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MeasurementofIndividualElements(Metrology)
15.7.

15.7.1.Measurementoftooththickness.
Thepermissibleerrororthetoleranceonthicknessoftoothisthevariationofactualthicknessoftoothfrom
itstheoreticalvalue.Thetooththicknessisgenerallymeasuredatpitchcircleandistherefore,thepitchline
thicknessoftooth.Itmaybementionedthatthetooththicknessisdefinedasthelengthofanarc,whichis
difficulttomeasuredirectly.Inmostofthecases,itissufficienttomeasurethechordalthicknessi.e.,the
chordjoiningtheintersectionofthetoothprofilewiththepitchcircle.Alsothedifferencebetweenchordal
tooththicknessandcirculartooththicknessisverysmallforgearofsmallpitch.Thethicknessmeasurement
isthemostimportantmeasurementbecausemostofthegearsmanufacturedmaynotundergocheckingofall
otherparameters,butthicknessmeasurementisamustforallgears.Therearevariousmethodsofmeasuring
thegeartooththickness.
(i)Measurementoftooththicknessbygeartoothverniercalliper,(ii)Constantchordmethod.(iii)Base
tangentmethod,(iv)Measurementbydimensionoverpins.
Thetooththicknesscanbeveryconvenientlymeasuredbyageartoothvernier.Sincethegeartooththickness
variesfromthetipofthebasecircleofthetooth,theinstrumentmustbecapableofmeasuringthetooth
thicknessataspecifiedpositiononthetooth.Furtherthisispossibleonlywhenthereissomearrangementto
fixthatpositionwherethemeasurementistobetaken.Thetooththicknessisgenerallymeasuredatpitch
circleandis,therefore,referredtoaspitchlinethicknessoftooth.Thegeartoothvernierhastwovernier
scalesandtheyaresetforthewidth(w)ofthetoothandthedepth(d)fromthetop,atwhichwoccurs.
Consideringonegeartooth,thetheoreticalvaluesofwanddcanbefoundoutwhichmaybeverifiedbythe
instrument.InFig.15.14,itmaybenotedthatwisachordADB,buttooththicknessisspecifiedasanarc
distanceAEB.AlsothedistancedadjustedoninstrumentisslightlygreaterthantheaddendumCE,wis
thereforecalledchordalthicknessanddiscalledthechordaladdendum.
InFig.15.14,w=AB=2AD
Now,AdD=8=36074N,whereNisthenumberofteeth,

Fig.15.14

Anyerrorintheoutsidediameterofthegearmustbeallowedforwhenmeasuringtooththickness.
Inthecaseofhelicalgears,theaboveexpressionshavetobemodifiedtotakeintoaccountthechangein
curvaturealongthepitchline.ThevirtualnumberofteethNvforhelicalgear=Mcos3a(a=helixangle)
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Theseformulaeapplywhenbacklashisignored.Onmatinggearshavingequaltooththicknessandwithout
addendummodifications,thecirculartooththicknessequalshalfthecircularpitchminushalfthebacklash.

GearToothCalliper.
(ReferFig.15.15).Itisusedtomeasurethethicknessofgearteethatthepitchlineorchordalthicknessof
teethandthedistancefromthetopofatoothtothechord.Thethicknessofatoothatpitchlineandthe
addendumismeasuredbyanadjustabletongue,eachofwhichisadjustedindependentlybyadjustingscrew
ongraduatedbars.Theeffectofzeroerrorsshouldbetakenintoconsideration.
Thismethodissimpleandinexpensive.Howeveritneedsdifferentsettingforavariationinnumberofteeth
foragivenpitchandaccuracyislimitedbytheleastcountofinstrument.Sincethewearduringuseis
concentratedonthetwojaws,thecalliperhastobecalibratedatregularintervalstomaintaintheaccuracyof
measurement.

Fig.15.15.GearToothVernierCalliper.

