A Novel artifact for evaluating

accuracies of gear profile and pitch

measurements of gear measuring
instruments

Sonko Osawa, Osamu Sato,

Yohan Kondo, Toshiyuki
Takatsuji (NMIJ/AIST)
Masaharu Komori (Kyoto University)
IMEKO2009 Lisbon
 Contents
 Background
 DBA used for evaluation of GMIs on the gear profile
measurement capability
 Two types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
 Characteristics
 Calibration method

 Evaluation of gear measuring instruments using calibrated

MBA
 Summaries

IMEKO2009 Lisbon
 Background
Requirements: reduction of noise The noise and vibration form the gears
and vibration are caused by the form deviation in
micro meter level of gears.
Therefore, the requirement of the gear
form deviation is “sub micrometer” level.

Capabilities of GMIs
are mostly evaluated by measuring
Test for the gear profile, lead, a calibrated gear artifact
pitch, etc.
Difficult to manufacture
with high accuracy

We propose
new concept artifacts
used simple geometries
Gear measuring instrument (GMI)
IMEKO2009 Lisbon
 Introduction
Gear artifacts Proposed artifacts
NMIJ: U95 Simple geometries U95 Profile: 0.3 µm
Profile: 0.6 µm

Ball Cylinder Plane

Profile artifact

Helix artifact

Pitch artifact Profile (DBA) Pitch (MBA) Helix (WA)

Difficult to manufacture the Easy to manufacture the
artifact with high accuracy artifact with high accuracy

The Aim of New artifacts

is to calibrate the gear measuring instrument at shop floor with
a minimum uncertainty.
IMEKO2009 Lisbon
 Advantages of using simple geometries

• Form deviation is smaller than that of gear

• Smooth surface (small roughness)
• Easy to manufacture with good quality
• Form and diameter are calibrated with
small uncertainties
• Easy to assemble different size artifact
• Inexpensive

IMEKO2009 Lisbon
 Contents
 Introduction
 DBA used for evaluation of GMIs on the gear profile
measurement capability
 Two types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
 Characteristics
 Calibration method

 Evaluation of gear measuring instruments using calibrated

MBA
 Summaries

IMEKO2009 Lisbon
 Double Ball Artifact (DBA)
 Use for evaluating GMI’s capability of a profile
measurement
 Reference axis is used as a center axis of gear
 Form checking ball is used as a tooth form
Cross-section of the DBA Started from 2002 fy
Form checking ball Centering ball
Datum plane

Spring
Reference axis
Prototype of DBA
IMEKO2009 Lisbon
 Principle of profile evaluation
X
Involute curve
Involute curve
stylus
M’ M’’

Base circle rb
M’’’
Y O
DBA measurement
Involute curve:
can be expressed mathematically.

However, manufacturing ideal involute is difficult.

Involute and arc (a part of circle) are similar.

The difference can be expressed mathematically.
Therefore, arc can be used instead of involute.
IMEKO2009 Lisbon
 Example of evaluation result

Calculated value - measurement [µm]

Tooth form deviation [µm]

Roll angle [deg]

Difference between two curves after fitting (right scale)
Calculated curve (left scale) Measured curve (left scale)
Details: ISO/TR 10064-5
IMEKO2009 Lisbon
 Contents
 Introduction
 DBA used for evaluation of GMIs on the gear profile
measurement capability
 Two types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
 Characteristics
 Calibration method

 Evaluation of gear measuring instruments using calibrated

MBA
 Summaries

IMEKO2009 Lisbon
 Pitch artifact using balls
Expand the DBA method to pitch evaluation

IMEKO2009 Lisbon
 How to assume as a gear
 The centering ball is used to set the reference axis assumed as
the center axis of a gear
 The reference axis is perpendicular to the datum plane and
passes through the center of the centering ball
 The pitch balls are used instead of gear teeth

Pitch ball Measurement plane Centering ball

Datum plane

Spring
Reference axis

IMEKO2009 Lisbon
 Pitch artifacts (Multi Ball Artifacts)

Combination type

Separation type (low cost) Separation type (environment robust)

IMEKO2009 Lisbon
 Combination type
Cylinder:
Glass plate  Advantages:
reference axis
 Simple principle
 Easy to assemble
 Many combinations are available

Pitch ball  Calibration is not necessary ideally

Combinations
Combination type MBA
Spheres are fixed by magnetic force.

