.
mission power, or to reduce the price likewise. Please select a product that fits your needs.
Stroke
Stroke
Motor bracket Support Coupling
■ Comparison table of permissible transmission force of hardened racks
unit
Linear guide
Table (fixed side) Motor bracket
Table Allowable force (kgf)
Motor
Motor Ball screw nut
Surface durability
Ball screw shaft 2500
Motor
Linear guide
Rack Table

Nut bracket
Pinion Base Rack Support unit (support side) Base
Pinion Hardened Rack SRF-H/KRF-H/SRF-HL Series
Conventional Rack SRF/KRF Series
2000
● Features of Racks & Pinions
Advantages Details
Few component parts Since it does not have parts such as balls and retainers, there is less risk of accidentally falling apart during assembly and disassembly.
Supports heavy loads Racks with large module can be used for heavy loads. 1500
Compact products can be manufactured Since it can be made smaller than products with ball screws, it can be used compactly for light loads.
High transmission efficiency High transmission efficiency of about 98% (excluding lubrication oil stirring resistance and bearing resistance).
High feed speed If the pinion diameter is large, it supports high-speed feeding.
No length limit Screws can only be up to about 2 m to avoid excessive bending, but racks can be joined together and used at greater lengths. 1000

Flexible production is available Materials, hardening, shapes and the like can be designed flexibly, allowing easy adjustment to the machine.
High-precision products can be manufactured Gear grinding can be provided to minimize pitch error.
Can be used for food-related machinery MC nylon and stainless steel products can be manufactured.
500
Disadvantages Details
Backlash is required for smooth rotation.
Backlash is present
Backlash may become a problem in forward/reverse rotation positioning.

Lubrication is required Metal racks require lubrication. Plastic racks do not require lubrication at light loads, but their precision is lower. 0

● Features of Ball Screws

Advantages Details
High transmission efficiency Transmission efficiency of 90% or higher. Comparison table per series (module 3, rack length: 1,000 mm)
High-precision products can be manufactured High-precision ball screws can be manufactured by grinding. Catalog Numbers Allowable force kgf Precision
Material Heat Treatment Series nominal total length mm
High feed speed High-speed feed is possible with high-lead ball screws. (Comparison Example) Bending strength Surface durability KHK R 001
No backlash The use of pressure eliminates backlash. SRF3-1000 S45C None (raw material) 879 186 Grade 4 300,500,1000,1500,2000
KRF3-1000 SCM440 Thermal refined 1410 421 Grade 4 500,1000
Disadvantages Details SRF3-1000HL S45C Laser hardened 879 407 Grade 4 1000,1500,2000
Length is limited Since the screw deflects, about 2 meters is the practical limit. SRF3-1000H S45C Induction hardened 799 468 Grade 5 1000
Hard to manufacture special products Since it is hard to manufacture special products, machines must be adjusted to the shape of the ball screw. Thermal refined /
KRF3-1000H SCM440 1280 725 Grade 5 1000
induction hardened
MRGF 3-500 (2 units) SCM415 Carburized 2070 1900 Grade 1 500

Laser Hardened ● Lasers used for hardening gear teeth

In this environmentally friendly hardening method, powerful light provides in-
■ Example of rack downsizing 75mm
The surface durability can be increased by hardening
Racks the gear teeth. By increasing the strength thus, the
stantaneous hardening and cooling water is not required due to diffusion of heat.
● Hardening is possible wherever laser irradiation is angular dimensions of modules and racks can be re-
Lasers excel at spot hardening. As long as the laser can be irradiated, even the duced. This helps reduce the cost. m8 rack angular dimension
inside of bores can be hardened.
40mm
● Less distortion due to burning during hardening
As the laser hardens necessary areas in spots, distortion due to burning can be Increased strength leads to

75mm
smaller size
minimized.
SRF8-1000 39.7kg
m4 rack angular

45mm
Lasers enable hardening KRF4-1000H 12.9kg
Mass reduced ⇒ 26.8 kg dimension
that barely changes the
precision grade.

* Please see Page 210 for products.

196 197