15.7.2.ConstantChordMethod.
Intheabovemethod,itisseenthatboththechordalthicknessandchordaladdendumaredependentupon
thenumberofteeth.Henceformeasuringalargenumberofgearsforset,eachhavingdifferentnumberof
teethwouldinvolve
separatecalculations,inustneproceaureDecomeslaboriousandtimeconsumingone.
Theconstantchordmethoddoesawaywiththesedifficulties.Constantchordofagearismeasuredwherethe
toothflankstouchtheflanksofthebasicrack.Theteethoftherackarestraightandinclinedtotheircentre
linesatthepressureangleasshowninFig.15.16.
Alsothepitchlineoftherackistangentialtothepitchcircleofthegearand,bydefinition,thetooth
thicknessoftherackalongthislineisequaltothearctooththicknessofthegearrounditspitchcircle.Now,
sincethegeartoothandrackspaceareincontactinthesymmetricalpositionatthepointsofcontactofthe
flanks,thechordisconstantatthispositionirrespectiveofthegearofthesysteminmeshwiththerack.

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Fig.15.16
Thisisthepropertyutilisedintheconstantchordmethodofthegearmeasurement.
Themeasurementoftooththicknessatconstantchordsimplifiedtheproblemforallnumberofteeth.Ifan
involutetoothisconsideredsymmetricallyinclosemeshwithabasicrackform,thenitwillbeobservedthat
regardlessofthenumberofteethforagivensizeoftooth(samemodule),thecontactalwaysoccursattwo
fixedpointAandB.ABisknownasconstantchord.Theconstantchordisdefinedasthechordjoiningthose
points,onoppositefacesofthetooth,whichmakecontactwiththematingteethwhenthecentrelineofthe
toothliesonthelineofthegearcentres.ThevalueofABanditsdepthfromthetip,whereitoccurscanbe
calculatedmathematicallyandthenverifiedbyaninstrument.Theadvantageoftheconstantchordmethodis
thatforallnumberofteeth(ofsamemodule)valueofconstantchordissame.Inotherwords,thevalueof
constantchordisconstantforallgearsofameshingsystem.Secondlyitreadilylendsitselftoaformof
comparatorwhichismoresensitivethanthegeartoothvernier.

15.7.3.BasePitch.
Thisisdefinedasthecircularpitchoftheteethmeasuredonthebasecircle.InFig.15.17,ABrepresentsthe
portionofagearbasecircle,CDandEFthesides
oftwoteeth,FDbeingthebasepitch.Fromthepropertyofinvolute,ifanylineasGHisdrawntocutthe
involutesandtangentialtothebasecircle,theGH=FD.
Thusbasepitchcouldalsobedefinedasequaltothelineardistancebetweenapairofinvolutesmeasured
alongacommongenerator.
Basecircumference=2kRb
..Basepitch=2kRb/N
Ifisthepressureangle,then
RB=P.C.R.xcos<t>=(P.C.D./2)cos<J>..Basepitch=(2nlN)x(P.C.D./2)xcos(j)=nmcos(|>
Thisisthedistancebetweentangentstothecurvedportionsofanytwoadjacentteethandcanbemeasured
eitherwithaheightgaugeoronanenlargedprojectedimageoftheteeth.ThisprincipleisutilisedinDavid
Borwntangentcomparatoranditisthemostcommonlyusedmethod.

Fig.15.17

15.7.4.BasePitchMeasuringInstrument.
Thisinstrumenthasthreetips.Oneisthefixedmeasuringtip,otheroneisthesensitivetipwhoseposition
canbeadjustedbyascrewandthefurthermovementofitistransmittedthroughaleveragesystemtothedial
indicator
andthethirdtipisthesupplementaryadjustablestopwhichismeantforthestabilityoftheinstrumentandits
positioncanalsobeadjustedbyascrew.Thedistancebetweenthefixedandsensitivetipissettobe
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equivalenttothebasepitchofthegearwiththehelpofslipgauges.Theproperlysetupinstrumentisapplied
tothegearsothatallthethreetipscontactthetoothprofile.Thereadingondialindicatoristheerrorinthe
basepitch.

