UNIVERSITY OF WALES [canDuey SCHOOL OF ENGINEERING ‘THE EFFECT OF SUPERFINISHING ON GEAR TOOTH PROFILE Sponsors: US Army Research Development & Standardisation Group UK London Contract Number N68171-96-C-9043 FINAL REPORT R W Snidle HP Evans M P Alanou Report No 2284 June 1997 sion of Mechanical Engineering and Energy Studies BISTRGUTION STAT! Eee “Approved for public release; Distdbution Unlimited COLEGY BRIFYSGOL YSGOL BEIRIANNEG 19970728 140‘THE EFFECT OF SUPERFINISHING ON GEAR ‘TOOTH PROFILE Sponsors: US Army Research Development & Standardisation Group UK London Contract Number N68171-96-C-9043 FINAL IR’ R W Snidle H P Evans M P Alanou Report No 2284 June 1997 DIC Qvattry mapp, ‘Approved for public release; Distribution Unlimited CTD 4Research Project "The effect of superfinishing on gear tooth profile" Sponsors: US Army Research Development & Standardisation Group UK London Contract Number N68171-96-C-9043 EINAL REPORT RW Snidle H P Evans M P Alanou ‘School of Engineering University of Wales Cardiff Cardiff CF2 3TA, UK SUMMARY ‘The report describes the results of a project carried out to determine the effect of superfinishing of gears on the profile and surface finish of the teeth. A batch of fourteen NASA 3.5 inches reference diameter spur test gears were prepared in the usual way by grinding. The gears were inspected for profile and lead quality and surface profiles taken. ‘The gears were then superfinished by the “Abral” process. Following superfinishing the gears ‘were again inspected and surface profiles taken. It was found that typically the surface finish improved from about 0.4m roughness average (Ra) to better than 0.1um Ra, Results of gear metrology inspection showed that the quality of the gears in terms of profile and lead was not affected by this process. It was concluded that approximately 2.5m had been removed from the tooth surfaces as a result of superfinishing. For further information please contact: Dr R W Snidte Division of Mechanical Engineering University of Wales Cardiff PO Box 925 Cardiff CF2 3TA UK Tel: (01222) 874273 Fax: (01222) 874317 E-mail: SnidleR@cardiff.ac.ukResearch Project "The effect of superfinishing on gear tooth profile” Sponsors: US Army Research Development & Standardisation Group UK London Contract Number N68171-96-C-9043 EINAL REPORT R W Snidle HP Evans M P Alanou School of Engineering University of Wales Cardiff Cardiff CF2 3TA, UK 1, INTRODUCTION ‘The objectives of this project were summarised in the STATEMENT OF WORK included in the contract document as follows: OBJECTIVES: The overall aim of the proposed research is to improve the durability of gears used in helicopter transmissions. The two primary questions to be addressed are as follows: a. Will the superfinishing process adversely affect gear tooth shape? b. What is the relationship between gear tooth surface roughness and gear life, especialty for superfinished gears? ‘The project carried out at University of Wales Schoo! of Engineering was mainly concerned with objective (a); the second objective (b) is to be completed at NASA-Lewis Research Center where fatigue testing of the superfinished gears supplied by the University is now taking place (June 1997). In order to accomplish task (a) arrangements were made for a batch of 14 standard NASA test ‘gears (28 teeth, 8DP, 6.35 mm facewidth) to be delivered to University of Wales. The gears had been finished by grinding in the usual way. On arrival the gears were inspected to determine the initial accuracy and surface finish. They were then superfinished and re- inspected to determine the effect of superfinishing on accuracy and surface finish. Detailed results of the project are given as follows. 2. INITIAL INSPECTION 2.1 Gear metrology Four gears were randomly selected for detailed inspection from the batch of 14 supplied. ‘These were already stamped with serial numbers as follows: AMS6260 #11 a5 oe) .‘The four gears were sent to the UK National Gear Metrology Laboratory at Newcastle University. The following parameters were measured on each gear: ‘© lead and profile errors on four teeth, left and right flanks, spaced at 90 degree intervals; © adjacent and cumulative pitch errors on all teeth, left and right flanks; ‘* radial runout of the tooth space; © mean circular tooth thickness. ‘A reference tooth (“tooth 1”) on each gear was marked so that re-examination could be carried out on the same teeth following superfinishing. Four teeth (Teeth 1, 8, 15, 22) were used in the gear metrology tests. This initial metrology showed that the gears were generally t DIN grade 5 or better on profile and lead. A copy of the metrology report on the gears as received (dated August 1996) is shown in Appendix 1. 2.2. Surface finish In order to show the detailed effects of superfinishing it was decided to take “re-located” profiles from the gear teeth before and after finishing. This was achieved by use of a special stepper motor-driven profilometer with which it was possible to take a profile or series of profiles at a precisely known location on a gear tooth. ‘The principle of relocation was based ‘on detection of the edges of the gear tooth by running the profilometer stylus in the axial direction of the gear to detect the side of the tooth and radially to detect the tooth tip. Three profiles were taken from both sides of two teeth (teeth 1 and 15) on each gear (i.e. a total of 12 profiles from each gear). ‘Two of the three profiles on each gear flank were located Imm from each side edge and the third profile was on the centre line as illustrated in Figure 1. Profile data was taken up to and slightly beyond the tip of the teeth as a direct means of verifying the accuracy of relocation in every case. Figure 2(a) shows a typical profile obtained in this way. It should be noted that the profiles are measured relative to a nominal circular-arc datum and the long wavelength undulations do not indicate any deviation of the profile from the desired involute but simply the deviation of the gear tooth profile from a nominal circular arc. All profiles were processed using a standard phase-corrected digital filter with a cut off of 0.08 mm. The length of the raw profile which appears in the filtered data is show Figure 2 (b) and the same length of profile after filtering is shown in Figure 2 (c). All Roughness Average (Ra) and ten-point height parameters (Rz) values quoted in this report are calculated from profiles filtered with the above cut off. The centre profile (y=3.175 mm) from each flank of the two teeth examined on all four of the gears as supplied are shown in Appendix 2 for reference. The remaining profiles taken at Imm from each edge of the flanks (y=1mm and y=5.35 mm) are not shown for reasons of space, but are available if required. 