EVALUATING

THE UNKNOWN
GEOMETRY OF
HIGH
ACCURACY
GEARING

40     gearsolutions.com
Finding the addendum modification coefficient using the
base tangent length (BTL) method is found to be useful
for gear parameter evaluation of an unknown gear.
By PRASMIT KUMAR NAYAK, A. VELAYUDHAM and C. CHANDRASEKARAN

E
valuation of geometry of used and broken gear parts. Suitable algorithms have been developed for
is a seldom practice followed in the fields such extracting and inspecting the mechanical component.
as maintenance repair and recycling. Although Data have been extracted from the image and used
gear  calculations and main parameters are to construct a 3D model and 2D drawing. It has been
standardized, this task can be complicated, espe- observed that the detecting of straight lines, holes,
cially when there is no information about mating and circles are faster and more reliable. However, the
gear and gearbox assembly, change in the accuracy accuracy of extracted data from the images are very
of used gears due to heavy wear, and sometimes the important for reproducing the component. Charles
gear geometry probably is non-standard. Such situa- D. Schultz, 2010, has brought out a methodology for
tion calls for effective and accurate methods of gear the reliable measurement, evaluation, re-design, and
profile geometry evaluation. Different methods like manufacture of replacement parts for gear boxes and
reverse engineering, iterative process, and analytical industrial machinery.
methods are being followed in gear industries. In the estimation of gear tooth geometry, profile
Apart from these, a diverse number of CNC gear shift/modification factor is an imaginary parameter
generative testing equipment and coordinate mea- used to represent the thickness of gear tooth. Negative
suring machines are available profile shift leads to smaller tooth
in the industry to inspect the thickness and tip diameter and
gears using fully automated Gear modifications positive profile shift corresponds
gear measurement cycles. But in
these advanced gear-measuring
are carried out by to the larger tooth thickness and
tip diameter. It is to be noted that
machines, the profile of the tooth
can be checked and compared
different means profile shift, real tooth thick-
ness, and real tip diameter may
with a flank topography refer- and each would not match precisely, due to vari-

influence different
ence, and by means of a trial-and ous design and technological con-
error procedure, it is possible to siderations. Therefore final draw-
obtain an approximate geometry
of the analyzed gears [Kumar,
parameters. ings of spare parts must contain
tooth thickness and tip diameter
2014]. Moreover, some advanced based  on direct measurements
measurement machines have incorporated special pro- and calculations of meshing quality (interference,
grams for measuring gears with unknown parameters undercut, overlap, minimum tooth thickness at the
and determining some important data of the basic tip circle of a gear, etc.).
gear geometry [Grimsley, 2003]. Unfortunately, these Of the above methods, the analytical method is
machines are costly and often inaccessible to the com- more accurate, scientific, and does not involve com-
pany or factory involved with gear remanufacturing. plex measurements and iterations. Hence, the main
Because of this, several researchers [Innocenti, 2007; focus of this paper is to investigate the used and
Belarifi et al, 2008; and Schultz, 2010] have proposed broken spur gear of a CNC machining center spindle
alternative procedures to determine the unknown gearbox and estimate the basic gear parameters using
gear geometry. standard measuring instruments followed by the use
Gonzalez et al, 2016, have proposed a procedure to of analytical gear equations as given in DIN 3960 and
obtain the fundamental gear parameters using con- graphical construction. Typically, the evaluation of
ventional measurement tools. In their approach, it is gears used in the old gearbox of a CNC machining
assumed that the involute surface of the flank of a center, implies challenges to the engineers, since the
cylindrical gear can give information about the basic gears used would be of higher accuracy, and the back-
gear tooth data needed to determine the unknown lash would be minimum. In general CNC machine tool
gear geometry. Jadhav and Sandooja, 2012, have adopt- manufacturers use modified gears.
ed a step wise analytical approach to find out the basic Gear modifications are carried out by different
gear parameters for an unknown gear pair, which means and each would influence different parame-
eliminated frequent trial and errors, iterations, and ters. Both the gear and pinion can be provided positive
complex measurements. Alshennawy, 2014, has adopt- or negative correction. Gears are usually modified to
ed a machine vision system coupled with CCD camera avoid undercutting or to maintain a desired center
as a reverse-engineering tool for developing gear spare distance in a gear box. In addition to that, the gear
June 2018     41
 Theform
the module is anchart
of flow important parameter
in Figure 3. Withinreferencedefining to theDIN
size3960.
of gear tooth. It cannot
measured directly from the gear, but can be calculated using equations of base tan
Module
Module
As per DIN 3960, the expression for finding the base tangent length is mentioned
The module is an important parameter in defining the size of gear tooth. It cannot
The module
(1) and is an important
(2). Using these twoparameter
equations,inthe defining the size
expressions forofmodule
gear tooth.
can beIt obtaine
cannot
and pinion are now positively corrected to achieve several benefi- measured
length. directly
As(3)perandDIN from
3960,the
the gear, but can be
expression for calculated
finding using equations of base tan
measured
equation directly from
(4). the
Further gear,
the but can be
equation (3) and (4) the
calculated base
using
are tangent
equations
combined andofa base
singletan
e
As per DIN 3960, the in expression for(1)finding theUsing
base tangent length is mentioned
cial effects. These positively corrected gears have better strength at As per DIN
is derived
length to3960,
find out
is mentioned the the
expression
standardfor
equation finding
module. and (2). the baseangle
Pressure tangent
these length
is two
also an is mentioned
unknown
equa- par
(1) and (2). Using these two equations, the expressions for module can be obtained
the root and the flank of the tooth. Due to positive correction, the (1)
tions,andthe
standard (2). Using angles
pressure
expressions thesefortwo
and equations,
the themodule
measured the
can expressions
base tangentfor
be obtained module
lengths
as arecan
equation be obtained
substituted in
equation (3) and (4). Further the equation (3) and (4) are combined and a single eq
tooth thickness at the root increases, thereby resulting in greater equation
and
(3) the
and (3)Further,
(4). andstandard
nearest (4).equations
Further
modulethe(3)equation
is derived.