Fig.15.18

15.7.5.TheBaseTangentMethod.(DavidBrowntangentcomparator).
Inthismethod,thespanofaconvenientnumberofteethismeasuredwiththehelpofthetangentcomparator.
Thisusesasingleverniercalliperandhas,therefore,thefollowingadvantagesovergeartoothvernierwhich
usedtwovernierscales:
(i)themeasurementsdonotdependontwovernierreadings,eachbeingfunctionofthe
other.
(ii)themeasurementisnotmadewithanedgeofthemeasuringjawwiththeface.Considerastraight
generator(edge)ABCbeingrolledbackandforthalongabasecircle
(Fig.15.19).ItsendsthussweepoutopposedinvolutesA2AA^andC2CCirespectively.Thusthe
measurementsmadeacrosstheseopposedinvolutesbyspangaugingwillbeconstant(i.e.AC=AiCi=
A2C2=A0Cq)andequaltothearclengthofthebasecirclebetweentheoriginsofinvolutes.
Furtherthepositionofthemeasuringfacesisunimportantaslongastheyareparallel\andonanopposed
pairofthetrueinvolutes.Asthetoothformismostlikelytoconformtoatrueinvoluteatthepitchpointof
thegear,itisalwayspreferabletochooseanumberofteethsuchthatthemeasurementismade
approximatelyatthepitchcircleofthegear.
Thevalueofthedistancebetweentwoopposedinvolutes,orthedimensionoverparallelfacesisequaltothe
distanceroundthebasecirclebetweenthepointswherethecorrespondingtoothflankscuti.e.,ABCinFig.
15.19.Itcanbederivedmathematicallyasfollows:

Fig.15.19.Generationofpairofinvolutesbyacommongenerator.
TheanglebetweenthepointsAandConthepitchcirclewheretheflanksoftheopposedinvoluteteethof
thegearcutthiscirclecanbeeasilycalculated.
LetussaythatthegearhasgotWnumberofteethandAConpitchcirclecorrespondstoSnumberofteeth.
(Fig.15.20)..DistanceAC=(S1/2)pitches
..AnglesubtendedbyAC=(S1/2)x2rc/A7radians.
AnglesofarcsBEandBD

Itmaybenotedthatwhenbacklashallowanceisspecifiednormaltothetoothflanks,thismustbesimply
subtractedfromthisderivedvalue.
TablesarealsoavailablewhichdirectlygivethisvalueforthegivenvaluesofS,Nandm.
ThisdistanceisfirstcalculatedandthensetintheDavidBrowntangentcomparator(Fig.15.21)withthe
helpofslipgauges.Theinstrumentessentiallyconsistsofafixedanvilandamovableanvil.Thereisa
micrometeronthemovinganvilsideandthishasaverylimitedmovementoneithersideofthesetting.The
distanceisadjustedbysettingthefixedanvilatdesiredplacewiththehelpoflookingringandsettingtubes.
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15.7.6.TangentialGearToothCalliper.
Itisutilisedformeasuringvariationsonthebasictoothprofilefromtheoutsidediameterofspurandhelical
gears.Theinstrumentconsistsofbody,ontheundersideofwhichtherearetwoslideshavingthetipsacting
likemeasuringcontacts.TheextendedspindleofadialindicatorwiththecontactpointA

Fig.15.20
passesbetweenthetwotipsalongtheverticalaxisofsymmetryoftheinstrument.Themeasuringtipsare
spreadapartorbroughttogethersimultaneouslyandsymmetricallyinreferencetothecentralaxisbyascrew
whichhasarighthandandalefthandthread.Thecontactfacesofthemeasuringtipsareflatandarrangedat
anglesof