3. INSPECTION AFTER FIRST PHASE OF SUPERFINISHING 3.1 Gear metrology Following initial inspection the gears were superfinished using the Abral process at Westland Engineering of Yeovil, England. In this process the gears are immersed in bed of small zinc chips, water and aluminium oxide powder. The container (a rubber-lined open tank) is vibrated for a period of several hours and the grade of the oxide powder is increased in fineness in several stages. In the first attempt at finishing the gears were clamped together and ‘mounted along with several other gears of different types that were being handled at the time 2by Westland Engineering. Although the NASA gears appeared at first sight to be suitably superfinished it was subsequently found on detailed inspection that a further stage of treatment was needed in order to achieve the finish (Ra<0. um) that was expected on the basis of previous work. The gears were, however, checked at this un-planned “intermediate” stage and this proved to give a good quantitative measure of the rate of surface removal in the process. Gear metrology was again performed at Newcastle where it was found that there was no significant change in the profile of the teeth. It was concluded from the metrology work that an average of approximately 1)um of stock had been removed from the tooth flanks. The inspectors also commented that the initial grinding marks were visible on some of the teeth. ‘The full report (dated December 1996) corresponding to this “intermediate” stage of finishing is given in appendix 3. 3.2 Surface finish ‘The above comments by the metrology inspectors were confirmed at Cardiff by relocated surface roughness profiles. Figure 3, for example shows relocated profiles from two teeth diametrically opposed on gear #11 (ie. teeth 1 and 15). Comparison of profiles before and after finishing of tooth 1 (Figures 3(a) and 3(b)) show a significant degree of surface improvement, but recognisable deep valley features are still present. These features are indicated with small arrows in both profiles as shown. From this comparison we can see that about 2j1m of metal has been removed from the surface. On the opposite tooth (tooth 15), however, there is less evidence of polishing and comparison of Figures 3(c) and 3(d), which are profiles from this tooth, suggests that about 11m or less has been removed. This uneven and incomplete finishing of the teeth was judged to be unsatisfactory and it was decided to carry out a second stage of finishing by repeating the process. In order to promote an even finishing during the repeat run the gears were clamped together on their own separate mandrel which could circulate freely in the vibrating finishing tank. The mandrel had “dumb-bell” ends to prevent contact between the gears and the sides and bottom of the tank. A run of the finishing process was devoted to the gears and they were the only parts in the tank. A photograph of the gears clamped on their mandrel is shown in Figure 4. ‘The gears were processed for the standard run time as before. After this second stage of processing the gears were found to have a superb mirror finish and visual inspection showed no signs of the initial grinding marks. 4, INSPECTION AFTER SECOND STAGE OF SUPERFINISHING 4.1 Gear metrology ‘The gears were again checked at Newcastle University and were found to be DIN grade 5 or better on both profile and lead as before. The report (dated March 1997, see Appendix 4) concludes: “The measurement results and a visual examination of the measurement traces shows that there is very little difference between the initial flank geometry and the final flank geometry. The superfinishing process has still not changed the basic flank form error but the grinding feed ‘marks have been removed on all the teeth. The normal circular tooth thickness measurementsshow that after the results are corrected for the probe datum error, an average of ‘approximately 2.5m of stock has been removed from each flank” 4.2. Surface finish Following the second stage of superfinishing the four sample gears were again inspected. ‘Three profiles from both sides of two teeth on each of the four selected gears were taken. ‘Typical comparisons of the initial ground finish, the intermediate finish and the final superfinished surface are shown in Figure 5. Again, the profile taken after the first stage of finishing shows persistence of identifiable grinding marks. These have almost completely disappeared from the profile taken after the second stage (Figure 5 (c)) although there are still faint signs of some particularly deep marks. One such mark is indicated with an arrow on all three profiles. Comparison of such features with the initial profile suggests that about 2-3 jum has been removed from the surface. This estimate taken ftom surface profilometry agrees well with the estimate obtained from the gear metrology measurements, Ra and Rz. values for all profiles from all the sample gears before finishing and after the second stage of superfinishing are shown in Tables 1-8. It should be noted that the profiles were digitally filtered with a cut off of 0.08 mm. The centre profiles (y=3.175 mm) from each flank of the two teeth examined on all four of the finally finished gears are shown in Appendix 5 for reference. ‘The remaining profiles taken at Imm from each edge of the flanks (y=Imm and y=5.35 mm) are not shown for reasons of space, but are available if required. ‘Typical three-dimensional surface plots from ground and superfinished surfaces are shown in Figures 6 and 7, respectively. Note that