AGMA Webinar Series

Analytical Gear Chart Interpretation:

Solving Manufacturing Problems
PART TWO

Dwight Smith
President, Cole Mfg. Systems, Inc.

June 7, 2012
Dwight Smith
Dwight Smith, President of Cole Mfg. Systems, Inc.,
has a wide range of experience in gear manufacturing,
workholding, metrology, analysis, and project
management.

He has been developing and presenting the Gear Basic

training sessions throughout North America since
1989. Smith serves as chairman of the AGMA
Nomenclature Committee and is an instructor for the
Basic Gear School for AGMA.

His company, Cole Mfg. Systems, Inc., represents

complementary gear-related equipment
manufacturers.

American Gear Manufacturers Association

 Chart Interpretation : Part 2

1. Some Things to Consider

2. Pitch Errors
3. Helix Errors
4. Profile Errors
5. Brief Overview of Several Gear
Standards
Things to Consider When Interpreting Gear
Inspection Charts

Errors occur outside of the analyzed area.

Errors can occur between the measured teeth.

Special Situations –
Burrs
Improper Undercut
Short Involute
Broaching Tears
Special Situations: Burrs

A burr on the end of the tooth This end of the

may be outside the analyzed tooth does not
zone. have a burr.
 Special Situations: Improper Undercut

Proper undercut will appear Plus material below the

on the chart as minus SAP indicates improper
material. undercut, possibly a
damaged or worn hob.
 Special Situations: Short Involute

Proper involute length or minimum When the involute trace falls off prior to
chamfer diameter falls off beyond end the end of analysis, it indicates a tooth
of analysis. that is shorter than specified.
 Special
Situations:

Broaching
Special Situations:

Broaching
Understanding Pitch Errors
 Correcting
Radial
Runout

Relocate part on
inspection arbor

Correcting
Helix
Variation
(wobble)
Cumulative
Pitch

vs.

Single Pitch
Cumulative Pitch (index) with Radial Runout
Data Calculated From Pitch Data
Non-Hunting Tooth Pattern

Three start hob cutting a 30 tooth gear.

Understanding Helix Errors
 Helix
Variation
Helix Variation
 Helix Variation

It is impossible for the tool to cause helix

variation.

It is in all cases caused by axial wobble.

If you use helix average values for tolerances,

you need to consider variation as well.
Helix Angle Deviation and Form Deviation
Helix Form Deviation: Cause?
In Tolerance Helix Chart – Hobbed Part
Helix Chart – Variation and Form Deviation
Helix Chart – Variation and Form Deviation
Helix Chart – Taper
Helix Chart – Variation and Form Deviation
Understanding Profile Errors
Profile Chart Overview
OD Variation
from Runout
Profile Form Deviation
Profile Chart
Profile Form Deviation – Cause?
Profile Form Deviation – Cause?
 Involute Error Patterns

•Plus slope (balance) •Very rough and irregular •Form error

•Both flanks surface •similar pattern RF and
LF

Tears from broaching

 Involute Form Waviness

Problem:
Involute Waviness on right
flank

Potential Cause:
Loose/worn outboard
bearing assembly on hob
head

Fix:
Tighten/replace outboard
bearing
Involute Form Waviness
Involute Form Deviation

Problem:
Plus material near root

Cause:
Excessive wear on hob cutter
teeth after only 50 pieces.
Cutter probably not
completely sharpened.

Fix:
Resharpen or scrap hob cutter
Pitch, Helix and Profile Charts
Surface Finish
Measurement
 Factors Influencing Gear Quality

Common Variables that Influence all processes

• Hob, shave, roll, broach, tool sharpening and measurement
– Workpiece spindle tooling
• Axial runout or wobble
• Radial runout or eccentricity
• Repeatability of mounting accuracy
– Tool spindle and bearings
• Radial and Axial Runout
• Backlash
– Tool maintenance and tool mounting
Contribution to Errors: Machine vs. Tool
• Hobbing machine
– Number of teeth
– Root diameter
– Tooth size or thickness
– Index
– Pitch
– Helix angle (lead)
• Wobble (lead variation)
• Taper, crown
– Profile form
– Pitch diameter runout
– Scallop pattern
• depth and variation
• Hobbing Tool
– Profile angle
– Profile modifications
– Tip chamfer
– Undercut
 Troubleshooting Gear Errors