and (4) (3)
are and (4) are combined
combined, and a and a single eq
single
is derived to find out the standard module. Pressure angle is also an unknown para
load carrying capacity. In case of a corrected profile, the active pro- is derived (7)
equation to find out the to
is derived standardout module. Pressure angle is also an unknown para
standard pressure angles andfind the measured the standard
base tangentmodule.
lengths Pressure
are substituted in
files formed from the involute curve are generated from the same standard
angle pressure
is nearest
also anstandardangles and
unknown parameter.the measured base tangent lengths
The standard pressure angles are substituted in
and the [(𝑘𝑘 − 0.5module
) 𝜋𝜋 + 𝑍𝑍is derived.
𝑊𝑊"#the
and = nearest
𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐standard module is# 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋# 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠-----------------
derived. (1)
base circle, but this time a different portion of the curve, which is and the measured base tangent lengths are substituted in equation
farther away from the base circle. The main advantage of these gears 𝑊𝑊
(7),"< = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 [( 𝑘𝑘 − 0.5
and the nearest standard module ) 𝜋𝜋 + 𝑍𝑍< 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 ] + 2 𝑋𝑋
is derived. < 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠---------------- (2)
with an involute profile is that even at an extended center distance, 𝑊𝑊"# = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍# 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋# 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠----------------- (1)
𝑊𝑊"# = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍# 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋# 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠----------------- Equation 1 (1)
and the
it continues to follow gear
the law of tooth also
conjugate does
action andnot become
continues to significantly
𝑊𝑊 =
weak.
𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
This correction is used
[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍< 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 ] + 2 𝑋𝑋< 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠---------------- (2)
where,
𝑊𝑊 "<
"< = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍< 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 ] + 2 𝑋𝑋< 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠---------------- Equation 2 (2)
transform uniformin the casevelocity
angular whereratio.
the reduction ratio is very large.
In another type of correction, the mating pair of gears receives 𝑊𝑊"# - Actual base tangent length of gear over 𝑘𝑘# no. of teeth
where,
Wwhere,
equal correction factors, but these two
Description of component factors are algebraically of 𝑊𝑊k1"<–- Actual
where, Actual base tangentlength
base tangent length ofofpinion
gear over
over 𝑘𝑘k<1 no.
no. of
of teeth
teeth
opposite signs. Normally, the pinion and gear are provided with posi- W𝑊𝑊k2 -
– Actual
Actual base
base tangent
tangent
=>? @=>?A? length
lengthof gear
of over
pinion over
𝑘𝑘 no. of
k 2 teeth
no. of teeth
𝑊𝑊"# - Actual
𝑚𝑚# = base tangent length of gear over 𝑘𝑘#
no. of teeth
-------------------------------------------- (3)
There
tive and negative correction, was a Inrequirement
respectively. to reverse
this case, the center dis- "#
engineer, reproduce
BCDEF and replace #
𝑊𝑊"< - Actual base tangent length of pinion over 𝑘𝑘< no. of teeth a
tance remains unaltered, it remains the same. Thicker 𝑊𝑊"< - Actual
=>G @=base tangent length of pinion over 𝑘𝑘< no. of teeth
broken gear component of an pinion teeth
old gearbox of
𝑚𝑚< a = typical >GA?horizontal
=>? @=>?A? CNC Machining
-----------------------------------------------------
Equation 3 (4)
are ensured, and the gear tooth also does not become significantly 𝑚𝑚B CDEF
= = @= -------------------------------------------- (3)
andcentre.
the gear tooth also does
A schematic of the notgear
become pair significantly
is illustrated 𝑚𝑚#weak.
#
=in Fig.
>?
This
BCDEF
BCDEF <1.correction
>?A?
The is used
machine was
-------------------------------------------- (3)
weak. This correction is used in the case where the reduction ratio = @=
manufactured
case whereinthethe year 1983 ratioand no large.
spare𝑚𝑚# < =
=was
=>G @=>?
= H@=
>?A?
available ---------------------------------------------------
I -----------------------------------------------------
as the machine tool (5)
is very large.in the reduction is very (4)
>GA?
𝑚𝑚 BCDEF Equation 4
𝑚𝑚<< = >GB CDEF >GA?
----------------------------------------------------- (4)
manufacturer closed down their company, thus necessitating B CDEF
@=J
G
< the proposed study.
Assume
𝑚𝑚 <
= H𝑚𝑚
=>? ?
= >?A? --------------------------------------------
Equation 5
---------------------------------------------------
I< axis (6)
(5)
DESCRIPTION OF COMPONENT
The centreofdistance
Description component between axis of the gear𝑚𝑚#broken # <
= H and BCDEF the
=>?@=J >?A?