It is impossible to
assemble a MBA with
perfect pitch angle.  disadvantage:
 not apply for steel stylus
Making a gap

IMEKO2009 Lisbon
 Stabilities of combination type MBA
0.2

Repeatability of single
pitch deviation[m]
0.1

-0.1

-0.2
1 2 3 4 5 6 7 8
Number
Repeatability of single pitch deviation
0.2
Repeatability of cumilative
Reproducibility of 5 times assemblies

pitch deviation[m]
0.1

-0.1

-0.2
1 2 3 4 5 6 7 8 9
Number
Repeatability of cumulative pitch deviation
IMEKO2009 Lisbon
 Separation type
Centering ball
Datum plane Pitch angles are defined by a curvic coupling.
Pitch ball  Advantages:
 Inexpensive
 Easy to manufacture
 Calibration is not necessary (pitch angles
are defined by those of a curvic coupling)
 Disadvantages:
Curvic coupling
Low cost type  Stability ? (Balls are fixed by glue)
Datum plane Base plane is made of a zero expansion
Pitch ball
ceramics (NEXCERA).
 Advantage:
 Environment robust
 Disadvantage:
Centering ball  Calibration is necessary
Environment robust type  Expensive
IMEKO2009 Lisbon
 Contents
 Introduction
 DBA used for evaluation of GMIs on the gear profile
measurement capability
 Three types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
 Characteristics
 Calibration method

 Evaluation of gear measuring instruments using calibrated

MBA
 Summaries

IMEKO2009 Lisbon
 Pitch angle calibration
Probing system Probing system
MBA MBA of GMI
of CMM

Index table

Calibration by a CMM Calibration by a GMI

IMEKO2009 Lisbon
 Multiple-orientation technique
This method eliminate the systematic errors of an instrument
Geometrical error, probing error, etc.

13 15
13
11 15
11 1
fj = 2
9 1
・・・
9 3
7 3
5 7 5

First orientation Second orientation

2 where
 j    j  1 ( j  1,2,, m) j: orientation number
m m:total number of orientations
IMEKO2009 Lisbon
 Pitch calibration results
(using a CMM and two GMIs)
GMI-I – NMIJ
GMI-II – NMIJ
Uncertainty of NMIJ
Single pitch deviation for right flank Cumulative pitch deviation for right flank
1,0 1,6
0,8 1,2
0,6
0,8
[µm]

[µm]
0,4
Difference [mm]

Difference [mm]
0,2 0,4
0,0 0,0
-0,2 -0,4
-0,4
-0,8
-0,6
-0,8 -1,2
-1,0 -1,6
0 1 2 3 4 5 6 7 8 9 1011121314151617 0 1 2 3 4 5 6 7 8 9 1011121314151617
Tooth number Tooth number

Single pitch deviation result Cumulative pitch deviation result

IMEKO2009 Lisbon
 Contents
 Introduction
 DBA used for evaluation of GMIs on the gear profile
measurement capability
 Three types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
 Characteristics
 Calibration method

 Evaluation of gear measuring instruments using calibrated

MBA
 Summaries

IMEKO2009 Lisbon
 Measurement setup
Gear measuring instrument：MGL-26A
Manufactured by Osaka Seimitsu Kikai

IMEKO2009 Lisbon
 Repeatability and reproducibility of GMI
2 2

Repeatability [m]
Repeatability [m]

1 1

0 0

-1 -1

-2 -2
1 3 5 7 9 11 13 15 1 3 5 7 9 11 13 15
Pitch number Pitch number

Repeatability of single pitch deviation Repeatability of cumulative pitch deviation

