SAE Gear Design Course - C0223 - th003

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Fundamentals of Gear Design and Application
I.D. #C0223
Duration: 2 Days
Through informative discussions and detailed explanations, this seminar will provide a solid
and fundamental understanding of gear geometry, types and arrangements, and design
principles. Starting with the basic definitions of gears, conjugate motion, and the Laws of
Gearing, those attending will be given the tools needed to understand the inter-relation and
coordinated motion operating within gear pairs and multi-gear trains. Basic gear system
design process and gear measurement and inspection techniques will also be explained. In
addition, the fundamentals of understanding the step-wise process of working through the
iterative design process required to generate a gear pair will be reviewed, and attendees will
also briefly discuss the steps and issues involved in design refinement and some
manufacturing considerations. Also, an explanation of basic gear measurement techniques,
how measurement equipment and test machines implement these techniques, and how to
interpret the results from these basic measurements will be covered.
Benefits of Attending
By attending this seminar, attendees will be able to:
• Describe the "Law of Gearing," conjugate action and specifically, involute profiles
• Review the various definitions and terms used in gearing
• Identify the function and operation of all gear arrangements
• Appraise preliminary design considerations and the gear system design process
• Explain practical gear measurement and inspection techniques, tools and equipment
• Recognize "Best Practices" in regards to gear system design
• Discuss some of the new and automated gear design systems
Who Should Attend

The intended audience for this seminar is powertrain engineers, engineering directors and
managers, component suppliers, vehicle platform powertrain development specialists, and
those involved in the design and application of geared systems and assemblies. This seminar
will appeal to anyone who is interested in gears, gear systems, design development or
measurement and inspection techniques.
More specifically, anyone responsible for the following will benefit:
• Mechanical power transmission system design, development, durability assessment

and application
• Application and development of geared systems technologies
• Management of transmission designers and manufacturers
• Supply of components and sub-systems to mechanical power transmission system
manufacturers
Prerequisites
Attendees should have an undergraduate engineering degree to attend this program. This
seminar is intended for powertrain engineers, engineering directors and managers, component
suppliers, vehicle platform powertrain development specialists, and those involved in the
design and application of geared systems and assemblies. Anyone who is interested in gears,
gear systems, design development or measurement and inspection techniques should attend.
Seminar Content
DAY ONE
• Principles of Gears
o Purpose of gears
o Basic concepts -- Law of gearing; common tooth forms
o Classification of gears
o Definitions and terms used in gearing
o Velocity ratio
o Pitch surfaces
• Gear Tooth Action
o Conjugacy
o Profile curves
o Surface of action
o Profile sliding
• Gear Geometry and Nomenclature
o Principle of planes
o Tooth nomenclature
o Blank nomenclature
• Gear Arrangements
o Simple gear train
o Compound gear train -- ratios
o Epicyclic -- configurations (solar, planetary, star); ratios; tooth number
selection and build requirements; application
• Preliminary Design Considerations
o Gear type selection
o Preliminary estimate of size
o Stress formulations
o Gear Drawing Data
DAY TWO
• Gear System Design Process

o Calculation of gear tooth data
o Gear rating practice
• Gear Design Process
o Layout
o Root geometry
o Backlash
• Gear Measurement and Inspection
o Dimension over pins
o Pin diameter
o Modify pin diameter and dimension over pins
o Pin contact point
o Charts - involute; lead; red liner
o Dimension sheet
• Gear Design Systems and Best Practices
o Common proportions
o Interchangeability
o Tooling considerations
o Mounting considerations
o Best practices
o Application
Instructor(s): W. Mark McVea

Dr. William Mark McVea is founder and chief technical officer of KBE+, Inc., an
organization that designs and develops complete powertrains for automotive and off-highway
vehicles, and also develops and delivers professional development seminars for the
automotive industry and its supplier base. Prior to founding KBE+, McVea was a manager of
the CAE group within a tier one, powertrain supplier to world automotive markets; a
consulting engineer in vehicle dynamics, with Gear Consultants, Inc.; a project manager of
traction systems for off-highway vehicles with Clark-Hurth International; and a research
laboratory supervisor, developing geared traction devices with Gleason Power Systems, Inc.
He also taught and lectured at Purdue, Michigan State and Syracuse universities. Dr. McVea
is published extensively on the topics of transmission systems, automated design assistant
systems, knowledge systems and knowledge based engineering in general. Dr. McVea holds a
BS in mechanical engineering from the Rochester Institute of Technology, a PhD in design
engineering from Purdue University, and is a licensed professional engineer. Currently, he is a
professor of information technology in the B. Thomas Golisano College of Computing and
Information Sciences at the Rochester Institute of Technology.
1.3 CEUs
Fundamentals of
Gear Design
and
Application
William M. McVea, Ph.D., P.E.

Copyrighted 2001 SAE #C0223
Introductions
• William Mark McVea, Ph.D., P.E.
– Chief Technical Officer of KBE+, Inc.
– 15+ Years of Geared Product
Design and Development
– Graduate Work:
• Automated Design of Automotive & Off-Highway
Transmissions Using the Techniques of Artificial
Intelligence
1
My Expectations
• #1: I want you to feel confident --
• Able to Understand & Correctly Use Gear
Terminology
• Basic Concepts of;
– Gears
– Path of Motion
– Transfer of Torque
• Gear Geometry, Development and Layout

• Inspection, Measurement & Application
My Expectations
• You Only Get Out of a Course
What You Put Into It
• Ask Lots of Questions

When You Have Them
2
Who Is In Attendance?
• Take a Moment & Find Out Who Is Here
ÎI Know, I Know . . .
Nobody Ever Likes Audience Participation
Your Expectations
• Let’s list all the points and topics you want
to cover during the next two days
3
Gears –
Let’s Face It
Ya’ Know Them
Ya’ Love Them
Course Content
• Principles of Gears & Gearing
• Gear Classification
• Tooth Forms & Geometry
• Nomenclature & Definitions
• Design Principles
• Drawing & Layout Techniques / Practices
• Measurement & Inspection
4
Principles of Gears
• Purpose of Gears
• Basic Concepts
– Law of Gearing
– Common Tooth Forms
• Classification of Gears
• Definitions and Terms Used in Gearing
Purpose of Gears
• Transmit Motion Between Shafts
• Transmit Power Between Shafts
• Modify Torque & Speed by Ratio
– Torque Increases as Speed Decreases
– Torque Decreases as Speed Increases
• Change Direction of Power Flow
• Change Axis of Power Flow
• Split Power Among Multiple Shafts
5
Basic Concepts
• Law of Gearing
• Conjugate Action
• Common Gear Tooth Forms
• Gear Tooth Action
Law of Gearing
• To transmit uniform rotary motion from one
shaft to another by means of gear teeth
• The normals of these teeth at all points of

contact must pass through a fixed point in
the common centerline of the two shafts
6
Rotary Motion
• Transmit rotary motion from one shaft
– The Driver or Driving Member
• To a shaft attached to it
– The Driven or Driven Member
A B
Rotary
Motion Driver Driven
Length ‘A’ = Length ‘B’

ζB = (B/A) * ζ A
ζB = ζA
14
7
A B
Rotary
Motion
A B
Driver Driven
15
A B
Rotary
Motion
A B
Driver Driven
Normal to Centerline
of Slot In Arm A
16
8
A B
Rotary
Motion
A B
Intersection Point Between

Normal and Line of Action
of Slot In Arm A
17
A B
Rotary
Motion
A B
Intersection Point Between

Normal and Line of Action
of Slot In Arm A
Length ‘A’ > Length ‘B’

ζB = (B/A) * ζ A
ζB < ζA
18
9
A B
Rotary
Motion
A B
Is Equal
of Slot In Arm A B
A To Zero
Length ‘A’ > Length ‘B’