G of mating gear is
I --------------------------------------------------- (5)
BCDEF
205 ±0.036
There was a requirement mmengineer,
to reverse as shown in Fig.and
reproduce, 1. replace Assume 𝑚𝑚 = J G
? Equation 6
-------------------------------------------- (6)
There was a requirement to reverse
a broken gear component of an old gearbox of a typical horizontal engineer,
Assume
[INSERT𝑚𝑚FIGURE
reproduce
J?G
= JG 3] and replace a
-------------------------------------------- (6)
JG
CNC machiningbroken gear
center. component
A schematic of the of
gearan old
pair gearbox of Then
is illustrated a typical horizontal (=>? @=>?A?)G
CNC Machining
Then 𝑚𝑚 in = (= Equation 7
------------------------------------------------------
centre.
in Figure 1. The A schematic
machine of the
was manufactured gearandpair
in 1983 is illustrated
no spare
[INSERT FIGURE Fig.
>G @= 1.
3]
>GA?
The
) BCDEF machine was
was available as the machine tool manufacturer closed down the
manufactured in the year 1983 and no spare was available [INSERT FIGURE 3]as the machine tool
(=>? @=>?A?)G
company, thus necessitating the proposed study. The center distance [INSERT
ThenFrom 𝑚𝑚 = TABLE
Table
2,>? 2]
it@=is observed
G that for pressure angle of 20 degrees,
------------------------------------------------------
manufacturer closed down their company, thus Then
the
necessitating
𝑚𝑚 = (=
difference
(=
>G @=>GA?
between
the
>?A?) proposed
calculated
study.
) BCDEF ------------------------------------------------------
andpressure
standard modules
between axis of the gear broken and the axis of the mating gear is From the Table>G2, it>GA? is observed that for of 20°, isthemini-
is angle difference betw
(= @= ) BCDEF
The centre distance between axis of the gear broken
mum. and
Hence, the
it is axis
verified of mating
that the gear
pressure angle and
205, ±0.036 mm as shown in Figure 1. calculated
[INSERT TABLE 2] and standard modules is minimum. Hence it isthe module
verified ofthe pressur
that
205 ±0.036viewmm asbroken
shown in is
Fig. 1. in Figure both [INSERT gear TABLE
and 2] are 20 degrees and 3.5 mm respectively.
The photographic of the gear shown the module of pinion
both gear and pinion are 20° and 3.5 mm respectively.
From the Table 2, it is observed that for pressure angle of 20°, the difference betw
2.The basic data of the gear pair are mea- From the Table 2, it is observed that for pressure angle of 20°, the difference betw
Addendum
calculated andModification
standard modulesCoefficient
is minimum. Hence it is verified that the pressure
sured using standard measuring instru- calculated and standard modules
the module of both gear ADDENDUM
and pinion are MODIFICATION
is minimum.
20°
Hence it is verified that the pressure
andmodule,
3.5 mm respectively.
ments as seen in Table 1. The common data After
the finding
module of the
bothvalues of pressure
COEFFICIENT
gear and pinion are angle
20°and
and 3.5 mm pitch circle diameters are c
respectively.
that can be directly measured are number using
Addendumstandard formula.
Modification The center
Coefficient
After finding distance
the is
valuesequal
of to half
the of theangle
pressure sum of referenc
Addendum Modification Coefficient
From the calculations it is found that the center distance is 199.5 mm. If it is less
of teeth, tip diameter, and root diameter for After finding the values of and pressure
module, angle andcircle
pitch module, pitch circle
diameters arediameters
cal- are c
After finding
than the the values
measured value,ofthere
pressure angle and
is a positive ormodule,
negativepitch circle on
correction diameters
either orare
botc
both the gear and pinion. The base tangent using standard formula. The center
culated distance
using is equal
standard to half of
formula. Thethecenter
sum of referenc
using standard
and pinion. formula.
In the case ofThe center correction,
positive distance is gears
equal are
to half of the
pulled apartsum byofanreferenc
amount
length across a fixed number of teeth (num- From the calculations it is found that
distance the center
is equal to halfdistance
of theis 199.5of mm. If it is less o
From
times the calculations
module. In this it is foundhigher
condition that theamount
center distance
of backlash issum
199.5
usually refer-
mm. If it isTheref
results. less o
ber of teeth to be obtained using DIN 3960) than the measured value, there is a positive or negative correction on either or both
than the measured value,ence therediameters.
is a positiveFrom the calculations,
or negative correction on it either
is or both
and pinion. In the case offound positive correction, gears are pulled apartmm.by an amount
was measured using a flange micrometer. and pinion. In the case of positive thatcorrection,
the center gears are pulled
distance apart by an amount
is 199.5
times module. In this condition higher amount of backlash usually results. Therefo
The module of an unknown gear cannot times module. In this condition higher
If it is less amount
or more thanof backlash
the measuredusually results. Therefo
value,
be measured directly. It can be derived from there is a positive or negative correction on
Fig. 1. Schematic of gearbox
base tangent length. In the case of a correct- either or both the gear and pinion. In the
The photographic view of the broken gear is shown in Fig.
ed gear, the profile modification factor is to case2.The basiccorrection,
of positive data of gears are pulled
be derived. This factor is found out from the apart by an amount ‘X1+ X2’ times module. In
the gear pair are measured utilizing standard measuring instruments are given in
measured base tangent length. It is also relat- this condition, a higher amount of backlash
ed to the centerTable.
distance1.between
The common
the gear data which can be directly measured areusually number of teeth,
results. Therefore, tip to minimize the
diameter and root
pair. An alternative method is also adopted diameter for both the gear and pinion. The base tangent length
backlash, the gear pairs are brought closer
across
to find the profile a fixedfrom
modification number
the tip of teeth
Figure 1:(number
Schematic ofof teeth to be obtained using
gearbox. DIN 3960) was
to an intermediate value (center distance
diameter of the gear and the pinion. Fig. 1. Schematic of gearbox modification coefficients, ‘y’ to get a new
center distance.)