the two surfaces are plotted to the same vertical scale for comparison. It should be noted that the profile data from the right flank of tooth 1 of gear #15 after superfinishing were badly affected by vibration during data acquisition; the Ra and Rz values for the three profiles affected should therefore be ignored. These profiles are not shown in Appendix 5.Table 1. Roughness Average (Ra) results (um), Gear AMS6260 #11 Tooth Flank Position Ra as ground | Ra after superfinish 0.434 10558 left 0435 0.0529 1 Oai7 0.0607 0.351 0.0805 right 0.358 0.0562 0346 0.0753 0432 0.0884 left 0.450 0.0707 15 0.455 C067 0522 0.0458 right 0.320 C087 0.350 0.0608 Table 2. Roughness ‘Average (Ra) results (um), Gear AMS6260 #15 Tooth Flank Position Ra as ground | Ra after superfinish =imm 0.484 0.0912 left y=3.1 75mm 0513 0.1008 1 y=5.35mm 0477 0.0926 y=imm 0.358 0.1322" right 0.366 0.1366" 0348 Oa 0.476 0.0620 left O47 0.0535 5 0.470 0.0658 0.333 0.0585 right 0.335 0.0552 0341 0.0676 * Vibration during acquisition of these three superfinished profilesTable 3. Roughness Average (Ra) results (um), Gear AMS6260 #20 Tooth Flank Position Ra as ground | Rafter superfinish y=imm o415 0.0723 left y=3.1 73mm 0.458 0.0759 1 35mm 0471 0.0972 0372 0.0829 right y=3.1 75mm 0.364 0.0575 35mm 0-350 0.0600 y=imm 0.394 0.0765 left y=3. 17mm 0.415 0.0785 5 y=5.35mm 0.435 0.0735 y=imm 0.351 0.0518 right y=3.175mm O34 0.0590 y=5.35mm 0.335 0.0598 Table 4. Roughness Average (Ra) results (um), Gear AMS6260 #23 Tooth Flank Position Ra as ground | Rafter superfinish y=imm 0.400 0.0711 left y=3. 175mm 0.402 0.0629 1 y=5.35min O48 0.0553 y=imm 0.270 0.0683 right 175mm 0275 0.0642 0.259 0.0659 0.345 0.0976 left 0.345 0.1082 15 0.355 0.0879 0.268 0.0623 right 0275 0.0750 0.267 0.0615Table 5. Ten-point parameter (Rz) results (um), Gear AMS6260 #11 Tooth Flank Position Re as ground | Re after supertinish yeinm 3.75 O6I left 175mm 3.64 0.55 1 y=5 35mm 35.50 a7 y=inm 3.03 1.07 right 175mm 3.24 1.56 3.08 0.86 3.0 120 left 4.01 0.88 15 3.8 0.63 2.72 0.50 right 2B 1.06 2.65 0.68 Table 6. Ten-point parameter (Rz) results (um), Gear AMS6260 #15 Tooth Flank Position Rz as ground | Rzafier superfinish Imm 3.84 1.36 left y=3.1 75mm 4.08 135 1 y=5.35mm_ 3.90 148 y=imm 38 123" right y=3.1 75mm 401 | 0.8" y=3.35mm 3.88 1.30" y=imm a3 cr) left y=3.173mm 430 OT 15 y=5.35mim 395 120 imm 37 0.77 right y=3.175mm 3.84 1.04 y=5.3omm 357 1.08 * Vibration during acquisition of these three superfinished profilesTable 7. Ten-point parameter (Rz) results (1m), Gear AMS6260 #20 Tooth Flank Rz as ground | Rz after superfinish y=inm 378 Tid left y=3.1 75mm 538 1.00 1 y=5.35mm 78 138 y=imm 3.38 0.49 right yas. 5mm 405 068 y=5.35mm 3.35 0.68 358 1.35 left y=3.1 75mm 3.61 Tis 15 3.46 Ti y=imm 3.49 0:59 right y=3.1 75mm 334 0.68 372 0.39 Table 8. Ten-point parameter (Rz) results (um), Gear AMS6260 #23 Tooth Flank Position Re as ground | Rz after superfinish y=inm 348 1.00 left y=3.1 73mm 3.34 0.95 1 y=5. 35mm 3.2 O82 y=imm 3.05 0.84 right 7.86 073 256 0.79 3.01 116 left 2.98 1.39 15 3.00 1.20 y=inm 2AT 0.68 right y=3.1 7mm 2.66 0.86 y=5.35mm 2.80 0.675.. DISCUSSION AND CONCLUSIONS Asa result of careful gear metrology and surface profilometry it was found that the amount of surface metal removed during the standard process as implemented by Westland Engineering was relatively small and did not have any adverse effect on the gear tooth geometry or profile. The test gears as supplied were found to comply to DIN grade 5 or better and they were still within this grade after finishing. One cycle of the standard process was found to leave witness traces of the initial grinding, and in order to achieve the best possible finish a second cycle of the process was applied, After two cycles of finishing it was concluded on the basis of both metrology and surface profile measurements that about 2.5um of surface metal had been removed from the gear flanks. This would appear to be about the imum required to remove all traces of the initial grinding marks for gears with an initial nominal finish of 0.4 um Ra, ‘The final surface finish of the gear flanks was in the range 0.05-0.1 ym Ra. In conclusion, therefore, the answer to the question “Will she superfinishing process adversely affect gear tooth shape?” is: no, the process as presently implemented gives minimum metal removal and ensures the integrity of the tooth profile. This conclusion assumes, of course, careful control of the process. 6. ACKNOWLEDGEMENTS We are grateful to Mr Graham Wilkie and Mr Paul Fisher of Westland Engineering for their careful finishing of the gears and to Mr Rob Frazer of Newcastle University Design Unit for his equally careful gear metrology. 7. FURTHER INFORMATION For further information please contact: Dr RWSnidle Division of Mechanical Engineering University of Wales Cardiff PO Box 925 Cardiff CF2 3TA UK Tel: (01222) 874273 Fax: (01222) 874317 E-mail: SnidleR@cardiff.ac.ukFigure 1. Illustration of gear tooth showing x,y coordinates and location of the three profiles (shown as broken lines) taken from both sides of two teeth from each gear. ‘The y-coordinates of the profiles shown are: @ 1mm ©) 175 mm © y=5.35 mm Start and end x-coordinates of raw profiles are x=3.097 mm and x=-0.1 mm, respectively. (The negative end coordinate ensures that tip of tooth is detected as a check on relocation of profiles in x-direction.)“8 g 8 @ RD861.DAT T | | I pm | ! | +4 100 pm NASA gear #11 (ground), tooth L/left, x=-.1mm y= 3.175mm 8 g ® RDE6I.DAT qT Iam = 100 am NASA gear #11 (ground), tooth L/left, x=-.1mm y= 3.175mm © RDB6LFIL i bh NM eA NA aie eae W\ WV \ay pein MAK on NASA gear #11 (ground), tooth 1/left,x=-.1mm y= 3.175mm Elwtn.t.no.: 24DESIGN UNIT Lead + Profile Test Designation: Mo 3.175, > 2 am 3, [Patios AMS62607.7. x28 Lp 30 x 85 |ReWaRKs: REF _15~1ST 20°00" Sy 83.539 on 33 6 o'o'o" 33 Be 33 |_Quality Readpr: 5 / Le:5 Actpe: 5 / Le: 2 Read.pr5 / te.5 Actin 4 / led 33 7 3 let Fank 2 + Weomn 2 Rin Fank 3 7 ae I i I 35 7 so. 1000: ae : 7 100 = a. 08 Lk | ahi® oC td) I Root i FC) a a umilve 1 2s = [ow 2 22 Bt 46 Jasls [0/7 ee eee gare ces aga & [heo/s i659 ag lasts love ‘Tanti 16 37 | ala 8 [tena 5 £ 1.8 =5 42 113 [+4 B 15. ah uz eee eee TS Tat Fene 2 1 wom z Bottom 18 8 4 Too} Not a e | ge Bele: | 2 x 1 y t 1 1 2 gf | a [ta Bo laces | | s Is 2 = \ | = oF i | 8 jio00: ya i . Z blo AI : Ba || um eal jf] | 23 S i a | Top | i fe) ws [Erte] 3 2 1 LumitVatue 4 2 3 4 S| $ [Foz nl ur [eda [o/7 Ta a ao Taal IS] 8 [foras [7 ges pee ge ligt [yates eae zt =| 2 [ho . ps ts Toa fee Tos sais :PITCH + RUNOUT TEST to DIN 3962 / AGMA 29003 en-Thodeande ofan Inch 4 m DESIGN UNIT NSB260, REMARKS: REF_15-45T m= 3 sem] b= 000 A a= Date/insp.06 08. 