ζB = (B/A) * ζ A
ζB = 0 19
Conjugate Action
• Transmit rotary motion from one shaft to a
shaft attached to it
• A profile of two mating members that when

run in contact produce uniform rotary
motion
10
Conjugate Action
Conjugate Action
• Transmit rotary motion from one shaft to
a shaft attached to it
• A profile of two mating members that

when run in contact produce uniform
rotary motion
• The output motion exactly matches

the input motion
– Disregarding the effect ratio
11
Involute Profile
Zero Transmission Error Theoretically
23
Conjugacy
• Conjugate Gear Tooth Action: Is the
action between such profiles, which
transmit uniform rotary motion
• In essence the gear tooth surfaces are
cams in which the common normal to both
profiles pass through the
Pitch Point
12
Definitions & Nomenclature
• Basic Definitions and Terms
• Velocity Ratio
• Pitch Surfaces
Classification of Gears
• Parallel Axis
– Spur
– Helical
– Double Helical
or Herringbone
13
Gear Type
Definition
STRAIGHT BEVEL
27
Parallel Axis
Spur Gears
14
Parallel Axis
Helical Gears
29
Parallel Axis
Double Helical or Herringbone Gears
15
• Parallel Axis
– Spur
– Helical
– Double Helical
or Herringbone
• Nonparallel Axis
– Straight Bevel
– Zerol Bevel
– Spiral Bevel
– Cross-Helical
– Face Gears
Non-Parallel
Axis Gears
32
16
Intersecting Axes
Straight Bevel
Intersecting Axes
Zerol Bevel
34
17
Intersecting Axes
Spiral Bevel
35
Intersecting Axes
Face Gear
36
18
• Parallel Axis • Nonintersecting
– Spur Nonparallel Axis
– Helical – Cross-Helical
– Double Helical – Worm
or Herringbone
• Single-enveloping
• Nonparallel Axis • Double-enveloping
– Straight Bevel – Hypoid
– Zerol Bevel – Spiroid
– Spiral Bevel
– Cross-Helical
– Face Gears
Nonintersecting
Nonparallel
Axes
Cross-Helical
19
Nonintersecting
Nonparallel
Axes
Worm
39
Nonintersecting
Nonparallel
Axes
Worm
40
20
Nonintersecting
Nonparallel
Axes
Single
Enveloping
Worm
41
Nonintersecting
Nonparallel
Axes
Double
Enveloping
Worm
42
21
Nonintersecting
Nonparallel
Axes
Hypoid
43
Nonintersecting
Nonparallel
Axes
Hypoid
44
22
Nonintersecting
Nonparallel
Axes
Spiroid
Nonintersecting
Nonparallel
Axes
Spiroid
46
23
Nonintersecting
Nonparallel
Axes
Helicon
47
• Parallel Axis • Nonintersecting
– Spur Nonparallel Axis
– Helical – Cross-Helical
– Double Helical – Worm
or Herringbone • Single-enveloping
• Nonparallel Axis • Double-enveloping
– Straight Bevel – Hypoid

– Zerol Bevel – Spiroid
– Spiral Bevel – Helicon
– Cross-Helical • Nonintersecting
– Face Gears Parallel Axis
– Basic Rack
24
Nonintersecting
Parallel Axes
Basic Rack
Spur
49
Nonintersecting
Parallel Axes
Basic Rack
Helical
50
25
Specialty Gear Forms
• Square or Rectangular
• Triangular
• Elliptical
• Scroll
• Multiple Sector
Square or Rectangular
Speed
Ratio
Driver Driven
One Revolution of Driver
26
Triangular
Speed
Ratio
Driver Driven
Elliptical
Speed
Ratio
Driver Driven
27
Scroll
Speed
Ratio Driver Driven
55
One Revolution of Driver One Revolution of Driver
Multiple Sector
Speed Driven
Driver
Ratio
One Revolution of Driver 56
28
Definitions & Nomenclature
• Basic Definitions and Terms
Common Profile Curves

• Involute
• Cycloidal
• Wildhaber-Novikov
• Formate Gearing
• Infinite Number of Shapes that Produce

Conjugate Action
– With Involute Being the Most Common
29
Creation of an Involute
59
Definition
of
Involute
60
30
Cycloidal
Cycloidal
31
Wildhaber-Novikov
w1
Pinion
r1 f
r2
Gear Lines of
Centers 63
Formate Gearing
Generated Form
Non-Generated Form
32
Gear Geometry & Nomenclature
• Ratio
• Tooth Nomenclature
• Gear Nomenclature
• Blank Nomenclature
• Principle Planes
Ratios
Gears have a
It’s all about ‘radius’
‘Leverage’ Gears rotate ‘in mesh’
Gears are always in ‘pairs’ R
That ‘radius’
R Acts like a lever
Ratio = R / r
You can have multiple
‘gear pairs’ to make
One overall ratio
The difference in the length of the lever
Is the difference in the amount of torque or rotational force it can transmit
Or the ‘ratio’ between the gears
33
Ratio
• Number of Gear Teeth
Number of Pinion Teeth
• Pitch Diameter of Gear

Pitch Diameter of Pinion
• Base Circle Diameter of Gear

Base Circle Diameter of Pinion
Gear Layout Nomenclature

• Tooth Numbers • Face Width
• Base Circle • Diametral Pitch
• Pressure Angle • Module
• Pitch Circle • Base Pitch
• Line of Action • SAP / EAP
• Center Distance • Contact Ratio
34
Tooth Numbers
• Based on Ratio
• 40 Teeth Minimum in Pair Desired
• Minimum Number of Pinion Teeth

Selected by Application
Tooth Numbers
• Pinion Tooth Numbers Based on Application
35
General Guide to Selection of Number of Pinion Teeth
No. Pinion Design Considerations
Teeth
7 Requires at least 25o pressure angle and special design to avoid undercutting.
Poor contact ratio. Use only in fine pitches
If 20o, outside diameter should be reduced in proportion to tooth thickness to
avoid pointed teeth
Subject to high specific sliding and usually have poor wear characteristics
10 Smallest practical number with 20o teeth. Takes about 145 percent long
addendum to avoid undercut. Poor wear characteristics
15 Used where strength is more important than wear. Requires long addendum
19 No undercutting with 20o standard-addendum design
25 Good balance between strength and wear for hard steels. Contact kept away
from critical base-circle region.
35 Strength may be more critical than wear on hard steels—about even on

medium-hard steels
50 Probably critical on strength on all but low-hardness pinions. Excellent wear

resistance. Favored in high-speed work for quietness.
Tooth Numbers
• Based on Ratio and Center Diameters;
– Calculate Pitch Diameters
– Then Tooth Numbers
36
Numbers of Teeth in Pinion and Gear vs. Pressure
Angle and Center Distance
No. of No. of Teeth in Gear and Pressure Angle
Teeth in 14 1/2 20 20 25
Pinion Coarse Pitch* Coarse Pitch+ Fine Pitch+ Coarse Pitch+
7 42++
8 39++
9 36++
10 25 33 15
11 24 30 14
12 52 23 27 12
13 51 22 25
14 50 21 23
15 49 20 21
16 48 19 19
17 47 18 18
18 46
19 45
Numbers of Teeth in Pinion and Gear vs. Pressure

Angle and Center Distance
No. of No. of Teeth in Gear and Pressure Angle
Teeth in 14 1/2 20 20 25
Pinion Coarse Pitch* Coarse Pitch+ Fine Pitch+ Coarse Pitch+
20 44
21 43
22 42
23 41
24 40
25 39
26 38
27 37
28 36
29 35
30 34
31 33
37
Tooth Numbers
• Based on Ratio and Center Diameters;
– Calculate Pitch Diameters
– Then Tooth Numbers
• Spur –
– Integer Diametral Pitch (i.e. 1, 2, 3 / use std. hobs)
• Helical –
– Normal Diametral Pitch to be Integer
Minimum Number of Pinion Teeth vs. Pressure Angle

and Helix Angle Having No Undercut
Min. No. of Teeth to Avoid Undercut

Helix Angle Normal Pressure Angle, on
(deg)
14 1/2 20 22 1/2 25
0 (spur gears) 32 17 14 12
5 32 17 14 12
10 31 17 14 12
15 29 16 13 11
20 27 15 12 10
23 25 14 11 10
25 24 13 11 9
30 21 12 10 8
35 18 10 8 7
40 15 8 7 6
45 12 7 5 5
38
Ratio Selection Considerations
• Hunting Tooth Ratio
– Number of Teeth in Pinion
– And Number of Teeth in the Gear
– Have No Common Factor
• Example;
– NP = 11
– NG = 41
Ratio Selection Considerations