Gear Characteristics Inspection Possible root Corrective

Element chart cause action
Category appearance

Hobbed/checked off Verify tooling

center (radial runout)

Runout Verify Master

Possible
Total Composite contamination

Tooth to Tooth
Profile error Check for involute
Nicks error

Mesh interference Check for plus tip

 Troubleshooting Gear Errors
Gear Characteristics Inspection Possible root Corrective
Element chart cause action
Category appearance

Helix Input correction Input correction

needed on machine
Slope (Angle)
error
Chips on fixture or Verify axial runout
Variation workholding of fixture
(wobble) misaligned (axial wear
runout)
Form or Inspect cutter
waviness Chips on cutter edge Verify
Cutting force to high workholding
rigidity
 Troubleshooting Gear Errors
Gear Characteristics Inspection Possible root Corrective
Element chart cause action
Category appearance

Involute Hob rake angle error Check hob

sharpening
(profile)
Angle (slope)
error Check workpiece
Radial runout of gear and fixture runout

Variation Cutter mounting error Check hob

(runout) mounting and
quality
Form or Excessive finish stock Check stock
waviness Worn tool removal amount
 Troubleshooting Gear Errors

Gear Characteristics Inspection Possible root Corrective

Element chart cause action
Category appearance

Runout of production Verify

fixture or inspection workholding
arbor
Pitch
(symbol fp)
Pitch Inspect hob for
Thread error on hob thread error
(index) Index (total
accumulated
pitch error-
symbol Fp) Wear or chips on Clean chips off
broach bar broach
 Troubleshooting Gear Errors
Gear Characteristics Inspection Possible root Corrective
Element chart cause action
Category appearance

Tooth Tapered hob Check hob for

proper quality
thickness
Heat causing
Size over pins
machine growth
or balls Monitor cutting oil
temperature
Hob swivel angle
error
Relative tooth
thickness Adjust hob swivel
angle for correct
size over pins
(DOB or DOP)
Gear Analysis Standards

AGMA 2000-A88 (Q)

AGMA 2015 (A)

ISO 1328

DIN 3960
Gear Analysis Standards

JIS

JGMA

France, Australia, Italy, UK

CAT

GM, Ford, Eaton, Honda, etc.

 Gear Analysis Standards
AGMA 2000-A88 AGMA 2015 DIN ISO

Allows use of "Design Profile" X X

Allows use of "Design Helix" X X

Total Deviation X X X
Angle Deviation X X X
Form Deviation X X X

Smooth Tolerance Curve X X

Optional Band Fit Analysis X

Bands Straight or Curved X

Steppped Tolerance Curves X X

Requires Band Fit Analysis X

Gear Analysis Standards - AGMA 2000-A88

AGMA 2000-A88
Gear Analysis Standards –
DIN, ISO, AGMA 2015
Gear Analysis Standards - AGMA 2015

AGMA 2015-1-A01
 Comparing Gear Analysis Standards
DIN, ISO, AGMA 2015

Description ISO DIN AGMA 2015

Cumulative Pitch Deviation Fp Fp Fp

Difference Between Adjacent
Pitch Measurements fu
Single Pitch Deviation fpt fp fpt
 Comparing Gear Analysis Standards
DIN, ISO, AGMA 2015

Description ISO DIN AGMA 2015

Helix Deviation, Total Fβ Fβ Fβ

Helix Slope Deviation fHβ fHβ fHβ
Helix Form Deviation ffβ fβf ffβ
(DIN calls it Tooth Trace)
Helix Crown Cb
 Comparing Gear Analysis Standards
DIN, ISO, AGMA 2015

Description ISO DIN AGMA 2015

Profile Deviation, Total Fα Fα Fα

Profile Slope Deviation fHα fHα fHα
(DIN calls it Profile Angle)
Profile Form Deviation ffα ffα ffα
 Thank You!
Dwight Smith
Cole Mfg. Systems, Inc.

dsmith@colemfgsystems.com

Office: 248-601-8145 Mobile: 734-516-1365

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AGMA 2012 - Education Calendar

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