1996/ACF t ix Fi Fal tT. 5 5 5 5 lg 5 ig 5.0] 6.0] 20.0] 42.0] 2 14.0] 3] 1.8) 2.2 44 3.7/5 4 els 2 1 1 2 |= 2 4 |s WANT.NOL 28 ‘eons Tbe rors E]mtn.1.no.: 17 fEimi.t.no.: 22 * |e pe Left Flank MAX.T.NO wees] ‘TO! ‘Li T.NO.: tf Elwtn.t.no.: 24 IFDMIN.t.no.: 17 TApDOWAE > El san.7.no.: 8Quality loves to ON 9962 / AGMA 390.03 ‘um/Tenthousands of an inte Yak 08: 24 ate: 07.08. 1996 Inspector ACF NATIONAL GEAR METROLOGY LABORATORY EMZ 632 Fob 018-4/96 DESIGN UNIT Lead + Profile Test Designation’ 3.175 b 6.35 PartNo: aMS6260/./. 26 20 x REMARKS. REF 20-4ST 20°0" 83.539 on 00 Gualty Read.pr: 5 7 Le: 5 Acker 5 7 Le 5 4 7 is 3 Lek Fank 2 7 Profile + oa =a Root Tinivane] a 3 Limi value 1 0/7 oF. tn 0/5: 2 Laue 1a 29 etd 5 Bottom 2 Tead 5.03 Top Umit vaive] 3 Lit value 50/7 4 a 13 aaa O/7 salt feo/ast 4 2 bhL Lf 15 074.5) 4 oT aaaat salt has-5, ai pane =6 =a +6 19‘Quality levels to DIN 3962 / AGMA 390.03, Values in y/Ten Thousands ofan ach TRpb OE + DESIGN UNIT PITCH + RUNOUT TEST Part Nox ANS6260/_7. REMARKS: REF 20-157 ze 2g [m= 3.175mm[ B= 0°00" A [4@= _G8.900 mm] Date/insp-06_ 08. 1995/ACF Py i [eae & Refs Tee eT Reqd. Qual 4 5 5 5 Sole 5 a 5 5 — Umavalve/§} 5.0 6.0] 20.0] 12.018] 5 6.0] 20.4 2, 14.08 act vat Je} a) a} es} a fel Ao) vel A 5.6/2 Act Qual. |S 4 4 3 2 |= : 1 - 1 3 |= WTA HB TaN pe = t | MIN.T.No.: 14 PO [Elmn,t.no.: 10 yi oo 10 = ea > eT Eb in.t.no.: 19 FR | ED MaN.1.No.: 5 oe j oss | of um — oe iat MAX.T.NO.: 20 El uax.t.no.: 9 F, oon 100 | eID epee — e Elsmn.t.wo.: 24DESIGN UNIT Lead + Profile Test Designation ™ 3.17 [> gag am 3, |[PartNo. ‘ANS6260/./ 28 Up 90 x 82 [pewancs ner 23-1st oo 20°00 dy 83.539 nm 38 aria g3 Bo gal Guaity T Reader's 7tes Aten 7 lea | RewhonS ing At boa 7 Les a: 2 3 Let Fank 2 Teoma 2 Ran Fank 3 7 33 38 i ai 38 oot Soe ae a FoQ/7 47 1 at 23 aaa | 0/7 25 19 4 19 8 [ove ri aah zi tags Tore (ip a2 as ag 3 [eecasl -7 ee 15 Tiga Tena 5 Lone gunais a 3 en Fark 2 7 tom Ron Rance i = | eotom is 8 1 Tooph Not 5 i ee | 3 gfe: 1 | i 3 , 1 i ys 3 RR a | 3 1.25 tae | a e | = oS | = bool i‘ g 2 I @ |1000: [5 i a | Z bok i Ea um 9 ea] « $3 1 4 f I Bl we | : wy [Umevane] ——¢ 2 2 1 umtVveue 4 2 a 4 = [Fs0/7 1a 12 12 o [salt Jo? Ba 29 126i 8 [eoast ep 12a Tide Tovast as eee 16 [asi 2 [eins ar eves 7 rr 1NATIONAL GEAR METROLOGY LABORATORY. levels to DIN 2962 / AGMA 390.03 Values in yn/Ten-Thousands ofan net a TApbOW-AE > ao PITCH + RUNOUT TEST | PartNo: _ause260 REWARKS. REF 23-157 z= 2g [m= ‘E= 88.900 Tm] Date/insp.07 08. 1996/ACF i i A Regd. Qual} é 5 5 a Bi oe Lit valve | 2] 5.0] 6.0} 20.0] 42.0] 14.0] § Act Value | B] 2.6) 20] 10.4) sol] 46/8| ‘Act. Qual. | 3 je] 4 1 3 3 ale. F max.t.No ee ee ee ve oS : ee ore | EE =r 2 EV MIN.T.NO.: 17 FIWIN.7.No.: 24 co Fl max.T.No.: 28 Fl wax.t.no.: 9 2 —— | 10 a inn um pe!) oe 5 - = T T.NO.: 25 Ff, mn. 7.10 ET MIN.T.No.: 13 —————— 28 a a et mS a SS NAX.T.NO.: 25 | [El max.t.no.: 13 F, a sonlfonfinifnenn as [Elumn.t.no.: 9APPENDIX AINTERPRETATION OF GEAR MEASUREMENT RESULT SHEETS. GENERAL, ‘The gear measurement results in this report are from CNC measuring machines in the UK National Gear Metrology Laboratory, which is run by Design Unit. The measuring machines Used are traceably calibrated to National Standards using a range of master gears and gear artefacts which have been calibrated at the European National Laboratory, PTS, in Germany. Gears have been measured in accordance with procedures layed down in DUCOP.03, a code of practice for involute Gear Measurement, which is issued by Design Unit and 8GA ( Srtsh Gear Association ) Itis the policy of the laboratory to measure lead and profile errors on 4 teeth equally spaced at 90 degree intervals. Both left and right flanks are measured, adjacent and cumiatv pitch errors onal teth on lef and ight aks «. rail runout ofthe tooth space, 4. tot hiekness. «. radial runout ofthe reference bands on the gear measuring mactine. Measured error are interprated sity in accordance wih the specie standards. tis the policy of the laboratory to evaluate errors in accordance with DIN 3962 ifthe accuracy requirements are not fully specified. The following sections show how to interpret the result sheets and define the parameters which are measured and evaluated,‘THE DEFINITION OF LEFT & RIGHT FLANKS. ‘A definon of lef and right flanks in accordance with ISO 1328 ( Technical Reports is given in Figure.1. Note thatt is important to know which way up the gear was mounted on the ‘measuring machine for he correct interpretation of the measurement records, At Definition of left and right flanks on an ‘extemal gear and teoth numbering tank m4 aetlaak SH A Pe AZ. Definition’ of left and right flanks on an intemal gear and tooth numbering Figure 1. The definition of left and right flanks,PROFILE ERRORS. Profle errors are measured to define the diference between a true involute form and the actual measured prof. Athough the involute is a curve, the difference between the trie involuta form and the measured form is given as a deviation fram a straight line. See figure.2. Profile errors are usually measured at mid face width unless specified otherwise. The profile error curve is evaluated between lines, one of which is the start of active profle and the second specifed as 8% of the total active length of the profile The measured results are compared to the DIN standard and the accuracy grade of the gear is determined. The largest error measured determins the accuracy grade of the gear. All errors are measured in the transverse plane, Errors are analysed in accordance with DIN 3962, which specifes 3 parameters fe profile form errors. fre profile slope error FZ total profile errar Guaity | Read PRET TES Ac PRTO7 Lett | aca PF Ee act PP e 7 o tahFenk = Tooth 7 T agerank 3 7 Profile Foot Uneven] 4 %_ O73: or eT gq saa gy a 4 q aa gq Figure 2. Profile error parameters.LEAD ERRORS. Lead or tooth alignment errors are measured at the pitch circle diameter af the gear assuming that the gear is mating with its basic rack. Lead errors are evaluated over 60% of the facewidth unless stated on the drawing, Deviations from the true helix of the gear are plotted as errors from a straight line All lead errors are measured in the transverse plane. ‘The parameters which are evaluated in accordance with DIN 3962 are fy lead form error. fr _ lead error slope. Fy total lead error. ‘An example of these parameters are given in figure. 