• Why Use A Hunting Tooth Ratio
– Good if you intend to lap gears for smooth
running & long life
– If a tooth develops a surface imperfection,
then there are multiple contact points to
smooth and remove surface abnormality
• Why Not To Use A Hunting Tooth Ratio

– If a tooth develops a surface imperfection
it may eventually damage all other teeth
39
Gear Layout Nomenclature
• Tooth Numbers • Face Width
• Base Circle • Diametral Pitch
• Pressure Angle • Module
• Pitch Circle • Base Pitch
• Line of Action • SAP / EAP
• Center Distance • Contact Ratio
Base Circle
40
Base Circle
• Theoretical Circle
– From which involute tooth profile is derived
Base Circle
82
41
Base Circle
• Theoretical Circle
– From which involute tooth profile is derived
• Involute Tooth Profile is Generated

– By un-wrapping a string
– From the base circle
Base Circle
84
42
Base Circle
• Base Circle Diameter is the;
– Pitch Diameter
times
– Cosine of the Pressure Angle
DBaseCircle = DP * cos(θ )
Base Circle
43
Pressure Angle
Tangent to Tooth Surface
at Pitch Line
φ P
Pitch
Circle
Pressure
Line
rB
r φ
Base
Circle
Pressure Angle
• Angle of Tangent to Tooth Surface at Pitch
Point: φ ( phi )
• Typical Angles: 14.5, 20, 22.5, 25, 30
• Selection Based on Available Tooling
• Strength vs. Noise Requirements
– Lower Pressure Angles Generally Quieter
– Higher Pressure Angles are Stronger
44
Pressure Angle
• Select Based on Hob Availability
• Select from Standard Hob PA’s;
– 14.5 degrees (older standard)
– 20 degrees (common standard)
– 25 degrees (for higher strength)
– 30 degrees (special applications)
Pitch Circle
45
Pitch Circle
• Theoretical Surfaces of a Pair of Gears
Which Would Roll without Slipping
• Pitch Circle Diameter –

– Number of Teeth / Diametral Pitch
– Circular Pitch
Normal
Pitch
92
46
Pitch Diameter
• Pitch Diameter =
– Number of Teeth / Diametral Pitch
• Base Circle Diameter =
– Pitch Diameter * cosine (PA)
• Addendum =
– 1.0 / Dp
• Dedendum =
– 1.25 / Dp
Pitch
Point
94
47
Line of Action
Line of Action
• In Gear Geometry
– Path of Action for Involute Gears
48
Line
of
Action
97
Line of Action
• The Line of Action

– Path of the Contact Point Between the Teeth
– As Teeth Roll Through Mesh it Defines a Line
• Straight Line Passing Through Pitch Point

• Tangent to Base Circles of Two Mating Gears
49
Line of
Action
99
Line of Action
• The Line of Action

– Path of the Contact Point Between the Teeth
– As Teeth Roll Through Mesh it Defines a Line
• Straight Line Passing Through Pitch Point

• Tangent to Base Circles of Two Mating Gears
• Intersection of Two Base Circles
– Defines the Pitch Point
50
Center
Distance
Center
Distance
Center Distance
• Distance Between the Centers of Two
Mating Gears
• Distance Between the Center of the
Support Shafts
• Sets Overall Dimension of Gearbox
51
Face Width
103
Face Width
• Width of Gear Tooth at Pitch Circle
• Actual is Measured Width
• Effective is Length of Contact Pattern
• Effective is Less than or Equal Actual
• Face Width is a Function of a Pair
• Effective is Equal for Pinion and Gear
52
Diametral Pitch
• Ratio - Teeth Number : Pitch Diameter
• Pd = N / D
(D for Gear, d for Pinion)
• English Only Concept

• Corresponding SI Concept is Module
Module
• M = D/N (Gear)
• Or M = d/n (Pinion)
• M = 25.4 / Pd
• Inverse Relationship to Diametral Pitch
53
Base Pitch
Base Pitch
• Pitch Along Base Circle
• Pb is the Circumference of the Base Circle

/ Number of Teeth
• Any two gears with the same Base Pitch

will roll together
54
SAP / EAP
109
SAP / EAP
• Start of Active Profile

– Point on Tooth which is First Contacted by the
Tip of the Mate
• End of Active Profile
– Point on Tooth which Contacts the SAP of the
Mate
• EAP May be Tip of Tooth
• Or Chamfer at Tip
55
Active Tooth Profile
• Define Active Tooth Profile
• Length of Tooth Profile

– Which Actually Comes into Contact with the
Mating Tooth
Tooth Action
Pinion
Driver
Angle of Angle of
Approach Recess
Angle of Angle of
Approach Recess
Gear
Driven
56
Tooth Action
• Angle of Approach
– Arc of Pitch Circle
– From Point of First Contact Along Pitch Circle
– To the Pitch Point Between Gear & Pinion
– Used to Calculate
• Length of Contact
• Contact Ratio
Tooth Action
• Angle of Recess
– Arc of Pitch Circle
– From Pitch Point Between Gear & Pinion
– To the Last Point of Contact Along Pitch
Circle
– Used to Calculate
• Length of Contact
• Contact Ratio
57
Contact Ratio
Contact Ratio
• Average Number of Teeth in Contact
• Length of Line of Action / Circular Pitch *

Cosine of Pressure Angle
• mc = Lab / p * Cos φ
58
Gear Tooth Nomenclature
• Addendum • Chordal Addendum
• Dedendum • Backlash
• Whole Depth • Fillet Radius
• Working Depth • Top Land
• Clearance • Bottom Land
• Circular Thickness • Circular Pitch
• Chordal Thickness • Tooth Flank
Addendum
59
Addendum
• Measured from;
– Pitch Circle
– Top of Tooth
• a = 1.0 / Pd
– Standard Tooth Proportions
Dedendum
60
Dedendum
• Measured from;
– Pitch Circle
– Root of Tooth
• b = 1.25 / Pd
– Standard Tooth Proportions
Whole Depth
61
Whole Depth
• Sum of;
– Addendum
– Dedendum
• Total Depth of Tooth
Working Depth
62
Working Depth
• Sum of;
– Addendum of Gear
– Addendum of Pinion
• Active Depth of Teeth
Clearance
63
Clearance
• Difference Between;
– Whole Depth
– Working Depth
• To Avoid Contact Between Top Land and

Root of Mate
Circular Thickness
64
Circular Thickness
• Arc Tooth Thickness on Pitch Line
Chordal Thickness
65
Circular Thickness
• Arc Tooth Thickness on Pitch Line
Chordal Thickness
• Length of Chord of Circular Thickness
• Used to Measure Tooth Thickness
– With Chordal Addendum
Chordal Addendum
66
Chordal Addendum
• Dimension from;
– Tip
– Center Span of Chordal Thickness
Backlash
67
Backlash
• Clearance Between Tooth Profiles
• Permits Smooth Operation
• Address Manufacturing Tolerance Stack
• Difference Between
– Circular Pitch
– Sum of Circular Thickness of
• Gear
• Pinion
Fillet Radius
136
68
Fillet Radius
• Stress Concentration Reduction
• Increases Tool Life
Top Land
138
69
Top Land
• Product of Tooth Thickness and Depth
• Minimum Required to Heat Treat
• Possibly Limits Strength Balance
Bottom Land
• Function of Point Width of Tool
Circular Pitch
140
70
Circular Pitch
• Sum of;
– Tooth Thickness of Pinion
– Tooth Thickness of Gear
– Backlash
• p = π / Pd
Gear Tooth Nomenclature

