Spur gears

1. Planes in helical gear, fig 1

1.1 Transverse plane: Plane normal to the axis of rotation, i.e. it is the
plane of gear rotation. All parameters with suffix “t” are considered in this
plane.
1.2 Normal plane: Plane normal to the gear tooth surface, oriented by the
helix angle relative to the transverse plane. All parameters with suffix “n”
are considered in this plane.

Fig 1: planes

1.3 Axial plane: Plane normal to the transverse plane and containing the
axis of rotation. All parameters with suffix “a” are considered in this plane.

In case of Spur gear, the transverse plane will be Normal plane.:

• β=0,
• All parameters will not have suffix.

2. Terminology,

2.1 Angular parameters

Helix angle “β” : It is the inclination of the projected tooth in plan view to the axis
of rotation. For Spur gear “β” = 0 .
Pressure angle “ψ” : It is The angle between the pressure line and common tangent
to the pitch circle. It exists between the tooth profile and a radial line to its pitch
point.

Tooth and space angle (circular pitch angle) “Ө”, fig 2 : It is the included angle
at the gear center of a tooth with the space. Ө = 360 / z (1)
Note: z is the number of teeth

Tooth angle “q”, fig 2 : It is the included angle at the gear center of a tooth without
the space. q = (2 * p) / D (2)
Note: p is the circular tooth thickness at the reference circle.
D is the radius of the reference circle.

Fig 2

2.2 Radial parameters, fig 3

Normal module (m) : It is the ratio between D and z in the normal plane.
m=D/z (3)

Radial clearance (Tip to root clearance) “c” : the radial distance between the tip
circle of one gear and the root circle of the meshed gear along the center line. In
DIN standard; c = 0.25 * m (4)
Addendum “ha” : The radial distance between the tip circle and the reference
circle in one side. For unmodified gear :
ha = m (5)
Dedendum “hd” : The radial distance between the reference circle and the root
circle in one side. For unmodified gear :
hd = m + c (6)

Pitch Circle Diameter (Reference diameter) “D” : The diameter of the circle
which is divided into two equal arcs one in metal and the other in the space.
D=m*z (7)

Outer Diameter (Tip diameter) “Do” : The diameter of the circle which passes by
the crest of the gear teeth. For unmodified gear :
Do = D + 2 * h a (8)

Base Diameter (Base diameter) “Db” : The diameter of the circle which the
involute was drawn from. . For unmodified gear :
Db = D * cos ψ (9)

Root Diameter (Root diameter) “Dr” : The circle which passes by the roots of the
gear teeth. . For unmodified gear :
Dr = D - 2 * h d (10)

Bore Diameter (Bore diameter) “Ds” : The diameter of the shaft or the hole
which the teeth will be fixed on.

Tooth depth (Tooth height) “h” : The radial distance between the tip circle and
the root circle in one side.
h = ha + hd (11)
Center distance “a” : the distance between the center lines of the shafts of the two
meshed gears. If D1 and D2 are the reference circle diameters of the two meshed
gears, then:
a = (D1 + D2) / 2 (12)
 Fig 3: terminology

Chordal height at reference circle “hc” : the depth of the chord from the tip. The
chord is the linear thickness of the tooth at the reference circle. For unmodified gear
hc = m + (D / 2) {(1 – cos(q / 2)) (13)

Constant chordal height “hcc” : the depth of the chord that joints the intersection
of two tangents to the base circle to the two side flanks. . For unmodified gear :
hcc = m * {1 –( π * cosψ * sinψ) /4} (14)

Fig 4
2.3 circumferential parameters
Tooth thickness “Sty” , fig 4 : the circular tooth thickness at depth “y” from the
tip. If y = 0 , it is the thickness of the tooth at tip circle. If y = h , then it is the
thickness of the tooth at root circle, and so on. At the reference circle it is “St”.
St = (π * m) / 2) – b (15)

Circular pitch “p” : It is the arc length of both the tooth and space at the reference
circle.
P=π*m (16)

Chordal tooth thickness “Wc” : It is the chord length of the tooth thickness at the
reference circle. For unmodified gear:
Wc = D * sin(q/2) (17)
Constant chordal tooth thickness “Wcc” : : the length of the chord that joints the
intersections of the two tangents of the base circle and the two side flanks. . For
unmodified gear :
Wcc = (π * m / 2) * cos2 ψ (18)

Base pitch “pb” : It is the arc length of both the tooth and space at the base circle.
It may also defined as the normal distance between two corresponding involutes on
two successive teeth.
Pb = π * m * cosψ (19)

Span length “L” : This is the linear dimension measured over “n” number of
teeth. (neglecting the circumferential backlash)
L = m * z * cosψ *{tanψ – ψ + π / (2*z) + (π * n) / z} (20)
If circumferential backlash is considered, then:
L = m * z * cosψ *{tanψ – ψ + π / (2*z) + (π * n) / z}- b * cos ψ (21)

Circumferential Backlash “b” : The difference between the tooth thickness of the
gear and its space thickness. It may be taken roughly as:
b = 0.06 * m (22)
2.4 Axial parameter
Gear width “B” : the width of the gear.