3. 7% Tygthen 2 7 mn Nod Tparran 345 ors as 7 1 Te 8G Bottom mit vava| 2 1 4 WS] sia OS a cy 3 a oat 2 & te O725| 34 watt 07s | J Fel sO TS ee a Tas] Figure 3. Lead error parameters.PITCH ERRORS. Pitch of spacing errors are measured on all teeth, both left and right flanks. Errors are measured at mid face width and at the lead measuring diameter unless specified otherwise, ‘Adjacent pitch errors ( errors between adjacent pairs of teeth ) are plotted on the record sheet land the largest error is printed out and compared to the DIN Standard, Cumulative pitch errors are calculated by summing the adjacent pitch errors andcalculating the total range of errors, Again the value of the error is compared to the DIN Standard, Radial runout of the tooth space is calculated by computing the radial postion that a ball would sit in the tooth space. The total variation inradial position is the radial runout erro. ‘The parameters evaluated are adjacent pitch error F, cumulative pitch error F, radial runout of the toothgap | Examples of the parameter calculated is given in Figure 4.PITCH + RUNOUT TEST Left Flank Hi Ne EXARKS. © j= 24 [m= 49 mm) 8= _9°9'o" A Date/Insp. 44/ @. Re TT Ae % camara Ee Rec. Qua ale a Alea wale unavatie|8] 20 | a5 71 7 5 s/s act vaiwe |=] 9 | 37 Fs : 8 68 6 | a || 77 13 sou [8) fo | i 8 a a a [8 23 a vin. B. mF Bar 33], 33) 4 = 33|_im d ge) sz <3 5 ey Ze | 24 ! Fie ' a” | i a é fa fnaenll oo te Loft Flank THpbOW-4E > | infnoll El ann.t.no. 4 FiGvZe 4, BAMAE & PITOT esr. iAPPENDIX 2 INITIAL SURFACE PROFILES OF GEARS AMS6260 #11 : #5 . #20 : 423,‘RD86L-FIL 100 pm NASA gear #11 (ground), tooth I/left, x=-.Imm y= 3.175mm (filtered:Ra=0.425,m/0.08mm cutof ~ RD867-FIL edna len lo + 100 pm NASA gear #11 (ground) tooth 1, right, x=-.1mm y= 3.175mm (filtered: Ra=0.358um/0.08mm cut em ~RDS6E-FIL re Ait 1 100 wm Imm y=3.175mm<(filtered:Ra=0.4504m/0.08mm cutoff) NASA gear #11 (ground), tooth 15/left,x: @ RD870.FIL Apion. +4 100 pm Imm, y= 3.175mm (filtered: Ra=0.320um/0.08mm c NASA gear #11 (ground), tooth 15/right, x@ ‘RD885.FIL Ni L 4 100 pm NASA gear #15 (ground) tooth 1/left, .1mm, y= 3.175mm (filtered: Ra=0.513m/0.08mm cuto: RD891.FIL ntti 1. 100 pm NASA gear #15 (ground) tooth L/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.366.m/0.08mm cut ‘RD8s.FIL va 100 um Imm, y= 3.175mm (filtered: Ra=0.471nm/0.08mm cub NASA gear #15 (ground) tooth 15/left, x: @ RDSSE FIL kenny AN 5 100 pm NASA gear #15 (ground) tooth 15/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.335pm/0.08mm ct@ 897 FIL, in Jam 100 pm NASA gear #20 (ground) tooth 1/left, 3.175mm (filtered: Ra=0.458um/0.08mm cuto ®) RD903-RIL Ne A Mel) 100 pm’ NASA gear #20 (ground) tooth /right, x=-.1mm, y= 3.175mm (filtered: Ra=0.364um/0.08mm cut RD9O0.FIL needa md 4 100 pm’ Imm, y= 3.175mm (filtered: Ra=0.415pm/0.08mm cut NASA gear #20 (ground) tooth 15/left, x: hare 4 100 pm Imm, y= 3.175mm (filtered: Ra=0.341ym/0.08mm ct NASA gear #20 (ground) tooth 15/right, x:@ RDE7S-FIL i = 100 pm Imm, y= 3.175mm (filtered: Ra=0.4024m/0.08mm cuto NASA gear #23 (ground) tooth 1/left, x: RDS75.FIL eno whit 4 100 um .275 um/0.08mm cut NASA gear #23 (ground) tooth I/right, x=-.1mm, y= 3.175mm (filtered: Ra* RDS76.FIL Renee reer L. + 100 ym --.1mm, y= 3.175mm (filtered: Ra=0.343.n/0.08mm cut NASA gear #23 (ground) tooth 15/left, RDSS2.FIL lr oo hil Hh 4 100 pm NASA gear #23 (ground) tooth 15/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.275um/0.08mm c.APPENDIX 3 INTERMEDIATE METROLOGY INSPECTION OF GEARS AMS6260 #11 . AS “ #0 : #23+R DESIGN UNIT ‘GEAR TECHNOLOGY CENTRE (es University of Newcastle upon Tyne Department of Mechanical Materials & Manufacturing Engineering Stephenson Building Newcastle upon Tyne NEI 7AU 4 December 1996 Project GM 373/2 ‘Superfinishing Investigation Final Measurement Results Cardiff School of Engineering, University of Wales, Queens Buildings, The Parade, P.O. Box 97, CARDIFF CF2 1XH Gear Reference: AMS 6260 ‘Samples Checked: NP. 11, 18, 20 and 23 (see GM 373/1 forthe initial measurement results) Parameters Measured: ‘The following parameters were measured on each gear: 1 2. 3. 4. Results: Lead and profile errors on 4 teeth, left and right flanks, spaced at 90° intervals. Adjacent and cumulative pitch errors on alll teeth, left and right flanks. Radial runout of the tooth space. Mean circular tooth thickness. ‘The measurement record sheets for each gear after superfinishing are included at the end of this report. Please refer to report GM 373/1 of 7th August 1996 for the original result sheets ‘An examination of the record sheets show that there is very litle difference in measured errors between initial and final results. The differences in total error parameters (F. and F,) and mean error slope (fy, and f,,) are predominantly caused by slight differences in ‘mounting error during measurement. Therefore, for this analysis, the average form error Diestor OA. Hofmann Ta tora 2226192 ME, Norman J Rosineki Direct Oia 10191) 222 Ashby Haigh Fax 10190) 22 EJMyers RC Frazer Madparameters for left and right flank f,, (profile form error) and fy (lead form error) have been used for comparison together with the average normal circular tooth thickness measured(S,). A summary of the results is given in table 1 Discussion of Results: ‘The measurement results in table 1 and a visual examination of the measurement traces shows that there is very litle difference between the initial flank geometry and the final