• Addendum • Chordal Addendum
• Dedendum • Backlash
• Whole Depth • Fillet Radius
• Working Depth • Top Land
• Clearance • Bottom Land
• Circular Thickness • Circular Pitch
• Chordal Thickness • Tooth Flank
71
Tooth Flank
143
Nomenclature of Gear Tooth Details
144
72
Gear Circle Nomenclature
Helical Gears
146
73
Involute Helicoid
• Paper Cut as Parallelogram Shape
Involute Helicoid
Cylinder
Axis
β
H
2πr
74
Involute Helicoid
• Wrapped Around Base Cylinder
Involute
Helicoid r
Helix
λ
Helix
Tangent
75
Involute Helicoid
• Unwrapped as to Generate Involute
Involute Helicoid
152
76
Involute Helicoid
• Unwrapped as to Generate Involute
• Paper Edge Defines Involute Helicoid
Involute Helicoid
154
77
Involute
Helicoid Involute
Curves
rb
Gear Contact Comparison

• Spur Gear
– Initially a Line
– Extends Across Entire Face
– Parallel to Axis of Rotation
• Helical Gear
– Initially a Point
– Becomes a Line as Teeth Engage
– Diagonal across Face of Tooth
78
Helical Gear Contact
• Gradual Engagement of Teeth
• Smooth Transfer of Load Tooth to Tooth
• Transmit Heavy Loads at High Speeds
• Contact Ratio
– Face Contact Ratio
– Transverse Contact Ratio
– Modified (Total Effective) Contact Ratio
Helical Gear
Involute Surface and
Line of Contact
Face Width
t
tac
Con
f
eo
Lin
Normal Length
Base Pitch of
Action
Base Helix
Angle
158
79
Helical Gear Nomenclature
• Hand of Helix • Transverse Pitch
• Helix Angle • Normal Pitch
• Lead Angle • Normal Pressure

Angle
• Lead
• Transverse
Pressure Angle

• Hand of Helix
80
Hand of Helix
Plane of Rotation
Pitch Cylinders
Lead Angle Helix
Contact Point
Axis
L.H.
R.H.
Lead – 6”
Lead – 12”

• Hand of Helix
• Helix Angle
81
Helix Angle
Plane of Rotation
Pitch Cylinders
Lead Angle Helix
Contact Point
Axis
L.H.
R.H.
Lead – 6”
Lead – 12”

• Hand of Helix
• Helix Angle
• Lead Angle
82
Lead Angle
Plane of Rotation
Pitch Cylinders
Lead Angle Helix
Contact Point
Axis
L.H.
R.H.
Lead – 6”
Lead – 12”

• Hand of Helix
• Helix Angle
• Lead Angle
• Lead
83
Lead
Plane of Rotation
Pitch Cylinders
Lead Angle Helix
Contact Point
Axis
L.H.
R.H.
Lead – 6”
Lead – 12”
Lead
Plane of Rotation
Pitch Cylinders
Lead Angle Helix
Contact Point
Axis
L.H.
R.H.
Lead – 6”
Lead – 12”
84
• Helix Angle
• Lead Angle
• Lead
Transverse
Pitch
85
• Lead Angle
• Lead
Normal
Pitch
86

Angle
• Lead
Normal
Pressure
Angle
87

Angle
• Lead
• Transverse
Pressure Angle
Transverse
Pressure
Angle
88
• Pitch Helix • Normal Helix
• Normal Plane • Transverse

Circular Pitch
• Transverse
Pressure Angle • Normal
Circular Pitch
• Normal
Pressure Angle

• Pitch Helix
89

• Pitch Helix
• Normal Plane
90

• Pitch Helix
• Normal Plane
• Transverse
Pressure Angle
91

• Pitch Helix
• Normal Plane
• Transverse
Pressure Angle
• Normal
Pressure Angle
92

• Normal Plane
• Transverse
Pressure Angle
• Normal
Pressure Angle
93


Circular Pitch
• Transverse
Pressure Angle
• Normal
Pressure Angle
94


Circular Pitch
• Transverse
Pressure Angle • Normal
Circular Pitch
• Normal
Pressure Angle
95
Internal & External Gears
96
Internal Gear Nomenclature
Bevel Gear Nomenclature

• Shaft Angle • Crown
• Pitch Angle • Pitch Apex
• Spiral Angle • Pitch Apex to Crown
• Face Angle • Outer Cone Distance
• Root Angle • Mean Cone Distance
• Back Angle
• Front Angle
97
Bevel Gear
Nomenclature
195
Bevel Gear
Nomenclature
196
98
Bevel Gear Nomenclature
See Nomenclature Listing in the Gear Handbook

by Darle Dudley 2nd Edition, Pg. 2.39, Table 2.7
Operating Dimensions
• Theoretical Center Distance
• Operating (Spread) Center Distance
• Operating Pitch Diameter of;
– Pinion
– Gear
• Theoretical Pressure Angle

• Operating Pressure Angle
99
Center Distance
C
d
Theoretical Center Distance

C = d + D
Theo.
2.0
Where: C is the Theoretical Operating Center Distance
d is the Pitch Diameter of the Pinion
D is the Pitch Diameter of the Gear
100
Operating (Spread) Center Distance
• Common Practice:
– Increase Center Distance Slightly
– Increases Operating Pressure Angle;
• If Operating Center Distance is 1.7116% Larger Operating
Pressure Angle will be 22.5 deg.s
Using 20 deg. Hobs
– Make use of available Tooling

• Hobs
• Cutters
• Shapers
Operating Pitch Diameters

d = 2.0 * C D = mG * d
Oper. Oper.
mG + 1.0
Where: dOper. is the Operating Pitch Diameter of the Pinion
DOper. is the Operating Pitch Diameter of the Gear
C is the Theoretical Operating Center Distance

mG is the Ratio;
Gear Teeth / Pinion Teeth
101
Theoretical Pressure Angle
• Given by Design
• Pressure Angle of Cutting Tool
• Angle Between Plane Normal to Pitch

Surface and Normal to Tooth Surface at
Pitch Point
Pressure Angle
Pitch
Base Circles
Circles
φ
Pressure
Angle
Pitch
Points
102
Operating Pressure Angle
φ = cos-1 (cos φ Theo.)
Oper.
m`
Where: φ is the Pressure Angle

m` is the Spread Ratio;
Operating Pitch Diameter / Theoretical Pitch Diameter
Gear Geometry & Nomenclature

• Principle Planes
• Blank Nomenclature
• Gear Nomenclature
• Tooth Nomenclature
103
Principle Planes
• Normal Plane
– Normal to the tooth at the pitch point
– Normal to the pitch plane
Principle Planes
Spur Gears
104
Principle Planes
• Normal Plane
– Normal to the tooth at the pitch point
– Normal to the pitch plane
• Transverse Plane
– Plane perpendicular to both the axial and the
pitch planes
Principle Planes
Helical Gears
105
Basic Rack
• What is the Basic Rack
• How is it used to
– Define Gears
– Design gears
– Design Cutters / Tools
– Why would one use it
Basic Rack
• As the Pitch Circle increases in size,
approaching infinite, it becomes a Rack
• Circle with an Infinite Radius is a Plane
106
Principle Planes
Helical Gears
Basic Rack
• As the Pitch Circle increases in size,
approaching infinite, it becomes a Rack
• Circle with an Infinite Radius is a Plane
• Pitch Surface becomes a Plane

– Which has Transnational Motion
– While Rolling with the Pitch Cylinder of its
Mate
107
Function of a Rack
• A Rack is the Basic Member for a Family
of Gears Conjugate to it
• Two Basic Racks are Complimentary if;