METHODOLOGY OF GEAR
The photographic view of the broken gear is shown in Fig. 2.The basic
For the data gear
modified of pair, the center dis-
GEOMETRYthe EVALUATION
gear pair are measured utilizing standard measuring instruments are given in of pitch circle radii
tance is equal to the sum
The procedure Broken teeth
Table.finding
for 1. Theout the profile
common data which can be directly measured are number of gear and of pinion
teeth,and tipthe sum of the center
modification factor and other data is illus- distance modification coefficient times the
diameter and root diameter for both the gear and pinion. The base tangent length
trated in Figure 3, with reference to DIN module. The center distance coefficient ‘y,’
3960. across a fixed number of teeth (number of teeth to be obtained using DIN pressure
working 3960) was angle (αw), and the sum of
modification coefficients, X1+ X2 (theoretical
MODULE value) are calculated using equations (8) to
The module is an important parameter in (10) as per DIN 3960.
defining the size of a gear tooth. It cannot be To derive the modification coefficient,
Broken teeth
measured directly from the gear but can be different methodologies are available. But,
calculated using equations of base tangent Fig.2 Photographic
Figure view
2: Photographic view of broken
of broken gear. gear since the study involves remanufacturing of
42     gearsolutions.com
 @# CDEF CDEF
between the gear pair. An alternative method is also adopted to find the 𝛼𝛼profile
P = 𝛼𝛼
cos
P = T T XGU
cosGU@#O# X -------------------------------------
-------------------------------------(9) (9)
modification from the tip diameter of the gear and the pinion. V? WVG V? WVGO#
Table 1 Data measured from gear pair (YZ[FM @YZ[F)
(YZ[F @YZ[F)
𝑋𝑋# + 𝑋𝑋𝑋𝑋
< #=+ 𝑋𝑋<< \LZF
= M
𝑍𝑍< )# + ------------------------------------
(𝑍𝑍# + (𝑍𝑍 -
𝑍𝑍< ) ------------------------------------ -(10) (10)
Parameter Gear Pinion ADDENDUM< \LZF
MODIFICATION COEFFICIENT
No. of teeth 𝑍𝑍 59 55 USING THE BTL METHOD
Across 8 teeth - 82.73 Across 7 teeth - 71.41Addendum
UsingModification
Addendum Coefficient
Modification
the equations (1) and (2),Using
Coefficient the BTL
Using
modification Method
the BTL Method
coefficients (X1, X2 ) are
Base tangent length (mm) 𝑊𝑊$
Across 9 teeth - 93.06 Across 8 teeth - 81.76 obtained
Tip Diameter (mm) 𝑑𝑑& 219.35 201.6
Using the
Using the from
equations (1)the
equations measured
and(1)(2)and BTL value.
modification The measured
coefficients
(2) modification (X1, X2(X
coefficients BTL
) are
1, X
values from th
obtained
2) are obtained f
and
measured calculated
BTL value. values
The of modification
measured BTL coefficients
values and (X
calculated
measured BTL value. The measured BTL values and calculated ,
1 2 X )
valuesareofgiven
modification
values of modi
Root Diameter (mm) 𝑑𝑑' 203.6 186
(BCD EBCDFD)L
in Table
coefficients X2)(Xare
(X1,3.*
coefficients given
1, X 2) arein Table
given in 3.
Table 3.
= (B ------------------------------------------------------
Diameter over pin (Ø 7mm) 𝑑𝑑' 223.36 207.61 (7)
[INSERT TABLE 3]
CLFD ) GHIJK
CL EBCentre [INSERT TABLE 3]
distance (mm) 𝑎𝑎) 205 ADDENDUM MODIFICATION COEFFICIENT
Methodology of gear geometry evaluation Addendum
USINGModification Coefficient
THEModification
Addendum TIP DIAMETER Using the
METHOD
Coefficient Tipthe
Using Diameter Method
Tip Diameter Method
Table 1:
Addendum Table
Data
modification 2.
measured Calculated
from
coefficient using values
gear pair. of module
BTL method Usingis the equations (11)(11)
and (12) modification coefficients (X1, X2)(X
(Xare
The procedure for finding out the profile modification factor and other data Using
Using equations
the equations and
(11) and(12),
(12)modification
modificationcoefficients
coefficients Xobtained
1,, X 2 )) are from
are obtaine
illustrated
Using in theequations
the form of flow
(1)chart
and in(2)Fig. 3. With reference
modification to DIN (X
coefficients 3960.
1, X2) are measured
obtained Tip
measured
obtaineddiameter
Tip
from value.
diameter
the The
measured measured
value. The
tip Tip diameter
measured
diameter Tip
value. values
diameter
The and
values
measuredcalculated
and tip value
calculated
from the measured Pressure
BTL value. The measured BTLDifference
values and calculated modification
valuesdiameter
of coefficients
modification X2)(Xare
(X1,calculated
coefficients
values and given
1, X 2) arein Table
given
values of in 4.