2 2
Reproducibility [m]

Reproducibility [m]
1 1

0 0

-1 -1

-2 -2
1 3 5 7 9 11 13 15 1 3 5 7 9 11 13 15
Pitch number Pitch number

Reproducibility of single pitch deviation Reproducibility of cumulative pitch deviation

IMEKO2009 Lisbon
 Evaluation result
6 0.6
Measurement uncertainty
pitch deviation [m]

OSK-NMIJ 0.4

OSK - NMIJ [m]

4
2 0.2 U 95  k uw2  ur2  u 2p  us2
Single

0 0
uw: standard uncertainty of calibration value
-2 -0.2
NMIJ ur: standard uncertainty of repeatability
-4 -0.4
OSK
-6 -0.6 up: standard uncertainty of reproducibility
1 2 3 4 5 6 7 8 9 10111213141516
Pitch number us: standard uncertainty of systematic error
6 0.6 k: coverage factor set to k = 2
pitch deviation [m]

4 OSK-NMIJ 0.4 OSK - NMIJ [m]

Cumulative

2 0.2 U95(fp) U95(Fp)

0 0
Left Right Left Right
-2 -0.2
NMIJ flank flank flank flank
-4 -0.4
OSK
-6 -0.6 0.42 m 0.50 m 0.46 m 0.49 m
1 2 3 4 5 6 7 8 9 10111213141516
Pitch number
IMEKO2009 Lisbon
 Summaries
 We proposed new artifacts for evaluation of GMI’s
measurement capabilities.
 MBAs are available for the gear profile and pitch evaluations.

 We proposed the multiple-orientation technique for

calibrating the angular pitch deviation of the MBA.

 We evaluated the pitch measuring accuracy of the gear

measuring instrument using the calibrated MBA.

MBA is effective for calibrating the gear measuring instrument

at shop floor with a minimum uncertainty.

IMEKO2009 Lisbon
 Thank you for your attention !!

IMEKO2009 Lisbon
 Angular pitch deviation
If the pitch balls are arranged at Y
equal intervals, we define the Reference circle
Centering ball
nominal angular position as the
center of the ith pitch ball by
2
i  1 i  1,2,, n
r
qi 
n X
where O
i: pitch ball number in the clockwise direction
n: the total number of pitch balls T(qi)

We define the angular pitch

deviation by Wi
Pqi   T qi   qi Center of ith pitch ball i-1th pitch ball

where
T(qi): the true angular position in the actual MBA
IMEKO2009 Lisbon
 Calibration parameter
The single pitch deviation for a
virtual gear is calculated by
Y
f pli  r  Pqi   Pqi 1   Ωi  Ωi 1 
Reference circle
Centering ball
f pri  r  Pqi   Pqi 1   Ωi  Ωi 1 

where r
r: reference circle radius X
Wi: angle between the measurement point
O
and the center of the ith pitch ball
T(qi)
 r 2
 C 2
 r 2
Ωi  cos1  i ci 
 2  r  C 
 i 
where Wi
rci: radius of ith pitch ball i-1th pitch ball
Center of ith pitch ball
Ci: ball center distance between the
centering ball and the ith pitch ball
IMEKO2009 Lisbon
 Measurement value
Measurement value
15
M qi , j   Pqi   E qi   j   Erand
M(qi , fj) and (qi) [arcsec]

10
E(qi): Systematic error
5
Erand: Non systematic error
0
Mean value
 
-5 1 m
 q i    M q i , j
-10 m j 1

   
-15
1 m
  Pq i   E q i   j  Erand
0 60 120 180 240 300 360
Nominal angular position qi [deg]
m j 1
 Pq   E m  q 
i i
Law of the Fourier series
When m-number of curve with a phase shift of 2/m at a time are
averaged, the averaged curve shows the sum of an integral multiple of
mth-order Fourier components of the original curve.
IMEKO2009 Lisbon
 Example of law of Fourier series
15 Original curve 6