– They can be fitted together face-to-face
– With coincident pitch & tooth surfaces
Interchangeable Gears
• Basis for Interchangeability is that the
Basic Member be Complimentary to Itself
108
Design of Gear Cutting Tools
• Hob design derived from the theory of
Basic Rack
• Hobs have Straight Cutting Sides
• Hob Representing the Basic Rack
– Rolls with the Work Piece
– Through a specific Relationship of Motion
– Such that it Generates the Involute Profile
• Motion is both relative Rotation and Translation
Interchangeable Gears
• Basis for Interchangeability is that the
Basic Member be Complimentary to Itself
109
Fillet Curve
• Shape is a Trochoid
– Generated by Radius at Corner of Hob / Tool
– May be Produced With a Protuberance Hob
• Provides Greater Clearance for Shaving / Grinding
Definition of a Trochoid
• Generally -- Trochoid is any curve that is
the locus of a point fixed to a curve A,
while A rolls on another curve B
without slipping
• Specifically -- Trochoid is defined as the

trace of a point, fixed on a circle,
that rolls along a line
110
Definition of a Trochoid
• Generally -- Trochoid is any curve that is the locus
of a point fixed to a curve A, while A rolls on
another curve B without slipping
• Specifically -- Trochoid is defined as the trace of a

point, fixed on a circle, that rolls along a line
Standard AGMA & ANSI Tooth Systems

for Spur Gears
Design Item Coarse Pitch Fine Pitch
[up to 20P full depth] [20P and up full depth]
Pressure Angle φ 20 o
25 o
20o
Addendum a 1.000 / P 1.000 / P
Dedendum b 1.250 / P 1.200 / P + 0.002
Working Depth hk 2.000 / P 2.000 / P
Whole Depth (minimum) ht 2.250 / P 2.200 / P + 0.002
Circular Tooth Thickness t π / (2 * P) 1.5708 / P
Fillet Radius rf 0.300 / P Not Standardized
(of Basic Rack)
Basic Clearance (minimum) c 0.250 / P 0.200 / P + 0.002

Clearance rf 0.350 / P 0.350 / P + 0.002
(Shaved or Ground Teeth)
Minimum Number of Pinion Teeth 18 12 18

Minimum Number of Teeth per Pair 36 24 36
Minimum Top Land Width to 0.25 / P Not Standardized
111
Gear Pair Action
• Principle Plane
• Line of Action
• Surface of Action
• Sliding
Velocity Ratio
• Ratio of the Pitch Diameters
• Ratio of Tooth Numbers
• Ratio of Base Circle Diameter
112
Pitch Surfaces
• Imaginary Planes, Cylinders or Cones that
roll together without slipping
• The Pitch Surfaces are:

– Planes for the Basic Rack
– Cylinders for Spur and Helical gears
– Cones for Bevel Gears
– Hyperboloids for Hypoid Gears
Parallel Axis Pitch Surfaces

Pitch
Plane
X1
Pitch
Element
X2
Pitch
Cylinders
113
Principle Planes
Bevel Gears
Intersecting Axis Pitch Surfaces

Pitch
X1 Plane
Pitch
Element
Pitch
Cones
X2 228
114
Hyperboloid Pitch Surfaces
229
Gear Tooth Pitch Point

Dedendum Circle
Pitch Circle
Base Circle
Involute
Addendum
Circles
Involute
Pitch
Circle
Base
Circle
Dedendum
Circle
115
Line of Action
231
Line of Action
– The path of action for involute gears
• The Line of Action is

– The path the contact point between teeth follows
while in contact during mesh
• It is the Straight Line passing through the Pitch

Point
– Tangent to base circles of the two mating gears
– Intersection of base circles defines the Pitch Point
116
Surface of Action
• Point of Contact is Actually a Line
– Called the Line of Contact
Surface of Action
117
Surface of Action
• Point of Contact is Actually a Line
– Called the Line of Contact
• As Conjugate Action Progresses

– Line of contact describes surface in space
– Defined as the Surface of Action
Surface
of Action
118
Sliding
• Efficiency Factor Due to Frictional Loss
• Failure Mechanism:
– Wear / Scoring / Scuffing
– Heat Generation
– Lubricant Film Breakdown
• Two Types:
– Profile
– Length-Wise
Profile Sliding
• Due to the constant change in radius of
involute relative to each gear (as they are
in mesh)
• The point of instantaneous contact on one

member must slide relative to the other
119
Length-Wise
• Sliding along the face length of the tooth
• Basic gear tooth geometry similar to screw

thread action
Length-Wise
120
Length-Wise
Contact Lines As
Helix Tangents
Base Cylinder
Helix
Sliding Direction
• Spur Profile only
• Helical Profile only
• Bevel Profile only
• Cross-Helicals Both
• Spiroids Both
• Hypoids Both
• Worm Gears Length-Wise only
121
Preliminary Design Considerations
• Gear Type Selection
• Preliminary Estimate of Size
• Stress Formulations
• Gear Drawing Data
Gear Type Selection

• Why would I select a Spur Gear
– Simplest Gear Form
– Lower Cost
– Lower Thrust Load
• Why would I select a Helical Gear

– Greater Load Carrying Capacity
– Quieter and Smoother Operation
– More Uniform Motion Transmission
122
Gear Type Selection
• Why would I select a Bevel Gear
– Transmit Power Through an Angle
• Non-Parallel Shaft Axes
Gear Type Selection

• Why would I select a Straight Bevel
– Lower Cost
– Lower Thrust Load
– Simplest Design
• Why would I select a Spiral Bevel

– Longer Effective Face Width
– Greater Contact Ratio
• For Same Packaging
123
Gear Type Selection
• Why would I select a Hypoid Gear
– Transmit Power Through an Angle
– Transmit Power with Off-set Shafts
• Straddle Mount Both Members
• Clearance Design Considerations
• Alignment Design Considerations
Gear Type Selection

• Why would I select a Spiroid Gear /
Helicon
– High Number of Teeth in Contact
– High Ratios Achieved (Dudley pg. 2-13)
• Why would I select a Worm Gear

– Very High Ratios
– Very High Contact
124
Other Types of Gears
• Skew Bevel Gears
• Face Gears
• Beveloid Gears
• Cross Axis Helical Gears
• Herringbone Gears
Other Types of Gears

• Worm Gearing
– Cylindrical
– Single - Enveloping
– Double - Enveloping
125
Gear Meshing Possibilities
Type Pinion Pinion
Of Pinion Pinion and Inter- One Pinion of 16
Gear and and Internal change- Tooth of 5 or
Teeth Gear rack Gear ability Pinion Teeth More
Teeth
Spur Yes Yes Yes Yes No No* Yes
Helical Yes Yes Yes No No* No* Yes
Straight Bevel Yes No* No No* No No* Yes
Zerol Bevel Yes No No No No No* Yes
Spiral Bevel Yes No No No No* No* Yes
Hypoid Yes No No No Yes Yes Yes
Gear Meshing Possibilities

Type Pinion Pinion
Of Pinion Pinion and Inter- One Pinion of 16
Gear and and Internal change- Tooth of 5 or
Teeth Gear rack Gear ability Pinion Teeth More
Teeth
Face Gear Yes No No No No No* Yes
Crossed Helical Yes Yes No Yes Yes Yes Yes
Single-enveloping Yes No* No* No Yes Yes No*

Worm
Double- Yes No No No Yes Yes No*
enveloping Worm
Beveloid Yes Yes No Yes No No* Yes
Spiroid Yes No No No Yes Yes No*
126
How to Obtain Ratios
Kind of Arrangement Minimum Number of Ratio Range