Table 4.
modification coefficients
ModuleSerial Module
modification moduleangle
Thecoefficients
is an , 'α'in
X2) are given
(X1important in Table
parameter (calculated
3.
in defining the size ofand
gear tooth. It (X1, X2 ) are given in Table 4.
cannotNo. directly from the'm' mm
Table 3 degree
be measured
Calculation gear, but can standard
of modification be calculated module)
coefficient based using
on BTL equations of
𝑑𝑑L# =𝑍𝑍𝑑𝑑# 𝑚𝑚+(1#+ 𝑦𝑦(− 𝑋𝑋<𝑦𝑦)𝑚𝑚
− 𝑋𝑋< )𝑚𝑚 ----------------------------------------- (11
base tangent length. As per DIN 3960, the expression for finding the base tangent L# =𝑍𝑍 𝑚𝑚+ 1+ -----------------------------------------
Equation 11
length is 1mentioned 17.5
in equation 3.4410
(1) and (2).
Base Tangent length Using these0.0590
two equations, the (1<+
𝑑𝑑L< =𝑍𝑍𝑑𝑑< 𝑚𝑚+=𝑍𝑍 𝑦𝑦(−
𝑚𝑚+ +#𝑦𝑦)𝑚𝑚
1 𝑋𝑋 − 𝑋𝑋# )𝑚𝑚 ----------------------------------------- (12
-----------------------------------------
Equation 12
expressions for module can be obtained as equation (3) and (4). Further the L<
Addendum 2
modification 20
coefficient
equation (3) and (4) are combined 3.4924
using
Measured BTL
value
and a single method 0.0076
Modification
equation co-efficient
(7) is derived to find out the
Gear VALIDATION OF ADDENDUM MODIFICATION
standard module. Pressure angle is modification
also an unknown parameter. The standard
Using 3 9 teeth)22.5
the
(across equations (1) and
pressure angles and the measured𝑊𝑊base
(2)3.5521
$* =93.06 𝑋𝑋*0.0521
coefficients
tangent lengths are
(X 1, X 2) are[INSERT
obtained TABLETABLE
[INSERT
substituted in equation COEFFICIENT
= 0.9728 4] 4]
from the measured BTL value. The measured BTL values and calculated values of
(7) andPinion
the nearest standard
(across 8
Table coefficients
2: It is here observed
module is derived. Validation of
Validation Addendum
of Addendum
The modification Modification Coefficient
Modification
coefficients Coefficient
obtained from the two different
modification (X1, X2that
) arefor
𝑊𝑊 pressure
given
$A angle of
in Table
=81.76 3. 20°, the 𝑋𝑋A difference
= 0.6509 between
teeth)
calculated and standard
𝑊𝑊$* = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 modules
− 0.5) 𝜋𝜋 + is
𝑍𝑍*minimum.
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋* 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠----------------- (1) The modification coefficients
methodologies are
The modification obtained
verified fromanother
through
coefficients obtainedthe twothe
from different
method methodologies
called
two different diameterare verif
methodologies ar
e Table 2, Table it is3 Calculation
observedof that modification for pressure
coefficient based angle of 20°,
on BTL the
through thedifference
ofanother method
gear called diameter
and pinion over the of the gear and pinion
recommended rollerover the recommended
through another method called diameter of the gear and pinion over the recomm
pin diameter.
𝑊𝑊$A = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍A 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋A 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠------------------ (2)
calculated and standard
Addendum modification modules
Base
coefficient using is
Tangent Tip minimum.
length
diameter method Hence it pin is verified
diameter.
The that
The
measured the
measured
pin diameter. The value
and and
measured
value the
value
the calculated
and valueare
the calculated
calculated value are compared.
value The
The calculat
are compared.
compared. The c
where, values are obtained by using the equations (13) to (22) and tabulated in Table
in 5.
angle Using
and the theequations
module(11)of both
and (12)value
Measured
gear and
modification
Modification
pinion
coefficients are 20° and
values 3.5
are
calculated
(X1, X2) are
co-efficient
mm
obtained
values by using the equations (13) to (22) and tabulated
are obtained by using equations (13) to (22) and Table 5
𝑊𝑊$* - Actual base tangent length of gear over 𝑘𝑘* no. of teeth
ely.
obtainedGear
from the measured Tip diameter value. The measured Tip diameter values
𝑊𝑊 - Actual base tangent length of pinion over 𝑘𝑘 no. of teeth
tabulated in Table 5.
(across
$A
and calculated 9 teeth)
values of modification coefficients
𝑊𝑊$* A
=93.06 (X1, X 2) are given in Table 4
𝑋𝑋* = 0.9728 BJ BJ Equation 13
BCD EBCDFD
------------------------------------------------ (3) 𝑆𝑆# = 𝑆𝑆# +
= 2 𝑋𝑋
< #+𝑚𝑚 2 𝑋𝑋
tan#𝛼𝛼𝑚𝑚 tan 𝛼𝛼 ------------------------- (13
-----------------------
um modification
𝑚𝑚* = GHIJK
𝑑𝑑 Pinion
=𝑍𝑍 𝑚𝑚+(1
coefficient
(across
+ 𝑦𝑦 8
− 𝑋𝑋 )𝑚𝑚 𝑊𝑊 =81.76------------------ 𝑋𝑋 -----------------------
= 0.6509 (11)
<
&* * A $A A
teeth)
𝑚𝑚𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼
BCL EBh
iCLFD
A = A =G HIJK + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 +
kL
−
G
------------------------------------------------ (4)
-----------------------------------(16) BJ
𝑆𝑆< = < + 2 𝑋𝑋< 𝑚𝑚 tan 𝛼𝛼 Equation 14
------------------------- (14
ter finding
𝑑𝑑&A =𝑍𝑍 the values
A 𝑚𝑚+(1 + 𝑦𝑦 − 𝑋𝑋of
hjL
* )𝑚𝑚pressure angle
hL UL
and module,
---------------------- pitch (12)
------------------- circle diameters
Table 3: =Calculation
B mno of modification
EBKCDFD A coefficient based--------------------------------
on BTL.