Fig.15.21.DavidBrownBaseTangentComparator.
14.5or20withthecentralaxis.Thecalliperissetupbymeansofacylindricalmastergaugeofproper
diameterbasedonthemoduleofthegearbeingchecked.Afteradjustingthetipsbythescrew,theseare
lockedinpositionbylockingnuts.Theproperlysetupinstrumentisappliedtothegeartoothandthedial
indicatorreadingshowshowmuchthepositionofthebasictoothprofiledeviatesinreferencetotheoutside
diameterofthegear.
15.7.7.TestPlugMethodforCheckingPitchDiameterandToothSpacing.Measurementovertherollers
placedinthespacebetweenapairofgearteethgivesaconvenientmethodforcheckingtoothspacingand
thepitchdiameter.Thespecialcaseoftherollerwithitscentreonthepitchcirclesimplifiestheproblem.It
is,therefore,considereddesirabletofindthediameterontherollerwhosecentrewilllieonthepitchcircle
andtoderiveanexpressionforthedistanceovertherollersplacedinoppositeteethspaceswiththecentres
ofrollerslyingonthepitchcircle.

Fig.15.22

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Fig.15.23
InFig.15.23aracktoothisshownsymmetricallyinmeshwithageartoothspace,thecurvedsidesofthe
geartoothtouchingthestraightracksidesatAandBonthelineofaction.Letusassumethatthecentreof
therollerliesonthepitchpointO.Now,iftheracktoothbeconsideredasanemptyspaceboundedbyits
outline,acirclewithcentreOandradiusOBwouldfitandtouchtherackspaceatAandBsinceOAandOB
areperpendiculartothesidesoftheracktooth.ThusthecirclewouldtouchthegearteethatAandB.
InAOBD,OBistheradiusofroller
OD=Circularpitch/2=(7t/4)m
OBD=90,BdD=<|>=pressureangle,..OB=ODcos<j>=(re/4)mcos<(>
Dia.ofroller=2xOB=2x(ron/4)cos<|)=(rc/4)mcos<|>.
Thisisthediameterofarollerwhichwillrestintoothspaceandliewithitscentreonthepitchcircle.This
valueisconstantforallgearsofsamepitchandpressureangle.
Forgearswithevennumberofteeth,adirectmeasurementbyplacingtworollersinexactlyoppositetooth
spacesispossible.Inthiscase,thegaugingdiameterovertherollers
Ifthegearhasanoldnumberofteeth,aradialmeasurementwiththegearbetweencentrescanbecarriedout,
usingacomparatorwiththegear.Theaccuracyofthespacingoveranynumberofteethmaybecheckedby
findingtheanglessubtendedatthecentreandcomparingthiswiththatobtainedfromachordalcheckofthe
plugs.
Asalreadyindicated,precisiongearsandothergearsaregenerallycheckedfortooththicknessbydimension
overpins,asthedimensionsoverpinsreadingismathematicallyrelatedtothetooththickness.Thisalso
verifiesthecorrectnessofprofileandotherelementsofgear.Underthismethodtwopinsofequaldiameter
areplacedintwooppositetoothspaces
forgearshavingoddnumberofteeth.
whereM=Requiredsizeoverthewires,m=Module,(j)=Pressureangle,d=Diameterofwire=1.728x
m,m=Pressureangleatcentreofpinandisgivenbytherelation
Usingtheaboveequations,thesizeAToverwirescanbecalculated.Incaseofhelicalgearstheformulae
usedareasbelow:

Thehelicalgearswithoddnumberofteethshouldnotbemeasuredwithtwowires,becauseinthiscasethe
correctionfactorcos(90/iV)isnotvalidandcanresultinseriouserrors.Insuchcasesthegearcanbe
mountedonanarbourandaradialmeasurementmadefromthetopofthewiretotheaxisofgear.
Sizeoverwires/ballsforhelicalgears

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15.7.8.CheckingofProfileofInvoluteShapeofGear.
Profileistheportionoftoothflankbetweentheoutsidecircleorstartoftoothtipandthespecifiedform
circleofdiameterapproximatelyequaltopitchcirclediameterminustwicethemodule.
Profileerroristhedeviationoftheactualtoothfromthetheoreticalprofileinthedesignedreferenceplaneof
rotation.Fortestingprofile,tipreliefandanyportionofthetoothsurfacebelowtheactiveprofileisnottobe
considered.Thetoleranceontheprofileerrorispermittedasperthefollowingtable.