Toothed Parts
5:1 50:1 100:1
Single Reduction: 2
Spur 2 Yes No No
Helical 2 Yes No No
Bevel 2 Yes No No
Hypoid 2 Yes Yes Yes
Face 2 Yes No No
Worm 2 Yes Yes Yes
Spiroid 2 No Yes Yes
Planoid 2 Yes No No
Simple Eplicyclic 3 Yes No No
General Design Procedure

for Parallel Axis Gears
127
Gear Design Methodology
• Synthetic K Factor Method
• Proportional to Hertzian Contact Stress
– Based on Roller Bearing Analysis
• Used to Estimate Preliminary Gear Size

• Based on Application and Material
Synthetic K Factor Method

• Synthetic K Factor
K = Wt * ( mG + 1 )
d*F mG
– Where;
– K = 1.5 to 1000 based on Material and Application
– WT = Tangential Driving Load (Wt = 2 * TP / d)
– D = Pinion Pitch Diameter
– F = Face Width
– mG = Ratio (NG / NP)
128
K Factor by Application
• Automotive Transmission
– Steel, 58 HRC…………………………… K = 1.5
• General Purpose Industrial Drive
– Steel 575 BHN / Steel 575 BHN...……. K = 800
• Small Commercial
– Steel 350 BHN / Phenolic……………… K = 75
• Small Gadget
– Steel 200 BHN / Zinc…………………… K = 25
• Small Gadget
– Steel 200 BHN / Brass or Aluminum…. K = 25
Procedure
• For a Given Application
• Assume a K Factor From;
– Use Table 2.15
– On Pg. 2.45
– “Handbook of Practical Gear Design” by
Darle Dudley
129
Derive Base Equation
• Solving for the Face Width and Pinion
Diameter, as one term;
d*F = Wt * ( mG + 1 )
K mG
Best Practices
• Good Practice;
– The Ratio “F / d” Should Not Exceed 1.0
• F – Face Width
• d – Diameter of the smallest diameter member
– If F / d > 1.0, Then;

• The effect of shaft deflection must be checked
• As it affects effective face width
130
General Design Procedure
for Parallel Axis Gears
• Compare Calculated Face Width, F to;
– Packaging Requirements
– Manufacturability Issues
– Iterate As Required
• Procedure to Calculate Center Distance

– More Involved
– Requires More Iterations
Next Step
• Once Diameter, Face Width are Selected
• With Given Ratio, mG
• Use Chart to Select Initial Number of Pinion

Teeth
131
Pinion Tooth Number Guideline
NPmax
NP / NG
Stress Formulations
• The Synthetic K Factor Method Provides
Preliminary Sizing
• Next Step is to Calculate Bending and
Contact Stress
• Surface Durability
– Approximately 120 to 150 (ksi)
• Dudley Pg.s 13.17 thru 13.24
• Bending
– Approximately 35 to 50 (ksi)
• Dudley Pg.s 13.28 thru 13.38
132
General Survey of Power and Efficiency
Kind of Arrangement Nominal Typical Efficiency, %
Maximum
5:1 50:1 100:1
kW (hp) Ratio Ratio Ratio
Single Reduction:
Spur 2,240 (3,000) 98
Helical 22,400 (30,000) 98
Straight Bevel 370 (500) 98
Zerol bevel 745 (1,000) 98
Spiral Bevel 3,730 (5,000) 98
Hypoid 745 (1,000) 95 80 60
Crossed Helical 75 (100) 95 80 60
Cylindrical Worm 560 (750) 95 80 60
Double-enveloping Worm 745 (1,000) 95 80 60
Gearbox Relative Size and Weight
Ratio Range
Kind of Arrangement 5:1 20:1 50:1 100:1
Single Reduction:
Spur, Helical, Bevel Small
Worm Small Small Small
Hypoid Small Small Small Small
Spiroid Small Small Small
Planoid Small
133
Gearbox Relative Size and Weight
Ratio Range
Kind of Arrangement 5:1 20:1 50:1 100:1
Double Reduction:
Single Power Path, Helical Gears Medium
Size
Multiple Power Path, Helical Gears Small Very
Small
Epicyclic Gears:
Simple Planetary Very

Small
Compound Planetary Very
Small
Double-reduction Planetary Very Very
Small Small
Compound Gear Train

• N – Number of Teeth
• n – Rotational Speed
– Note: Gears 4 & 5 Rotate at Same Speed
• Final Speed;
n6 = N2 N3 N5 n2 (rpm)
N3 N4 N6
134
Gear Arrangements
• Simple Gear Train
• Compound Gear Train
– Ratios
• Epicyclic
– Configurations (Solar, Planetary, Star)
– Ratios
– Tooth Number Selection and Build
Requirements
– Application
Planetaries
135
Epicyclical Trains
• Sun Gear • Single / Simple
• Several Planet Epicyclic Trains
Pinions – Planetary
• Ring Gear – Star
– Solar
• Planet-Pinion Carrier
• Compound Epicyclic
• Input & Output Shafts
– Planetary
– Star
– Solar
Simple Epicyclical Trains
Ring Gear
Sun Gear
Planet
Carrier
Planet Pinion
136
Epicyclic Geartrain
Planetary Configuration
Fixed Annulus Planet Wheels

or Rotate About
Ring Gear Spindles
Planet
Carrier
Sun Gear
Epicyclic Geartrain
Star Configuration
Planets
Rotate on Spindles
Rotating
Annulus Rotating
Sun Gear
Fixed
Planet Carrier
137
Epicyclic Geartrain
Solar Configuration
Planets
Rotate on Spindles
Rotating
Fixed
Planet Carrier
Sun Gear
Rotating
Annulus
Simple Epicyclical Train

Ratio Ranges
• Planetary
– 3:1 to 12:1
• Star
– 2:1 to 11:1
• Solar
– 1.2:1 to 1.7:1
138
Ratio Equations
Revolution of
Operational
Sun Carrier Ring
Condition
Sun Fixed 0 1 1 + N s / Nr
Carrier Fixed 1 0 - N s / Nr
Ring Fixed 1 + N r / Ns 1 0

Build Requirements
• Nr -- Number of Ring Gear Teeth

• Ns -- Number of Sun Gear Teeth
• q -- Number of Planet Gears
• (Nr + Ns) / q Must Equal an Integer
139
Compound Planetary Gear
Fixed Annulus
Planet Gear or Ring Gear
Housing
Sun Gear
Rotating Carrier
Rotating Carrier
Compound Star Gear

Rotating Annulus
Star Gear or Ring Gear
Housing
Sun Gear
Rotating Carrier Fixed Carrier
Star Pinion
140
Compound Epicyclical Train
Ratio Ranges
• Planetary
– 6:1 to 25:1
• Star
– 5:1 to 24:1
• Solar
– 1.05:1 to 2.20:1

Ratio Equations
Revolution of
Operational
Sun Carrier Ring
Condition
1 + Ns * Npr
Sun Fixed 0 1
Nps * Nr
- Ns * Npr
Carrier Fixed 1 0
Nps * Nr
1 + Nps * Nr
Ring Fixed 1 0
Ns * Npr
141
Build Requirements
• Nr -- Number of Ring Gear Teeth

• Ns -- Number of Sun Gear Teeth
• q -- Number of Planet Gears
• Npr -- Number of Planet Gear Teeth in
contact with the Ring Gear
• Nps -- Number of Planet Gear Teeth in
contact with the Sun Gear
• (Nr * Nps - Ns * Npr ) / q
Must Equal an Integer
Epicyclical Design
Considerations
• Load Share Between Planets