ulated using
Addendum 𝑚𝑚𝑑𝑑*l*
Table
A
standard
= 𝑚𝑚𝑍𝑍
M *CDmno
4 Calculation
modification Nformula. The centre distance
of---------------------------------------------------
modification
KD coefficient
GHIJK using coefficient
Tip based
diameter is (5)equal
on Tip diameter
method
(17) to half
𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼# = of
cd
ce?
the
+
f
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + ? −
c?
B
N?
-------------------------
Equation 15 (15
eferenceAssume diameters.
Using 𝑑𝑑lA𝑚𝑚 ==𝑚𝑚𝑍𝑍
L
O mno K
D
the Oequations
* mno K
From theTip
(11) and
calculations
diameter
(12) modification
it is coefficients
found that
------------------------------------------------------ (6)the
--------------------------------
(X1(18)
centre distance
, X2) are c f B Equation 16
L L 𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼< = d + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + G − ------------------------- (16
mm. If itfrom
obtained is, less
the measured orqr more than the
Tip diameter measured
value. The measured value, there values
Tip diameter is a positive ceG or cG NG
𝑑𝑑l* = 𝑑𝑑* cos MU N --------------------------------- (19)
correction
and calculated onvalues either or Measured
of modification
D
both coefficients
thevaluegear(Xand pinion.
Modification
1, X2) are inInTable
co-efficient
given the4 case 𝑑𝑑g#of positive
= 𝑚𝑚𝑍𝑍
hij F
# hij F
Equation 17
------------------------- (17
?
n, gears are pulled + 𝑦𝑦MU−N𝑋𝑋apartA )𝑚𝑚 𝑑𝑑&*by an amount 1+X2' times
'𝑋𝑋*X----------------------- module. In hij this
, qr
𝑑𝑑lA
𝑑𝑑&* =𝑍𝑍 =Gear
* 𝑚𝑚+ (𝑑𝑑1A cos = 219.35 --------------------------------
------------------ = 0.9714 (20)(11) F
L
𝑑𝑑g< = 𝑚𝑚𝑍𝑍# Equation 18
------------------------- (18
higher𝑑𝑑&Aamount
=𝑍𝑍
𝑀𝑀&*A 𝑚𝑚+
Pinion
,
= (𝑑𝑑1l* ++of𝑦𝑦 𝑑𝑑−s backlash
𝑋𝑋* )𝑚𝑚 𝑑𝑑&A = 201.6usually----------------------
results. Therefore,
------------------- to
----------------------------------(21)
𝑋𝑋A = 0.7356 (12)minimize the
hij FG

, the gear Table

pairs 𝑑𝑑lA , are brought closer to an intermediate value (centre
𝑀𝑀&A 4=Calculation + 𝑑𝑑s of modification coefficient----------------------------------(22)
based on Tip diameter
𝑑𝑑g# = distance
,
𝑑𝑑# cos H I
lm
N?
Equation 19
------------------------- (19
ion coefficients,
Table 4: Calculation ‘y' to ofget a new
modification centre
coefficient distance.
based
Table 5 Values obtained for verification using Pin over diameter
on tip diameter.
, lm
Equation 20
Tip diameter
Validation of addendum modification co-efficient 𝑑𝑑g< = 𝑑𝑑< cos H I ------------------------- (20
NG
or the modified gear
The1 modification
2 pair,3Atheobtained
coefficients centre distance
3B from is equal
the twoDifference
different to the 𝑀𝑀
methodologies sum= of , pitch
𝑑𝑑g# + 𝑑𝑑o ------------------------- (21
Measured value Modification co-efficient L# Equation 21
dii of gear and pinion
are verified through another and value
method
Calculated the over
called sum pins of the centre distance modification
diameter of the gear and pinion over the
,
recommendedGear roller pin diameter. The measured value and 𝑋𝑋* the calculated value are 𝑀𝑀L< = 𝑑𝑑g< + 𝑑𝑑o -------------------------
Equation 22 (22
nt times
compared.
theThemodule.
minimize
Measured
the
calculated
value
The
backlash, the
Using
values
centre
𝑑𝑑&* = 219.35
gear pairs distance
are brought
Using
are obtained
coefficient
by usingcloser
= 0.9714 'y',
to an intermediate
the equations
working
(13) to (22)
pressure
value (center
w) and
andtabulated
the
distancesum of 5modification
inmodification
Table.
Pinion
coefficients,
Coefficients ‘y’
coefficients,
to get a(2)
Coefficients newandcenter
𝑋𝑋AX 1+X2 (theoretical value) are
(3A) distance.
(2) and (3B).