2.5 Form Parameters

2.51 Involute profile
2.52 undercut at root
2.53 tip relief at tip

3. Gear tolerances
The following tables are only a guide.
3.1 tolerances on profile for gears having grade 4 to 8
Accuracy Class or Grade of Gear Profile Tolerance in Microns
4 4.0+0.25xk
5 5.0+0.40xk
6 6.3+0.63xk
7 8.0+1.0xk
8 10+1.6xk
Here k is a tolerance factor and is given by k = m + 0.1 D

Where m is module, and D is the pitch circle diameter in mm.

3.2 Tolerances on adjacent circular pitch error for gears having grade 4 to 8
Class Permissible Error in Microns
4 3.2+0.25F
5 5.0+0.40F
 6 8.0+0.63F
7 11+0.90F
8 16+1.25F

Class or Grade Permissible Error in Microns

4 0.900 F+ 11
5 1.4 F + 18
6 2.24 F + 28
7 3.15 F + 40
8 4.0 F + 50
Here F = m + 0.25 D
Where D, is the pitch circle diameter

3.3 Tolerances on composite errors for gears having grade 4 to 8

Class or grade of gear Total composite error Tooth or tooth compos
in Microus errors in Microns
4 16+1.25F 6+0.45F
5 25+2.0F 9+0.56F
6 40+3.2F 12+0.90F
7 56+4.5F 16+1.25F
8 71+5.6F 22+1.8F
Here factor F = M + 0.25 D
 Answer the following questions

1. Describe the different methods used to measure the chordal thickness of a spur
gear? Is this chord is the same value for different gears having the same
module but with different number of teeth? Verify your answer by calculating
the chord thickness for two gears with 4 mm module but with 30 and 80 teeth
respectively?

2. Describe the different methods used to measure the chordal thickness of a spur
gear? Is this chord is the same value for different gears having the same
module but with different numb2er of teeth? Verify your answer by
calculating the chord thickness for two gears with 4 mm module but with 30
and 80 teeth respectively?

3. Describe the different methods used to measure the base pitch of a spur gear?

4. In measuring the cumulative pitch error the following readings were taken
over a gear having 20 teeth, 4 m(0.01mm)m module and 20̊ pressure angle. If
the gear grade is 7, is this gear is accepted ?
Tooth no. 1 2 3 4 5 6 7 8 9 10 11
Reading 0 2.5 6 8 11 13 14 14.5 15 16.5 17.5
(x 0.01mm)

Tooth no. 12 13 14 15 16 17 18 19 20 1
Reading 18.5 21 22 23 26 28 31 36 37.5 38
(x 0.01mm)

Pitch measuring Instrument

5. Deduce that the Maximum chord (Span length) of a standard spur gear is:
z. m. cos ψ (tan ψ - ψ - (  / 2. z) + (  . n / z)
z is the number of gear teeth
n is the number of measured teeth
ψ is the pressure angle

6. A spur gear having 32 teeth, 4 mm module, 20 degree pressure angle and a

circumferential backlash of 0.091 mm, calculate:-
i. The axial shift of the cutter to produce the backlash
ii. The maximum chord
iii. The chordal thickness and chordal height

7 a) What is meant by the best pin or ball when measuring gears?

b) derive the equation of the best pin over a spur gear ? What will be the size over
this plug?
c) What would be the reading if the pins used were the best and the gear is having
31 teeth, 3 module and 20 pressure angle?

8. a) State the equations of the size over any pins over a spur gear?
b) What would be the reading if the pins used were bigger than the best size by 0.758
mm for the same gear in question number 2?

9. a) State the measurement over pins in case of helical gear with even number of
teeth.
b) State why in case of helical gear with odd nmber of teeth the two pins is not
accepted?
10. For a spur gear having 200 pressure angle, 36 teeth and 4 mm module, calculate:
a) Plug diameter.
b) Distance over plugs in opposite sides.
c) Distance over plugs if spaced 12 teeth apart.

11. Calculate the length of base tangent over two teeth for a helical gear having 30
mm gear width, 10 teeth, 300 helix angle, 200 pressure angle and 4 mm module.

12. Determine the chordal and the constant chordal thickness for a gear having 45
teeth and 4 mm module.

13. what is the difference between the tooth angle for a gear with 4 mm module
and 40 teeth if the circumferential backlash is considered.