• High Planet Pin Bearing Loads
• Rotating Balance of Planet Carrier
• Complicated Assembly
• More Sensitive to Debris Entrainment
• More Lubrication Required
142
Two Common
Compound Epicyclical
• Ravigneaux -- Planetary
– Two Separate Sun Gears
– Two Sets of Planet Gears
– One Planet Carrier
Ravigneaux
Short Long
Planet Gear Planet Gear
Reverse
Sun Gear
Forward (Input)
Sun Gear
Ring Gear
Rear View (Output)
143
Ravigneaux
Long
Ring Gear
Planet Gears
Planet Carrier Input
Reverse
Forward Sun Gear
Sun Gear
Short
Planet Gear
Rear
Facing
Output
Two Common
• Ravigneaux -- Planetary
– Two Separate Sun Gears
– Two Sets of Planet Gears
– One Planet Carrier
• Simpson -- Planetary
– Two Separate Ring Gears
– Two Separate Planet Carriers
– One Common Sun Gear
144
Simpson
Thrust Front Rear Planet Rear Annulus

Washer Annulus Driving Shell Gear Assembly Gear
Sun Gear
Front
Planet
Gear
Low & Reverse

Drum
Drive Shell
Input
Shell Snap Ring
Thrust
Washer
Sun
Gear
Snap
Ring
145
Gear Selection Considerations
• NVH -- Noise, Vibration & Harshness
• Durability
• Power Density
• Support Requirements
• Lubrication
NVH
• Helical;
– Smoother Operation
– Quieter
• Tooth Contact Ratio;
– Axial Contact ratio
– Transverse Contact Ratio
• Spur Gears;
– Only Transverse of 1.2 to 1.5 Typical
146
Durability
• Bending Stresses & Contact Stresses
Should be Balanced for Application
• Helical will be Smaller than Spur
• Carburized or Carbo-Nitrided
• Surface Finish Key Control
Power Density
• Helical Planetaries Provide Highest PD
• Spur Gears Lowest Cost / Lowest PD
• Helical are More Expensive to Mfg.
• Helical Gears Require More Expensive
Support
• Helical Require Better Control of Mounting
and Positioning
147
Support
• Helical Gears Require Axial & Radial Thrust
• Spurs Only Radial
• Double Helical Gears Produce Only Radial
• Very Expensive to Manufacture
• Spur Gears Most Tolerant of Misalignment
Lubrication
• All Gear Teeth Require Lubricant Flow
• Pressure Lubrication;
– 20% - 30% Incoming Mesh (lubrication)
– 70% - 80% Output Mesh (cooling)
• Splash or Dip Method;

– Case Design to Provide Adequate Supply
• Forced Lubrication;
– Shaft Design to Put Lubrication where Needed
148
Lubricant Cooling
• Internal Lubricant Circulation
• Convective Air-Cooling In-Situ
• Natural Flow Exchange
• Forced Cooling
– Radiator
– Circulation Pump
Drawing Information
• Gear Data Tabular Information
• Gear Measurement & Inspection
• Tolerances
– Spur
– Helical
– Bevel
• Straight
• Spiral
149
300
150
Lead Tolerance Chart
Lead Tolerance Data
151
Tooth Profile Crown Note
304
152
Gear Measurement and Inspection
Tooth Thickness
• Gear Tooth Caliper
• Pin Diameter
• Dimension Over Pins
• Modify Pin Diameter and Dimension
Over Pins
• Pin Contact Point
• Span Measurement
153
Drawing Information
• Gear Data Tabular Information
• Gear Measurement & Inspection

Tooth Thickness Caliper Setting
for chordal
Pitch Check
tooth thickness
Involute
Test
Diameter
Over Pins
Concentricity
360
o Runout Taken
with a Ball
Number of Teeth Checker
154
Tooth Chordal Dimensions
Addendum Chordal Addendum
Arc Chordal
Thickness Thicknes
(t) s
(tc)
Gear Tooth
Caliper
310
155
Gear Tooth Caliper
• Used to Measure Gear Tooth Thickness
• At Pitch Line
• Affected by Gear Diameter Variance
– Undersize Blank
• Measure Too Large
– Oversize Blank
• Measure Too Small
• Technique Sensitive
Measurement Over Pins

• Most Accurate Method
• Not Affected by;

– Blank Dimensional Variances
– OD Run Out
• Affected by;
– Tooth Spacing Errors
– Profile Errors
156
Measurement Over Pins
• Helical Gears
– Use Balls or Dumbbell Pins
– Due to Curvature of Tooth Space
– Critical for Odd Number of Teeth
• Method for Parallel Axis Gears Only
Measurement
Over Pins
157
Pin Sizes Used to Check the Tooth Thickness of Spur Gears
Type of Tooth Pressure Angle Pin Diameter

Constant
External, standard or near 14 ½ to 25o 1.728
standard proportions
1.920
1.680
External, long-addendum 14 ½ to 25o 1.920

pinion design
Internal, standard designs 14 ½ to 25o 1.680

1.440
Calculate Dimension Over Pins

• For Standard Pin Diameter
• External Spur Gears
• Even Tooth Numbers
– Dudley Practical, Pg. 9.21 – Table &
Method
• Odd Tooth Numbers

Method
158
• Internal Spur Gears
Method

Method
Pin Contact Point

• Tangent Point of contact between pin and
tooth, must be on tooth
• Outside edge of pin must be beyond the
tooth OD
• Inner edge of pin must not contact root
• Pin should contact tooth at or above the
middle of the tooth height
159
• External Helical Gears
Method

Method

• Internal Helical Gears
Method

Method
160
Span Measurement
Block Measurement of Gear Teeth
M = 3 Pb + tP
BC
• Pb – Normal Base Pitch

• tP – Circular Tooth Thickness at Base Circle
BC
Where;
tP = B *ν (for spur gears)
BC
tP = B *ν* sin (θn) (for helical gears)
BC
sin (θt)
ν = tP + Inv (θt)
t
PD
161
• Involute Chart
• Lead Chart
• Red Liner Chart
Involute Chart
o o o
o 6 12 18
0
162
Involute
Chart
Involute Measurement
• Measure of Gear Tooth Profile
• Rolling Gear on Base Circle
• Produces Contact Traces of Profile
• Relation Between Roll Angle / Profile
• Variations in Tooth Geometry
– Deviations from Straight Line on Chart
• Run Out / Gear Wobble Effect Trace
• Measure at Several Axial Positions
163
Involute Measurement Results
True Involute
True Profile
Actual Involute
Form Diameter
“V” Type Chart 0

Theoretical
or
True
Involute
+5 -5
Acceptable
Involute
Profiles
164
Equivalent Band Chart 0
-5
True
Involute
Acceptable
Involute
Profiles
-5
329
0
“K” Type Chart

-5
20% of
Total -5
Roll Angle
165
Modified “K” Chart -3 -8
With Tip OD 1
and
Flank Relief 2
PD 3
TIF 5
-3 -8

Minus Pressure Angle
True Involute
Actual Profile
Actual Involute
Form Diameter
166
Plus Pressure Angle
True Involute Actual Profile

Actual Involute
Form Diameter

Undercut & Tip Chamfer
True Involute
Actual Involute
Actual Profile
Form Diameter
167
• Involute Chart
• Lead Chart
Lead
• Axial Advance of a Helix for One Complete
Turn
168
Lead
Plane of Rotation
Pitch Cylinders
Lead Angle Helix
Contact Point
Axis
L.H.
R.H.
Lead – 6”
Lead – 12”
Lead
• Axial Advance of a Helix for One Complete
Turn
• Lead Tolerance
– Is the total allowable lead variation
• Lead Variation
– Is measured in the Direction Normal to the
Specified Lead of the Gear
169
Lead Chart
• Lead
– Usually Specified Between Points
– Represent 85% of Face Width
• Teeth are Often Chamfered

– Points A & D
Lead Chart
Good Profile
340
170
Lead Chart
Acceptable Profile
341
Lead Chart
Concave Profile
342
171
Lead Chart
Profile with
Protuberance
Lead Chart
Profile with
Protuberance
172
Lead Chart
Profile
Outside Gauge
Lead Chart
• Lead
– Usually Specified Between Points
– Represent 85% of Face Width
• Teeth are Often Chamfered