Table
AccuracyClassorGradeofGear ProfileToleranceinMicrons
1
2.0+0.06x*
2
2.5+0.10xk
3
3.0+0.16xA
4
4.0+0.25xh
5
5.0+0.40xk
6
6.3+0.63xk
7
8.0+1.0xk
8
10+1.6xk
9
16+2.5xk
10
25+4.0xk
11
40+6.3xk
12
63+10xA

Wheremismodule,andDisthepitchcirclediameterinmm.
(a)Inspectionofprofileusingdividingheadandheightgauge.
ThismethodhasbeenderivedfromthepropertyoftheinvoluteasshowninFig.15.24.Thedistancebetween
pointsAandBmeasuredonthegeneratixtangenttothebasecircleisequaltothearcfromthetangentpoint
BtotheoriginPoftheinvoluteonthebasecircle,i.e.arcBP=AB=(Dbji/360)xez
S.No. DividingHeadReading ezvalues DbxnABvalues=.xe,obu
1
ez
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2
CO
4
5
6
7
CO
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ez+10
ez+20

ez10
e,20

Wheninvoluteprofileisrotatedondividingheadbysmallrollangles,thentheconsecutiveprofilepointsA
fallontotheverticaltangentline.ItispossibletocomputesuitablerollanglesforanydiameterDzfromthe
correspondingpressureanglebyequations:DJDb=sec<j>z,ez=(180/rc)xtan
Initiallyforanyknowndiametersaypitchdiameter,thevalueofezandsoABisfound.Thehighestgauge
issettozeroatthisheightabovethegearcentrebymeansofslipgauges,thenthecorrespondingpositionof
gearprofileisobtainedbyrotatingthegeartoothtowardsindicatingstylusuntilzeroisobtained.Numberof
anglesisincreasedordecreasedinstepsof10orhalfdegreeasisconvenientandforthesevaluesofezthe
valuesofABarecalculated,andtheheightgaugeissettothisheightbymeansofslipsandthenthedial
readingoverthetoothiscompared.Thedeviationofdialreadinggivestheerrorofprofileatthesepoints.
Thisisaverytimeconsumingmethodbutbestsuitedforcalibrationofmasterinvolute.Itisthereforeuseful
onlyforveryprecisioncomponentsandinvolutemastercams.
(b)Gearinvolutemeasuringmachine.Thismachineisdesignedforcheckingtheinvoluteprofilesofthe
spurandothergears.Themachineissuitableforinspectionofgearhavingmodulefrom1to10mmhaving
maximumoutsidediameterupto300mm.Themachineisprovidedwithameasuringstylus.Thekinematic
designofthemachineissuchthatwhenjobisrotatedthemeasuringstyluswhichisinitiallysetatbasecircle
radiusofthegearbymeansofslipgauge,isalsoslidedalongtheinvolutecurve.Thedeviationofthetooth
profilefromthecorrectinvoluteisindicatedbyadialindicatorofaccuracy0.001mmconnectedbylever
mechanismwiththestylus.Amasterinvolutetemplateisalsoprovidedwiththemachineforsettingand
calibrationofthemachine.
(c)Checkingofinvoluteshapeofgear.AstheinvolutecurveistracedbytheendAofastraightedge
whichrollswithoutslippingonabasecirclediametercylinder,anypointConthecurvewillcorrespondto
thepositionCEofthestraightedge,which,therefore,alwaysremainstangentialtothebasecircle.
Converselyifthebasecirclecylinderweretorollonafixedstraightedge,anyfixedpointe.g.,Cwould
moveinaninvolutepath,suchasCA,asthecylinderrollsalongthestraightedgeCE.
Astraightedgerolledontheedgeofadiscwillbeseentobetheequivalentofthisarrangement,and
providestheprincipleonwhichtheinvolutetesteroperates.Thegeartobetestedisheldonthemandrelm,
whichcarriesagrounddiscdhavingexactlythesamediameterasthebasecircleofthegearundertest(Fig.
15.25).Astraightedgeeismountedonaslideonthebodyoftheinstrumentandincontactwithbasecircle
disc,sothatasthestraightedgemovesalongtheslide,thebasecirclediscandgeararerotatedwithoutslip.
Apointonstraightedgethusdescribesthetrueinvolutecorrespondingtothebasecircle,andifthetopofan
indicatorofsomekindis
mountedexactlyintheplaneoftheedgeofthestraightedgeandincontactwiththetoothflankitwill
registerbyitsmovementsanydepartureofthetoothprofilefromthetheoreticalinvoluteresultingeither
fromerrorsorfromdeliberatemodificationoftheprofile.Theindicatorcanalsobereplacedbythesensing
elementofarecordersothatpermanentrecordsofthegearteethprofilescanbemade.