flank geometry. The superfinishing process has not changed the basic flank form. (This is supported by a visual examination of the gears which show that on most of the tooth flanks, the grinding feed marks are still visible) The normal circular tooth thickness measurements show that after the results are corrected for the probe datum error, an average of approximately ‘im of stock has been removed from each flank. A visual examination of the gears shows that stock removal is uneven: some teeth are highty polished but on others the grinding marks and ground ‘dul! finish still predominates the flanks. In this test, we must conclude that process was not correctly controlled. Sample | Flank Initial Results Final Results i fp 5, a fy = " uF | 28um | t.4ym | 471mm | 29um | 1.8um | 4.868mm RF | 4.99m | 1.4um : 1:8um_| 1.8m : 5 uF | 3.5um | ogpm | 4.883mm | 3.6um | 1.2um | 4.881mm RF | 2.4m | O.7um - 3.0um_ | O.7um - 20 uf | 2.0um | 27m | 4.863mm | 1.7um | 2.¢um | 4.860mm RF | 1.9m | _1.4um - 24ym_ | _1.6um : 23 uF | 2.5um | 16pm | 4.ee4mm | 2.5ym | 1.9um | 4.880mm RF | t.9um | 24um : 4.8um | 2.3ym : Table 1: Summary of Results Note: The difference in probe diameter, calibration size is 1.2um (ie. the probe calibrated +1.2um during the final measurements). This will reduce the nominal measured tooth thickness in the final results by 1.2m compared to the initial results,(DESIGN UNIT aaa rence ei University of Newcastle upon Tyne Department of Mechanical Materials & Manufacturing Engineering Stephenson Building Newcastle upon Tyne NEV 7AU, GEAR MEASUREMENT SUMMARY SHEET Client: huverody of wWalen DUReterence: Grn S7S/2 GearDrawing: AMS 6260 GearReference: EF WS ~20£ 25 Manufactured By : Parameters Measured : Lead /Profie / itch / Runout / Tooth thickness / runout of reference bands. Runout of Reference Bands mevatiig! arpandiig mandiel with etched Aetuls at Ha tp | Accuracy requirements Results PARAMETERS | TOLERANCE | MAX ERROR ‘COMMENTS (Gm) am) LEAD PROFLE ‘ADM. PITCH (CUM PITCH RUNOUT, PITCH DIF. THICKNESS General comments : 1 Gears have been measured in accordance with the code of practice DUCOP.03 for Involute Gear Measurement. DMeacuwrement Aefals ace werhtal to Gu373/t Equipment: Machine: Mofler ou 22 Probe: f/-2 ‘All measurements were carried out on traceably calibrated equipment in the UK National Gear Metrology Laboratory (NAMAS Accreditation number 0250 ) Measured by Riggers Date: 3 Dec 9G Director OA. Holman Tet wen 222 6192 M.E,Nownan J Rosinki Deeet Oia (0191) 222 Ashby 3 Haigh Fax: (0191) 2226198, EJMyes A.C Fazer EMailNATIONAL GEAR METROLOGY LABORATORY EWZ 632 HOFLER Jevels to DN 9962 / AGMA 390.03, hited in umn/ton Trousande of ah neh Qual 03.12.1996 16: 57 Date: Inspector?CF Fob 018-4/9E. DESIGN UNIT Lead + Profile Test Designation 73.475 ae [> gg5 ne PartNo: AMS6260/.7 228 ty 90 x REMARKS” REF_11-2ND oo 20°00" dy 83.539 nn B o'oro"” Bs Quality T Readpr5 / tes Actors / tes [Readers / eS Act pris / tee 4 3 LatRank 2 1 woh 7 2 Gh Fark 3 7 To. | act | =o He on . a ad i | 4 + 10 | wm | oot I Uni vaue] 3 2 1 umilvave 1 2 3 ‘ POT 18 Hl a 20 Tada lo? [4 ia ay TI [tore 5927 tg 20 fais Los | 4 11s 6ld Toba 2 6 216 fina [east a7 2 a 6 Gat Rank 2 Teoh 7 2 Ran Fak 3 pottom | ©)z2 18 8 4 Toon Not 8 22 ® a: on 1 ° lo SL ° 4000: 4 | Pi 10 om - | 1 Unitveive| a 2 2 1 umivawe 1 2 3 4 FS0/7 ao teeta [ele To/7 2 a7 [oe fo0/ 4. A 18 44 13 | tal o/a5 | pe 16 47_| tal og [uy pa [as Ts ieee st ToaDESIGN UNIT Lead + Profile Test Designation: mm 3175 mS 6.35 am 8, | PartNo. AMS6260/.// z 26 tp 90 % 2 lpewanks: REF 15-2N0 en 20°09" iy 83.539 nm ae 6 p'oo"" 3 Bs @5[Guaiy | Feadprs /te5 Aten G 7 tee |ReadenS/tes AtPrS / lel ee 4 3 aan 2 Tom 2 Rh Fank 8 7 Fa Be ie ae N Ee z LC I 000: 7 ] ay | Jo | { 10 4 | 5]! | |e - 1 Foot ' Simm] ss wl 1 2 3 5 [oe fees ad [aals To/7, L 42) a9 & [o/s 4 igo: 47 [ase foe | 43 4926 8 [teras 17 ete e [eee oes ef ea peta ata ng Poe eee ee 7 J ut Fane 2 7 wom 7 han Fark 5 z= | eottom | ©)ze is é 1 ToD} Not oe 15 28 a8 era 5 a) a (te g lo 2 s_ g ° B |1000: 4 z bi 10 | ST top w [Doman] 3 [Row A & [sora 16 op it [yale Toras [10 6 af ai 2 [tors a. 2 -9 [eat [4-6 = =f =4 g i= 1itDESIGN UNIT PITCH + RUNOUT TEST PartNo ANS52607. 7. REMARKS. REF_11~2ND z= 28 [m= __3.475mm| B= _0°0'0" A d= 88.900 _mm| Date/insp.:03. 12. 1996/ACF i te] & [fae i | Regd. Qual} 5 5 5 5 |g 5 5 5 5 Sele Limit Vatve | 5 5.0) 66.0] 20.0) 12.0) 5.0) 6.0] 20 12 14.03 Act Value |e 27 25] 14.39 7.35 24 2.0] 42 6 6.2 jAct Qual, | 4 3 4 4 |e 2 3 4 4 3 [8 : Ree ¥ ee ee < Elwn.t.no.: 2DESIGN UNIT PITCH + RUNOUT TEST Pan Nos AMS6260/.7. REMARKS. REF _15-2N0 z= 26 [m= 3. 475mm Ooo A _[o= 68,909 mm] Dale/insp..03. 12, 1996/ACF t Ee. [fae 3 Se, & | fae ale eegd. Qual] 2 5 5 G 5 lg 5 5 5 5 Gels Umeveue|§] 5.0) 6.0] 20.0) 12.018] 5.0) 6.0] 20 12 14.0|5 At Value | oe ee et 2 10.28 act Qual |S} 2 3 3 3 fe] 1 4 4 1 a8 . El max.T.No.: 43 ee cee ee aa) 36) : $3) um 2 gs a 3 i). 8G) ¢ _[Clum.t.no. 5 28 4 sep (El aax.t.no.: 27 El max.t.no.: 19 wy, 10 & pm_ NATIONAL GEAR METROLOGY LABORATORY Ebmax.t.no.: 12 El max.t.no.: 28 TR pode >Peerererrerteteeneeteeeteneere eterna eter ener levels to ON 3962 / AGMA 990.02 ‘alot in um/Ten-Thousaade ofan inch ual 16: 29 ate: 03.12.1996 5Y LABORATORY Inspector ACF NATIONAL GEAR METROLOG EMZ 632 Fob 018-4/06 HOFLER) DESIGN UNIT Lead + Profile Test Designation: Mn 3.175, Load IEEE “FE 1 = PartNo: AMS6260/.7. 