Table𝑑𝑑&A
3 = 201.6Table 4
= 0.7356 RESULTS AND DISCUSSION
d using𝑆𝑆For
equations [INSERT TABLE 5]
2 𝑋𝑋 (8)
𝑚𝑚 tanto (10)theascenter
per DIN 3960.
the
GO modified gear pair, distance is equal to the sum of pitch circle
Fromradii
Tableof 5,
gear
it can be seen that the sum of the differences DxG and
= +223.360
*Gear 𝛼𝛼223.864 223.845 -----------------------------------(13)
∆S*t = 0.504 ∆SAt = 0.485
and pinion
A and* the sum of the center distance modification coefficientResults
times the
andmodule. The
DxP areDiscussion
minimum in the case of Dx1G and Dx1P. Thus the profile modi-
o derive𝑆𝑆center
Validation the
Pinion
ofGOdistance
addendum coefficient
modification
207.610 ‘y,’ working
coefficient,
207.921
modification
A = A + 2 𝑋𝑋A 𝑚𝑚 tan 𝛼𝛼
pressure
208.452
co-efficient ∆S*uangle
different= 0.311(αw)∆and
methodologiesthe sum of modification
SAu = 0.842 are
-----------------------------------(14)
From the
available.
fication
table itcoefficients
can be seenobtained through
that the sum of thethe BTL method
differences are ∆closer
∆ and aretominimum
coefficients, X1+X2 (theoretical value) are calculated using equations (8) to (10) as per DIN qr qs
e the study
The3960. involves
modification
hi
remanufacturing
Sumcoefficients
of differencesobtained from
kD G
of the used
0.815 one, 1.327
two different it methodologies
is proposed
case ofthe to follow
and ∆
measured
∆q#r q#s . Thus the profile modification coefficients obtained through BT
value.
𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼 = + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + − -----------------------------------(15)
hods which
are verified
To
*
Tablederive
5:
use
through the
hjD another
thepin
Values
measurement
modification
obtained
method
hD
coefficient,
for verification
of existing
UD called diameter
usingdifferent
pin over
of the gear component.
methodologies
diameter.
and pinionmethod overIn
are available.
the
arethis
Thecloser
gearstudy,
toand
But, since the
the pinion
measured
withvalue.
the above obtained modification coef-
Results
recommended and discussion
roller diameter. The measured value and the calculated value ficients
are are brought closer by, i.e.modification
0.1829 mm,coefficients
to achieve minimum
d compared.
base tangent
study The involveslength
calculated (BTL)are
remanufacturing
values and tip diameter
of used
obtained one,
by itusing have
is proposed
the tobeen used
follow(13)
equations the forand
Themethods
gear
to (22) finding
pinionuse
which the above obtained
with are brought closer
a used one, it is proposed to follow the methods that use the mea-by (𝑋𝑋 backlash
+ 𝑋𝑋 − of 0.03
𝑦𝑦) 𝑚𝑚, mm,
i.e. which
0.1829 mm is equal
to to
achieve DIN Class
minimum 5backlash
accuracyofstandard
0.03 mm which
ntsand
and pin
the
tabulated
surement over
measurement
From the diameter
in Table.table
of
of
it can
an5existing
be was
existing
seen used for
component.
that the
component.
sum
In verification.
In
of this
the study, measured
differences ∆ St
this study, measured base
base
and ∆ Su tangent
are # length
< (BTL)
value that is required for a high accuracy CNC machine tool gearbox
minimum
and tipindiameter
the casehave S*t and ∆
of ∆been . Thus
usedS*ufor thethe
finding profile modification
coefficients equaldiameter
and coefficients
pin over to DIN was
Classused
5 accuracy standard value that is required for high accuracy CNC
GO length (BTL) and tip diameter have been used for finding
tangent
obtained
𝑆𝑆*for through
+ 2 𝑋𝑋BTL
= verification.
* 𝑚𝑚 method
tan 𝛼𝛼 are closer to the measured value. machine tool
and
-----------------------------------(13) gearbox
maintaining andthe
maintaining the center
center distance distance
of gear pair.of gear pair.
A
the coefficients, and pin over diameter was used for verification.
GO gear
The and𝑚𝑚pinion Conclusion
coefficients are brought CONCLUSION
&T U 𝑆𝑆VU
A = + 2 𝑋𝑋A tan 𝛼𝛼 with above obtained modification
-----------------------------------(14)
= - closer
D
-L *N+ON𝑋𝑋A − 𝑦𝑦) 𝑚𝑚, i.e. 0.1829 mm
L A
by (𝑋𝑋
𝑦𝑦 = M - ? G -
-------------------------------------
to achieve minimum backlash of 0.03From
------------------------------------- From(8)
mm the approach
Equation 8 (8) of evaluating
the approach unknownunknown
of evaluating geometry of high accuracy
geometry gear
of high the followi
accu-
O A Jequal
which
𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼is
hi < to DIN Class
kD 5Gaccuracy standard value that is required for high
* = h + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + h − U
conclusions can be drawn:
-----------------------------------(15)
accuracy CNC jD machine toolD gearbox
D and maintaining the centre distance of gear racy gear the following conclusions can be drawn:
CDEF A relation between module and pressure angle was established,
= cos pair.𝛼𝛼P = HIJK
E*
Z cos @# T GU X
^V?WVGO# Equation 9 (9)  
-------------------------------------
------------------------------------- (9)is applicable
) L[
V* A relation
• which between module
for bothand
thepressure
gear andangle was The
pinion. established which
different stan-is applic
\D ]\L
Conclusion both the gear and pinion.angles
The different standard value of pressure angles is ass
(YZ[FM @YZ[F)
Equation dard value of pressure is assumed and the corresponding
𝑋𝑋# + 𝑋𝑋< = (𝑍𝑍# + 𝑍𝑍< ) ------------------------------------ - 10 (10)
and the corresponding
(_`aK T E_`aK)
< \LZF module was obtained module
from thewas obtainedThe
relation. from the relation.
obtained valueThe obtained va
of the
+ 𝑋𝑋A = From the (𝑍𝑍* + 𝑍𝑍A ) ------------------------------------gear
approach of evaluating unknown geometry of high accuracy -- module
(10)and the standard value of module were compared. The actual value of
A b&`K
the following conclusions can be drawn: was ascertained where the difference is found to be minimum.