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Fig.15.25.PrincipleofInvoluteTester.
(d)Involuteprofiletestingmachine.Suchmachinescanbesettodesiredbasecircleradiusvalues,thus
doingawaythenecessityofhavingbasediscforeachgearofdifferentdimensions.Thisfacilityisprovided
byamasterbase,discorinvolutecam,builtintothemachine,andcoupledtoalinkagesystemwhichenables
thebaseradiusofthegeneratedcurvetobevariedbyadjustmentofthelinkagebarpositions.
Thesemachinesgeneratetherequiredinvoluteshape,measurethedeparturesfromitthatexistontheactual
toothflanksofthegear.Theprincipleofoperationisthatofabasecirclerollingwithoutslipalongastraight
edge,orviceversa.Astylusdetectsthedeviationsinthemetalconditionofthetoothflankfromthetrue
involuteintheformofacontinuoustraceonastripchartrecorder.Aperfectprofilewillresultinastraight
traceparalleltothelongitudinalaxisofthechartpaper.

15.7.9.MeasurementofGearPitch.Gearpitchcanbemeasuredinthefollowing
ways:
(i)Cumulativecircularpitcherroroveraspanofteeth.
(ii)Adjacentpitcherrororpitchvariation.(iii)Basepitchvariation.
HereL=Knm2,whereIfisthesectorofpitchesoverwhichpitcherroristobechecked.
Thepitcherrorofgearcanbeeasilydeterminedbycomparingthespanlengthoveraspecifiednumberof
teethi.e.,thecumulativeerroronasectorofpredeterminedpitchesismeasured.
Thepitchvariationisthedifferencebetweenthelongestandshortestcircularpitchinthewholegear.
Themeasurementofcumulativeerroroveraspanofteethandalsothepitchvariationscanbeconveniently
measuredusingadividingheadandheightgaugefittedwithdialindicator.Thebasicmethodof
measurementinvolvesindexingthegearthroughsingleormultipletoothanglesanddeterminingflank
positioncircumferentiallybymeansofaprecisionindicatormountedonaradiallydisposedslide.Bymeans
ofthedividinghead,rotationtothegearisgivenbytheamountoftheoreticalangularpitch,thevariationin
thepositionoftoothismeasuredbythedialindicator.Forlargergears,theangularaccuracyofthedividing
tablemustbehigherinorderthatpitcherrorisdeterminedaccurately.Thoughdividingtableswith10
secondsofarcresolutionarecommon,dividingtablesareavailablewhichcanbereadtothenearestsecond
ofarc.Ofcourse,thesehavetobecalibratedusingprecisionpolygonandphotoelectricautocollimator.The
indicatorunitshouldbecapableofmeasuringreliablyupto0.001mmoverarangeof0.025mm.Forgears
havinglargercumulativepitcherrors,indicatorsoflowersensitivityhavetobeused.