– Points A & D
• Crest of Crown
– Specifies Position Along Tooth
– Differing Based on Design & Application
173
Crown Tolerance
Crown Tolerance
348
174
Long & Short Lead
Lead of Crowned Teeth
Spur Helical
Gear Gear
175
Lead of Tapered Teeth
Spur Helical
Gear Gear
Lead & Involute Error

Causes
• Machine Setup
• Machine Capability & Condition
• Condition of Work Holding Equipment
• Die Wear / Dull Tooling
• Handling
• Heat Treat Changes
176
• Involute Chart
• Lead Chart
• Red Liner Chart
Red Liner
• Double Flank Tester
• Master Gear
177
Red Liner
Schematic of Gear Rolling Device
Red Liner
• Master Gear
• Motion of Center of Test Gear
– Recorded (Trace)
– During Roll with Master
178
Red Liner
Typical Chart
357
Red Liner
• Master Gear
• Motion of Center of Test Gear
– Recorded (Trace)
– During Roll with Master
• Measures Variation of Test Gear
– Composite Test & Master Gear Error
– Master Variation Assumed to be Negligible
179
Red Liner Data
• Total Composite Error
Red Liner
Typical Chart
360
180
Red Liner Data
• Tooth to Tooth Composite Error
• Tooth to Tooth Error
Red Liner
Typical Chart
362
181
Red Liner Data
• Tooth to Tooth Composite Error
• Tooth to Tooth Error
• Runout
Red Liner
Typical Chart
364
182
Red Liner Limitations
• Test Run with Zero Backlash
– Not at Operating Pitch Diameter
• Test Run with No-Load

• Both Flanks are Engaged
• Can Not Differentiate Between
– Involute Errors
– Lead Errors
– Profile Modification Errors
– Combination of Errors
Single Flank Gear Tester

• Measures Similar Parameters
– With Backlash
– On Operating Pitch Diameters
183
Schematic
367

• Measures Similar Parameters
– With Backlash
– On Operating Pitch Diameters
• Measures Transmission Error
• More Accurate Representation of Error
184
CMM
• Index Variation
• Lead Variation
• Involute Variation
• Topological Plots
• Generates Surface of Actual Tooth Form
Topological Plot
of a Gear Tooth
Surface from an
Automated CMM
370
185
Gear Design Systems and Best
Practices
• Common Proportions
• Interchangeability
• Tooling Considerations
• Mounting Considerations
• Application
This Is The Slide We’ve

Been Looking For
• Questions ?
• Did I Meet Your
Expectations ?
• Comments ?
• Suggestions ?
• Thanks !
186
Gear Seminar Reference List
1. “Gear Handbook” by Darle W. Dudley. First Edition, McGraw-Hill, Inc. 1962.
2. “Dudley’s Gear Handbook, Second Edition” by Dennis P. Townsend. McGraw-Hill, Inc. 1992.
(ISBN: 0-07-017903-4)
3. “Spur Gears” by Earle Buckingham. First Edition, McGraw-Hill, Inc. 1928.

4. “Handbook of Practical Gear Design” by Darle W. Dudley. First Edition, Technomic Publication,
Inc. 1994. (ISBN: 1-56676-218-9)
5. “A Treatise of Gear Wheels” by George B. Grant. Twenty-First Edition, Philadelphia GEAR
Works Inc. 1899. Reprinted 1980.
6. “Gear Geometry and Applied Theory” by Faydor Litvin. First Ed, Prentice-Hall, Inc. 1994.
(ISBN: 0-13-211095-4)
7. “The Internal Gear”, by The Fellows Corporation. Seventh Ed, Fellows Corporation. 1978.
8. “Encyclopedic Dictionary of Gears and Gearing” by D.W. South and R.H. Ewert. McGraw-Hill,
Inc., New York, New York. 1994. (ISBN: 0-07-059795-0)
9. “MAAG Gear Book” by MAAG Gear Company Ltd. 1990.
10.“Gleason Fachworter” by The Gleason Works. Alfred Wentzky & Co. 1967.

1. “Mechanical Engineers Reference Handbook” by Edward H. Smith. Twelfth Edition, Society of
Automotive Engineers, Inc. 1994. (ISBN: 1-56091-450-5)
2. “Machinery’s Handbook” by Erik Oberg, Franklin Jones, and Holbrook Horton. Twenty-third
Edition, Industrial Press, Inc. 1914. Revised 1989. (ISBN: 0-8311-1200-X)
3. “Engineering Unit Conversions” by Micheal Lindeburg. Professional Publications, Inc. 1988.
(ISBN: 0-932276-89-X)
4. “Mechanics of Materials” by E. P. Popov. Second Edition, Prentice-Hall, Inc. 1976.

5. “Formulas for Stress and Strain” by Raymond Roark and Warren Young. Fifth Edition, McGraw-
Hill, Inc. 1975. (ISBN: 0-07-053031-9)
6. “Mechanical Engineering Design” by Joseph Shigley. Third Edition, McGraw-Hill, Inc. 1977.
(ISBN: 0-07-056881-2)
7. “Mechanical Designs and Systems Handbook”, by Harold Rothbart. Second Edition, McGraw-
Hill Inc. 1985. (ISBN: 0-07-054020-9)
8. “Mark’s Standard Handbook for Mechanical Engineers ” by Eugene Avallone and Theodore
Baumeister. McGraw-Hill Inc. 1978. (ISBN:0-07-004127-X)
187
9. “Rules of Thumb for Mechanical Engineers” by J. Edward Pope. Gulf Publishing Company.
1997.
10.“Mechanisms and Mechanical Devices Sourcebook” by Nicholas Chironis and Neil Sclater.
Second Edition, McGraw-Hill, Inc. 1996. (ISBN: 0-07-011256-4)
11. “Stress Concentration Factors” by R. E. Peterson. John Wiley and Sons, Inc. 1974.
188

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Who Should Attend

More specifically, anyone responsible for the following will benefit:

• Mechanical power transmission system design, development, durability assessment

• Gear System Design Process

Instructor(s): W. Mark McVea

William M. McVea, Ph.D., P.E.

• Gear Geometry, Development and Layout

• Ask Lots of Questions

• Common Gear Tooth Forms

• Gear Tooth Action

• The normals of these teeth at all points of

Length ‘A’ = Length ‘B’

Intersection Point Between

Intersection Point Between

Length ‘A’ > Length ‘B’

Length ‘A’ > Length ‘B’

• A profile of two mating members that when

• A profile of two mating members that

• The output motion exactly matches

• Basic Definitions and Terms

– Straight Bevel – Hypoid

One Revolution of Driver

One Revolution of Driver 56

• Basic Definitions and Terms

Common Profile Curves

• Infinite Number of Shapes that Produce

• Pitch Diameter of Gear

• Base Circle Diameter of Gear

Gear Layout Nomenclature

• 40 Teeth Minimum in Pair Desired

• Minimum Number of Pinion Teeth

19 No undercutting with 20o standard-addendum design

35 Strength may be more critical than wear on hard steels—about even on

50 Probably critical on strength on all but low-hardness pinions. Excellent wear

Numbers of Teeth in Pinion and Gear vs. Pressure

Minimum Number of Pinion Teeth vs. Pressure Angle

Min. No. of Teeth to Avoid Undercut

Ratio Selection Considerations

• Why Not To Use A Hunting Tooth Ratio

• Involute Tooth Profile is Generated

• Pitch Circle Diameter –

• The Line of Action

• Straight Line Passing Through Pitch Point

• The Line of Action

• Straight Line Passing Through Pitch Point

• Ratio - Teeth Number : Pitch Diameter

• English Only Concept

• Pb is the Circumference of the Base Circle

• Any two gears with the same Base Pitch

• Start of Active Profile

• Length of Tooth Profile

• Length of Line of Action / Circular Pitch *

• Total Depth of Tooth

• Active Depth of Teeth

• To Avoid Contact Between Top Land and

• Increases Tool Life

Gear Tooth Nomenclature

Nomenclature of Gear Tooth Details