228 Uy 90) x REMARKS: REF _20-2ND_ on _20°0'0"" dh 83.539 am 6 ooo Es Quality Readpr: 5 / Le: 5. Actpr: 4 / Le: 5 Read. pr: 5 / Le:5 Act. pr: 4 / Le: 2 4 3 LaiFank 2 Tooth 7 AGH Rank 3 + + 1 | | | Root I 7 I Cnnwne] ce 1 Limite 1 23 4 F0/7 4 5s 20 23 Tada for fir ee psa Tazla 70/6 pee ego ge gee ng et ay 45 2g 20 20 Lana least -42 25 -5 2 Tol4 z J let rank 7 on Taare S aotom | ©)z2 s 1 Too} Not auerents © asa Ba = 1.25 =< lo fone ° 4000: 4) 10 4 pm © I ‘Umit Valve | 4 3 2 4 mit\aue 1 a a 4 0/7 4 came ada lor [ae coer 12 [oie 30/4 ri 77 aegis foes ua ig te 12 Lisle egal] ey eee ger ates Tes Te te eeerare ee TEE TEESE TEESE EE SESE ESE EEE EEE EES & 33 83 Be i pate: 03.12.1995 Inspector CF NATIONAL GEAR METROLOGY LABORATORY EMZ 632 HOFLER Feb 018-4/9E DESIGN UNIT Lead + Profile Test Designation: 3.475. mm [e635 am PartNo: AMS6260/./ 228 Lp 90 x EMARKS: REF 23-2ND eo 20°00" Op 63.539 no 6 o*o'o Bo l Gealty | Readpr§ / les Actes / lee [Reders/les Aterd / Le 7 3 eh Fank 2 1 two 2 RR Fank & 7 To 1 2:4 | 9 A | | + 1 1000 v . ad 4 P29 | em | | oot 1 Umavaue] 4 2 2 ‘ untae 1 2 3 ‘ Feo/T ug 2s 2a 9 Toda Jor [ep 2 22 Tale 60/6 a5 at to at Lass Toe [a3 22 gis [isis fo sg 1g o 12 Ty03 Teas 4 g 2 ats 1000 Hed Oz Get ank 2 é Tom 7 1 ‘oan Not pm 6 Z Top Unitvane| 6 3 2 1 Limite 1 2 3 4 Foo/7. aan a o Tools Torr ceneeaiy y 25 [oat feo/4 ee a_i8 [role fovas [oe 5 4 + foal hoe <3 =y 6 Laat 16 i 1 A zuPecreeteeeeereeeestestesete ete ete teen ett ete te te tee ee eee eee eee eee geeg cease geese See eee eee eee eee eee eegeeg eee GEAR METROLOGY LABORATORY NATIONAL, HOFLER TR pb OWE > El mtn.t.no.: 13 Elmint.no.: 10 El max.t.no.: 4 DESIGN UNIT PITCH + RUNOUT TEST | PartNo AMSE260/.7 EMAEKS. REF_20-2ND z= m= 3.175mm[ B= 0-00" A 8,800 mm] Dete/insp.03. 49, 1996/ACF & Gi naleeh, ta [are % a | A Reqd. Qual) 5 5 5 5 lg 5 5 5 5 5 le Umbvawe}] 5.0 G.0] 20.0] 12.0} = 5.0} ) 0] 20. 12 14.08 acvaue fe] 2 2) gif 5.f8] ot 2a] ed 6 4] sol ‘Act Qual. | 5 4 : : Emi 1 1 2 2 a {8 Hl waxct.no. 25 a a ar er El max. t.No.: 5 Right Flank El max.t.na.: 24 GD max.t.no.: 10 Elatn.t.no.: 250 ——————— DESIGN UNIT PITCH + RUNOUT TEST Pathos ausaono/ 7 REMARKS AEF 23-2N0 z= oq [m= =a 99 wn] Daterinsp.n3, 4p. 4996/Acr t i 7 Recd. Qual «| 5 5 5 5 3 5 5 5 5 5 |e limtvave|B] 5.0] 6.0 | 20.0] s2.0/€/ 5.0] 8.0) 20.0 s2.0ff 14.0] § We le 3} a2] 42.7) 5.9/8) 22] 22] too] sll 56/8 acto 3] 33} 3 i reat aL “ aL 38 3 1 ee oe 32 5 3 gs v | 8G] _ Flmn.tno. at c= ze 5) wew.t.no.: 20 ae * 23 és [El win.t.no.: 25 [FlMin.T.No.: 13 NATIONAL GEAR METROLOGY LABORATORY [5 wax.t.No.: 25: E) max.T.no.: 14 Tap Owe > EV wtw.t.no.: 9APPENDIX 4 FINAL METROLOGY INSPECTION OF GEARS AMS6260 #11 7 415 : #20 . #23DESIGNUNIT SS CGEAR TECHNOLOGY CENTRE University of Newcastle upon Tyne Department of Mechanical Materials & Manufecturing Engineering ‘Stephenson Building Neweastle upon Tyne NET 7RU 143 March 1997 Project GM 373/3 ‘Superfinishing Investigation Final Measurement Results Client: Cardiff School of Engineering, University of Wales, Queens Buildings, The Parade, P.O. Box 97, CARDIFF OF2 1XH Gear Referens AMS 6260 ‘Samples Checked: N°. 11, 15, 20 and 23 (see GM 373/1 and GM 373/2 for the previous ‘measurement results). Note: The 4 sample gears have been superfinished for a second time because stock removal after the first attempt was uneven, Parameters Measured: ‘The following parameters were measured on each gear: 1. Lead and profile errors on 4 teeth, left and right flanks, spaced at 90° intervals. 2. Adjacent and cumulative pitch errors on all teeth, left and right flanks. 3. Radial runout of the tooth space. 4, Mean circular tooth thickness. Results: ‘The measurement record sheets for each gear after superfinishing are included at the end of this report. Please refer to report GM 373/1 of 7th August 1996 for the original result sheets and GM 373/2 for the second set of result sheets. ‘An examination of the record sheets show that there is very ttle difference in measured Director: 0.A. Hofman Tek oan 2226102 MLE. Norman J. Rosinsks Doct Oia (0191) 222 RAsty oh Haigh Fax (0191) 2226198 EdMyers RC. Frazer E. Maierrors between inital and final results. The differences in total error parameters (F, and F,) and mean error slope (F,, and f,.) are predominantly caused by slight differences in ‘mounting error during measurement. Therefore, for this analysis, the average form error parameters for left and right flank (profile form error) and fy (lead form error) have been used for comparison together with the average normal circular tooth thickness measured{S,). A summary of the results is given in table 1. Discussion of Results: ‘The measurement results in table 1 and a visual examination of the measurement traces shows that there is very ite difference between the initial flank geometry and the final flank geometry. The superfinishing process has stil not changed the basic flank form error but the grinding feed marks have been removed on all the teeth, ‘The normal circular tooth thickness measurements show that after the results are corrected for the probe datum error, an average of approximately 2.5m of stock has been removed from each flank. Sample Flank Initial Results Final Results aa 5, f 5 4 uF 2.8um 1.4ym_ 4.871mm | 3.1um (2.0ym 4.865mm ae | gum | tum | = | toum | 23mm | = 15 uF 3.5um 0.9um 4.883mm | 3.6um 1.6um | 4.877mm RF | 280m | o7um =| 30um | t3ym | 20 ur | 20um | 2.7um | 463mm | tem | stum | 4657mm ar | eum | taum | | imum | 23um | 23 ur | 25um | 16um | 480mm | 27m | 2aum | 4877mm ar | asym | 2ium | - | taum | 28um | = Table 1: Summary of Results Note: The difference in probe diameter, calibration size is 1.2ym (ie. the probe calibrated +1.2um during the final measurements). This will reduce the nominal ‘measured tooth thickness in the final results by 1.2m compared to the initial results,LOGY LABORATORY Inspector ACF NATIONAL GEAR METROL EMZ 632 hausars ot an ines mt Din 3962 / AGMA 390.03 Valuoe in um/ten 3 05: 17 Date: 07.03.1997 Fobow-43e DESIGN UNIT | Lead + Profile Test Designation 3.475 om [> 6.35 am Part No. AMS6260/.7 2 28 te 30 & REMARKS. REF. 43RD a 20°00" dy 63.539 on Boo Be Quality ReqdPr: 5 / Le: 5 ActPr5 / Le 3 Read. Pr:§ / le:5 Act Pr5 / Led 7 3 at Fank 2 Teh 2 Agra 3 7 Tp | oot | I T q 1 %, | | i | | oot i ‘Umit Value 4 3 1 ni value i a 4 Fe0/7 2.8 21 [ass [0/7 2a 28 43 4100/6 27 26 ais [ove 6 14 32 Sek ete aa ate pee] 1 ga seein gee pS a! tr 7 2 Re Rank 9 7 ete pi Fae Battom fra no : 5 © | | Ee | I “ 4 \ ys | | i | | i | | i sae | 0 t = Tt f : i Limit value 4 3 2 1 mt value t) 2 3 4 Fi0/7 2a 4 15 19 [222 To/7 it ee oe wo/a.s{ 28 20 is as feala jo/as Tay a4 ig at Tagla fet 322g Plt ds 1 gered pees aNATIONAL GEAR METROLOGY LABORATORY ‘Qualty levels to DIN 3962 / AGMA 990.09 ‘Values in pmTen-Thousands ofan inch sk vet an LL DESIGN UNIT PITCH + RUNOUT TEST PartNo: MSB260/ REMARKS: AEF. 11 38D z= 28 m= 3.175 ooo" A 86 300 ‘mm Date/Insp-07 03, 1997/ACF Reqd. Qual mit Value Act Value Act. Qual. i a* | _F Fale o ts ia Fa F Right Flank 0 7 oe 10 Right Flank c [El wan.t.no.: 14 [EDMIN.T.No.: 45 ar o TRpbOw4E > eps pontine ofa on | [ED atN.t.no.: 24 IE] MIN.T.NO.: 8 [Elmax.t.no.: 24 ba 10 vm 4 MAX.T.NO.: 15 Elwin.t.No.: 4NATIONAL GEAR METROLOGY LABORATORY EMZ 632 HOFLER DESIGN UNIT Lead + Profile Test Bottom Inspector ACF Cead Top Unit vee] Gust rank 2 + wah 1 2 i 5 4 Ton} No Designation: 3.175 em [® 6.35 am Part No. ‘AMS6260/ 7. 