TolerancesonpitcherrorsA.ToleranceoverasectorofKPitches
GradeofAccuracyClassofgear PermissibleErrorinMicrons
1
0.25<L+0.6
2
0.4a/L+1.0
3
0.63VZT+1.6
4
1.0+2.5
5
1.6<L+4.0
6
2.5VT+6.0
7
3.55^+8.0
8
5.0<L+12
9
7.1VT+17
10
10+28
11
144L+33
12
20VT+83

B.ToleranceonPitchVariations
Class PermissibleErrorinMicrons
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2
3
4
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0.80+0.06F
1.25+0.1F
2.0+0.16F
3.2+0.25F
5.0+0.40F
8.0+0.63F
11+0.90F
16+1.25F
22+1.80F
32+2.50F
45+3.55F
63+5.0F

Thebasepitchisthecircularpitchoftheteethmeasuredonthebasecircle,asweknowthatthebasepitch=
pxcos.Thisisalsothedistancebetweenthetangenttothecurvedpositionsofanytwoadjacentteeth.The
basepitchcanbeveryconvenientlymeasuredusingordinarybasepitchmeasuringinstrumentswhich
measurethestraightdistancebetweentangentstotheadjacentteeth.
Basepitchcanbeaccuratelymeasuredusingtoolmakersoruniversalmicroscope.
HereF=m+0.25H5whereDisthepitchcirclediameterinmm.
Toothtotoothpitcherrorscanbeeasilydeterminedbyuseoftwodialgaugesbymeasuringthepositionofa
suitablepointonatoothafterthegearhasbeenindexedthroughasuitableangle.
Thegearismountedinthecentrewithindexingarrangement.TwodialgaugesaremountedasshowninFig.
15.26.Thereisaspindlebelowthedialgaugehavingasmallsphereattheendandtouchingthegeartoothat
thepitchcircle.Thegearisthenindexedthroughsuccessivepitchestogiveaconstantreadingondialgauge
A.AnychangesinthereadingondialgaugeBindicatethatpitcherrorsarepresent.Theactualerrorcanbe
determinedbydeductingtheindividualreadingondialBfromthemeanofthereadings.
Thepitchofthegearteethcanalsobemeasuredbymeasuringthedistancefromapointononetoothtoa
suitablepointonthenexttooth.

CircularPitchMeasuringMachine.
Thisinstru

Fig.15.26
mentisusedlorcheckingthecircularpitcholgeartooth.Thetwomeasuringcontacttipsareappliedonthe
samesidesofadjacentteethofthegear.Thelefthandtipisfirstsetuptotherequiredmodulebymeansof
somesuitablearrangement.Therighthandtipisatwoarmedleverwhoseonecontactsthegeartoothandthe
otheroneactuatesthecontactpointofthedialindicator.Twoguidepointsarealsoprovidedforthestability
oftheinstrument.
ThepitchvariationscanalsobemeasuredbytheinstrumentshowninFig.15.27.Itemploysafixedfinger
andstopforconsistentpositioningonsuccessivepairsofteeth,andamovablefingerwhosemovementcan
besensedbyadialindicator.
Itmaybenotedthatreadingsobtainedbyaboveinstrumentwillbeaffectedbyprofilevariationsandrunout
ofthegear.
Inthecaseofhelicalgears,measurementsmaybemadeinthenormalplaneoftheconjugaterackand
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dividedbythecosineofhelixangleforcomparisonwithstandardtolerances.
Itmaybementionedthattheabovemethodofmeasuringpitcherrorcanbeappliedtomediumsizedgears
measuringfromafewcmsuptoaboutametrediameter.Smallgearsasusedinwatchesandclockare
inspectedbyopticalprojectioninwhichtheenlargedimagesofsomeoftheteetharecompared

Fig.15.27.Schematicarrangementofapitchcheckinginstrument.
againstamasterdiameteratthescreenoftheprojector,borthickgearsconvergentilluminationisusedto
enableopticalfocussingataselectedsectionacrossthefacewidth.EffectofEccentricityofPitchError
Itmaybeemphasizedthatgearpitcherrorandtootheccentricityareinseparablebecausepresenceofone
affectstheother.Sinceeccentricitycantakeanypositionwithreferencetothetoothunderconsideration,the
effectiveeccentricityforvariouspositionsofgearrotationatangle6isexpressedasequaltoesecsin(cj)
+8),wheree=eccentricityand<|>=pressureangle.
Thusifagearhasbeenmeasuredfortoothspacingerror,theeffectofitsmountingeccentricallyonpitch
errorcanbetakencareofbyapplyingcorrectionsprogressivelytotheobservederrorvaluesbycalculating
thecorrectionapplicabletoeachtoothfromtheaboveequation.