Amplitude [arcsec]
Shifted curve
deviation [arcsec]

10
Angular pitch

5 4
0
-5 2
-10
Phase shift of 
-15 0
0 60 120 180 240 300 360 1 2 3 4 5 6 7 8
Nominal angular position qi [deg] Fourier component
15 6
Mean curve
Average curve

Amplitude [arcsec]
10
Average [arcsec]

5 4
0
-5 2
-10
-15
0 60 120 180 240 300 360 0
Nominal angular position qi [deg] 1 2 3 4 5 6 7 8
Fourier component
IMEKO2009 Lisbon
 How to set virtual gear dimension
rb  rc sin cos  cos C 2  rc 2 cos2 

Reference circle Line of action

Base circle
Y A P I

rb Oc Pitch ball
r rc

C
α X
O B

IMEKO2009 Lisbon
 Measurement value
Measurement value
M qi , j   Pqi   E qi   j   Erand
15
P(qi): Angular pitch deviation

M(qi , fj) and (qi) [arcsec]

10
E(qi): Systematic error
Erand: Non systematic error 5
0
Mean value

   
-5
1 m
 Pqi   E qi   j  Erand -10
m j 1
-15
 Pqi   E m 
qi  Expected value 0 60 120 180 240 300 360
Nominal angular position qi [deg]
is zero
By law of Fourier series
the sum of an integral multiple of mth-order
Fourier components of the systematic error
IMEKO2009 Lisbon
 To obtain the systematic error: 1st step
15

M(qi, fj) [arcsec]

10
5
Measurement value
M qi , j   Pqi   E qi   j   Erand
0
-5
-10
-15
Phase shift of j 0 60 120 180 240 300 360
Nominal angular position qi [deg]
at each orientation
15

M(qi - fj , fj) [arcsec]

10
Shifted value 5

M qi   j , j   Pqi   j   Eqi   Erand

0
-5
-10
-15
0 60 120 180 240 300 360
Nominal angular position qi [deg]
IMEKO2009 Lisbon
 To obtain the systematic error: 2nd step
15

M(qi - fj , fj) [arcsec]

10
Shifted value
M qi   j ,  j   Pqi   j   Eqi   Erand
5
0
-5
Average -10
-15
0 60 120 180 240 300 360
Mean value of shifted curves Nominal angular position qi [deg]

1 m
  
P q i   j  E q i   Erand  3

Mean value [arcsec]

m j 1 2
1
P ( m)
qi   E qi  0
-1
-2
P(16)(qi) is never analyzed in -3
0 60 120 180 240 300 360
accordance with the sampling theory Nominal angular position qi [deg]
IMEKO2009 Lisbon
 To obtain the systematic error: 3rd step
3

Mean value [arcsec]

2
1
The phase of the systematic
0
error in the measurement value
-1
is different at each orientation
-2
-3
0 60 120 180 240 300 360
Systematic error Nominal angular position qi [deg]
E qi  2

Shifted value [arcsec]

Phase shift of j 1

at each orientation 0


E qi   j  -1

-2
0 60 120 180 240 300 360
Nominal angular position qi [deg]
IMEKO2009 Lisbon
 Calibration value

M(qi , fj) - E(qi+fj) [arcsec]

   
15
M q i , j  E qi   j 10
 Pq i   Erand 5
0
Average for all orientations -5
-10
Calibration Value -15
0 60 120 180 240 300 360
Nominal angular position qi [deg]
1 m
 Pqi   Erand 
m j 1 3

 Pq i 
Dispersion [arcsec]
2
s =0.24 arcsec
1
0
Measurement -1
uncertainty
-2
-3
0 60 120 180 240 300 360
Nominal angular position qi [deg]
IMEKO2009 Lisbon
 Calibration for length

CMM with an interferometer

U  2602  340L  [µm]

2

(k=2)
IMEKO2009 Lisbon 37