June 2018     43
Addendum Modification Coefficient Using the BTL Method • The method of finding addendum modification coefficient, using BTL method
 BTL

Figure 3: Gear data calculation steps.

44     gearsolutions.com
 dr2 – Root circle diameter of pinion
module and the standard value of the module were compared. The
actual value of the module was ascertained where the difference is Wk1 – Actual base tangent length of gear
found to be minimum. Wk2 – Actual base tangent length of pinion
The method of finding the addendum modification coefficient a – Standard center distance between the gear and pinion
using the BTL and tip diameter methods and verification using pin
aw – Modified center distance between the gear and pinion
over diameter is found to be useful for gear parameter evaluation
of an unknown gear. y – Center distance modification coefficient
The BTL method is observed to be better for finding the adden- dg – Measuring pin diameter
dum modification coefficient for the gear pair based on the minima S1 – Gear tooth thickness for the corrected gear
obtained between the calculated and measured values of pin over S2 – Gear tooth thickness for the corrected pinion
diameter.
dp – Distance between the pin for the even number of teeth
The amount by which the gear pair is to be brought closer to
obtain the desired backlash as per DIN class accuracy can be derived d'1 –Distance between the pin for the odd number of teeth
using the above methodology.  Ma – Diameter over pin
a1 – Pressure angle of the involute profile at the pin center for gear
REFERENCES
a2 – Pressure angle of the involute profile at the pin center for pinion
[ 1 ] Kumar, A.; Jain, P.K.; Pathak, P.M. (2014). Machine element reconstruc-
tion using integrated reverse engineering and rapid prototyping approach. DxG – Difference between the measured and calculated value of pin over diam-
Proceedings of the 26th All India Manufacturing Technology, Design and eter on gear
Research Conference, IIT Guwahati, Assam, India. December 12-14, 2014 DxP – Difference between the measured and calculated value of pin over diameter
123, 1-5.
on pinion
[ 2 ] Grimsley, P. (2003). Software solutions for unknown gear. Gear Solutions.
June 2003, 16-23.
[ 3 ] Innocenti, C. (2007). Simple techniques for measuring the base helix angle
ABOUT THE AUTHORS
of involute gears. In Proceedings of the 12th IFToMM World Congress,
Besançon, France, June 18-21, 2007, 406-412. Prasmit Kumar Nayak, A. Velayudham, and C. Chandrasekaran are
with the Combat Vehicles Research and Development Establishment
[ 4 ] Belarifi, F. and Bayraktar, E. Benamar, A. (2008). The reverse engineering to in Avadi, Chennai, India. Nayak can be reached at prasmit1@gmail.
optimise the dimensional conical spur gear by CAD. Journal of Achievements com, Velayudham at [email protected], and Chandrasekaran at
in Materials and Manufacturing Engineering. 31 (2), 429-433. [email protected].
[ 5 ] Schultz, C. D. (2010). Reverse Engineering. In proceedings of the AGMA
Fall Technical Meeting. AGMA Technical Paper 10FTM09. 9pp. Milwaukee,
Wisconsin.
[ 6 ] G. Gonzalez Rey, A. G. Toll and C. I.E.R. Gonzalez, A Procedure to deter-
mine the unknown geometry of external cylindrical gears, Gear Solutions,
Feb 2016.
[ 7 ] Jadhav, S. and Sandooja, A. (2012), “Analytical Approach to Gear Reverse
Engineering (Spur and Helical),” SAE Technical Paper 2012-01-0812,
2012.
[ 8 ] A. Alshennawy, (2014), A Reverse Engineering Technique for Reproducing
Spare Parts using Computer Vision System, International Journal of
Scientific and Engineering Research, Volume 5, Issue 10, October-2014.
[ 9 ] Charles D. Schultz (2010), Reverse Engineering, AGMA Technical Paper
10FTM09.

NOTATIONS
Z1 – Number teeth on gear
Z2 – Number teeth on pinion
m – Module of gear and pinion
X1 – Modification on gear
X2 – Modification on pinion
a – Pressure angle
aw – Working pressure angle
d1 – Pitch circle diameter of gear RUSSELL, Precision Gear Products
HOLBROOK &
STOCK : HOBS : HSS & CARBIDE
d2 – Pitch circle diameter of pinion STOCK : SHAPERS : Disc & Shank
db1 – Base circle diameter of gear HENDERSON, INC. STOCK : MASTER GEARS
RFQ on specials gear tools welcome
db2 – Base circle diameter of pinion 25 E Spring Valley Ave., Maywood, New Jersey 07607
P: 201-226-9000 F: 201-226-9004 E: [email protected] Diametral Pitch 12 and finer
d a1 – Tip circle diameter of gear CELEBRATING 100 YEARS IN BUSINESS STOCK AVAILABLE
d a2 – Tip circle diameter of pinion
dr1 – Root circle diameter of gear www.tru-volute.com
June 2018     45