15.7.10.Runout.Runoutmeanstheeccentricityinthereferenceorpitchcircle.
Gearsthatareeccentrictendtohaveavibrationperrevolution.Abadlyeccentrictoothmaycauseanabrupt
gearfailure.Therunoutinthegearsismeasuredbyemployinggeareccentricitytesters.Thegearisheldona
mandrelinthecentresandthedialindicatorofthetesterpossessesthespecialtipdependinguponthemodule
ofgearbeingchecked.Thetipisinsertedinbetweenthetoothspaces.Thegearisrotatedtoothbytooth.The
maximumvariationisnotedfromthedialindicatorreadinganditgivestherunoutofthegear.Therunoutis
twicetheeccentricity.Theadjoiningtableindicatesthepermissiblerunouts.
ClassorGrade PermissibleRunout
inMicrons
1
0.224F+3.0
2
0.335F+4.5
3
0.560F+7.0
4
0.900F+11
5
1AF+18
6
2.24F+28
7
3.15^+40
8
4.0F+50
9
5.CF+63
10
6.3F+80
11
8.0+100
12
10.0F+125

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MeasurementofIndividualElements(Metrology)

15.7.11.Lead.
Itistheaxialadvanceofthehelixorthewormthreadperturn.Thecontrolofthreadleadisnecessaryto
ensureadequatecontactacrossthefacewidth.Therelationshiptothehelixanglehasalreadybeenexplained
earlier.
Theinstrumentwhichcheckstheleadconsistsofaprobebeingadvancedalongatoothsurface,parallelto
theaxis.Theprobeisasuitabledialindicatortipfixedinasuitabledevice.
Whenthegearisrotated,thedisplacementoftheprobeinonecompleterevolutionofgearisfoundwhichis
thelead.
Inthecaseofwormthread,theaxialpitchofthethreadisfirstmeasuredwhichmultipliedbythenumberof
threadsinthewormgivesthelead.

15.7.12.Backlash.
Backlashinthegearsistheplaybetweenthematingtoothsurfaces.Forthepurposesofmeasurementand
calculations,backlashisdefinedastheamountbywhichatoothspaceexceedsthethicknessonanengaging
tooth.Backlashinthegearteethresultsonaccountoferrorsinprofile,pitchthicknessofteethetc.Itis
measuredbymountingthegearsinspecifiedposition.Backlashshouldbemeasuredatthetightestpointof
themesh.Thepinionisheldsolidlyagainstrotationandarigidlymounteddialindicatorisplacedagainstthe
toothattheextremeheelperpendiculartothesurface.Thebacklashisdeterminedbymovingthegearback
andforth.Thebacklashvariationismeasuredbylocatingthepointsofmaximumandminimumbacklashin
thepairandobtainingthedifference.Forprecisiongearsthevariationshouldnotexceed0.02to0.03mm.

15.7.13.LeadMeasurement.
Inorderthattoothloadbeuniformlydistributedacrossthefacewidthofthegears,itisessentialthatleadper
toothofmatinggearsshouldbecloselymatched.Errorsinthehelixofeithergearwouldresultinnon
uniformloadconcentration,resultinginnoisyoperationanddamage.Irregularitiesinleadcouldoccurdueto
eitherpoormanufactureorfromthepresenceoftoothundulations.
Itisimportanttonotethatwhilethehelixangleofpinionandgearissamebuttheirleadisdifferent
dependingontheirdiameters.Alsothehelixanglevalueincreasesfromtherootstothetipsoftheteeth.
Leadcanbemeasuredeitheronapointtopointbasis,orbymeansofcontinuousgenerationusingspecial
purposemeasuringmachines.Onetypeofgeneratingmachineincorporatesasinebarmechanismtogether
withameansofconvertingaderivedlinearmotionintoarotarymotion.
Nextpost:CompositeMethodofGearChecking(Metrology)
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