228 Ty 90 % BE |REMAAKS: REF. 15 SAD on 20°0'0 Jp 83.539 nm 33 5 0'0'0" 83 Be 35 [Guay | fecdPrs 7tes ActPrs 7 tee [Readers /te5 Ac Pra / tet a: 7 7 lokFank 7 Teoh 2 eR Fen 3 7 | 1 ge]2: 1 le an ls 4 1000: 4 ja 438 \ lr 10 | eo} oot S[Gmwe| 4 sn 1 untlewe 1 A = [ror 45 18 63 St [ans [o/7 [a3 a1 20 46 [aale & [eove atest c gett ee 6g | ll 0 tse eet 2 Reta tala 5 [hata rises a Ea ee 2 eee eee @ ight Fark 5) é is ye | | 1 | | | | | I | i | | | ! 1 I 1 mite 0/7, oie 1 26 [222 lo/7 [43 19 [alt 190/45 19 4 46 [ase [ovas [ 14 salt Fob 016-4736 he-6 at Af 18 a3 [ot [6 7-3 ain‘Quality loves to DIN 3962 / AGMA 290.03 Valuoe in ym/Ten Thousands olan Inch NATIONAL GEAR METROLOGY LABORATORY JEIMIN.T.NO.: 45 (Elmax.t.no.: 27 G oo PITCH + RUNOUT TEST Part Noi ANS6260/-7 REWABKS AEF _ 15 380 z= 26 [m= 3s7omm[B= OOO A [@= 68 900 mmm] Date/inep-07.05. 4997/ACE | t tA] se [ae t ens ea ee ems] Read. Qual} 5 5 5 5 |g 5 5 5 5 5 & umitvaue |S] 6.01 6.0] 20.0 12.0/@] 5.0] 6.0] 20.9 © t2.} 14.01 | actvaue Je gg} 62.3] aal 3.alB) te ts] 5. 2.0) 8] Act. Qual. | $ 2 1 1 1 |& 2 1 2 2 4 [S) Elwax.t.no.: 28 a |”Dh—hrs—~S~—sis—SS | TRpDOWSE > ssf aoieae 9| | BS fe Loft Flank [Elmax.t.no.: 14 7 [Eimmn.t.No.: 26 OT EJMIN.T.NO.: 19Pe eteteereetete ener tte enn eg Ege geese ele : DESIGN UNIT Lead + Profile Test Designation: mq 3.475, baal 6.35 mm g, [Pathos 4W562607-7 228 Tp 90 % SE |REMARKS: REF. 20 3AD 0 20°0'0" dy 83.539 nm 38 8 0°0'0" a3 Be 38 [| Quality ReadPr: 5 / Le: 5 ActPr: 5 / Le: G Reqd.Pr:5 / Le:5 Act.Pr:5 / Le:3 83 4 3 Left Flank 2 1 tooth 2 Fight Flank 3 a. BE se #B + | g | a | = | Root I & [Gmevece| 4 se 1 nae An = [Rov za 3049 19 [ee fo/7 [2s 56 a0 12 [agi S | fe0/6_ 32 12 14 15 1814 [0/6 dt 34 16 dt 74 5 [etna [16 at 47 13 figs [eas [23-37 a 22 [4715 & = | Bottom a8 Zhe: s 3 2 & Ba} gles Ce lee 2 lo = oc g ° 1000 | zZ 40 5 Es | um _ Bl ny | fe] 2 Limit Value| 4 3 2 4 umitVvelve 1 2 3 4 (i]s | F0/7 b a 0 + Jams [o7 26 26 2a 13 23 Fa) [feoses[ ao 25g a0 Tals Tovas [or ap pa taal S| & [tet-6: See eed 2/1213 [+6 a tt i 3 altQuality levels o DIN 2962 / AGMA 290.03 Values in ye/ten-Thousands ofan iach NATIONAL GEAR METROLOGY LABORATORY Tap OWE > DESIGN UNIT PITCH + RUNOUT TEST 3 PartNo: ANS6260/.7 REWARKS: REF 20 3A0 i z= 28 [m= 3.175mm| p= mm } Date/insp.:07 03.1997 /RCF j t oe ZA | Reqiaua|e| 5 | 5 5 5 5 5 13 Umtvene|Z} 5.0] 8.0 8.0] 20. 2d) 12.01 §| | 30 3.3 a3] an sa] 9.6/3 Ss 4 3 _ 4 a 4 3! fl tart ° ‘ t [ElMmw.t.o.: 14 El MIN-T.ND.: 15 oeg 10 = mes a aa | 10 & | : fJmin.7.No.: 19 | f=] min, 5 23 10 um § 3 F a 10 im IEDMnn.7.No.: 26Poi ccc ccc cece r rete levels fo DIN 3962 / AGMA 390.03 ‘alued in umn Thousands of an inch ual 05: 04 07.03.1997 Date: 2 Inspector ACF NATIONAL GEAR METROI MZ 622 Fob018-4/3E HOFER DESIGN UNIT Lead + Profile Test q Designation: mm 3.175 mm 6.35 am Part No. ‘AMSE260/. 7 = 26 Tp 90 ® [REMAPKS: AEF. 25 SAD e_ 20°00 dy 63.539 nn 6 0'0'0" Be Guaity | Readers / eS ActPr5 7 tea [Redprns/te5 Aten / led z Tet Fan 2 1 toom 1 2 RghFank 3 7 Tp 1 acd | oe 4 5 - 4000 bt 10 | ‘m Foot Tne] a a 2 2 Limi viva 2 3 4 F0/7, Sgro meg ee 27 | aiolig | 07 igen aaa p21 (0 00/6. 47 23 10 29 fans 10/6 22 23 13a [ial Wena S| AT tae 0 fla [44S 7 ee eT ai Fane Top F Rah Fak 9 TA pottom | ©)22 ceo 1 Toot nol emia a) | | a:a 1 : ie ‘ 4.25 ; e | lo = | 2 | 1000: a I ! | re | ym 6. — w 1 Uneven] 2 2 1 Linitvawe 1 2 3 ‘ 0/7 242427 7 [ese Jov7_ [a3 32 4 ar Tale 190/45, aa 18 2 a 23 |o/4.5 a 27 22 22 5/3 fesh-6 2-6 pe eat Ts g 10 7 e [sitDESIGN UNIT PITCH + RUNOUT TEST “0 PartNo ANS6260/.7 REWARKS: REF23 SAD z=" 29 [m= __3.175mm[ B= "0-0" R___[4= 86.900 mom] Datevinsp.07 03. 1997/RCF z Gesleahy Fe 5 etary Fal8 isle Reqtoul| et 5 | 5 5 5 it] 5 $ 5 5 3 18 timevaio |] 5.0] 8.0] 20.0] w2.0f] 5.0] 8.0] 20. sag] 14.8 Faioars 2.3 3.2) 10.3) 5.6)5 19 0 2.21 40.4 5 5.5/2 ‘Act Qual 2] 3 3 3 jel 2 t 3 3 2 |8 arene Tem ioe OTL ee "eer x tare o a oe a hn gee pe Ebwtn.t.no.: 24 FEY MIN.T.NO.: 24 Quai lvels to DIN 9962 / AGMA 990,03 ‘Values in yn/Ten-Thousands of an inch (Emax. t.no.: 9 El wax.7.No.: 15 ee 10g) MIN. T.No.: 28 NATIONAL GEAR METROLOGY LABORATORY (Elmax.t.no.: 27 El wax.t.no.: 19 TRpbOWAE > EDMIN.T.No.: 9PROBE NUM PROBE ORIENTATION ENTER OF THE MACHINE REAL STYLUS DIAMETER EASURED PROBE DIAMETERAPPENDIX 5 FINAL SURFACE PROFILES OF GEARS AMS6260 #11 . #5 : #20 : #23@ RDI070-FIL 100 um NASA gear #11 (polished) tooth 1/left, ® ‘RD1073.FIL 7] + 100 um’ © ‘RD1067-FIL jitters remy ureaeny mer mnenartgtpanntinyn eres tinea 100 pm @ RDI076.FIL pre ert yrenninaenate tometer 4 100 wm Larner einai htneednertneartetaerenrtonotningnn Ium -.1mm, y= 3.175mm (filtered: Ra=0.053ym/0.08mm cut NASA gear #11 (polished) tooth I/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.096m/0.08mm c. NASA gear #11 (polished) tooth 15/left, x=-.Imm, y= 3.175mm (filtered: Ra=0.0714m/0.08mm ct 1pm NASA gear #11 (polished) TOOTH 15/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.067m/0.08m@ RDI079.FIL I } uae VY ium 4100 pm --.1mim, y= 3.175mm (filtered: Ra=0.1014m/0.08mm cut NASA gear #15 (polished) tooth 1/left, ® RD1082.FIL pemyanyernenin ney pene lpm 100 um NASA gear #15 (polished) tooth 15/left, x=-.1mm, y= 3.175mm (filtered: Ra=0.053ym/0.08mm cx [oO RD1088-FIL | im 100 wm NASA gear #15 (polished) tooth 15/right, x=-.1mm, y= 3.17Smm (filtered: Ra=0.05Sum/0.08mm «@ RDIOO-FIL fora ryrrmmmcntnstpeyminnmnayhytinymannantn tn A Py I Iam 100 um NASA gear #20 (polished) tooth I/left, x=-.1mm, y= 3.175mm (filtered: Ra=0.076um/0.08mm cut ® RDI097.FIL haremtnemenyeatpnreneennmn— ifn dpm 4 100 pm NASA gear #20 (polished) tooth I/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.0574m/0.08mm a © RD1094.FIL ppmntrneneenryereynetyrnny tata 4 100 pm NASA gear #20 (polished) tooth 1S/left, x=-.1mm, y= 3.175mm (filtered: Ra=0.078um/0.08mm ct @ RDI100.FIL 4 100 pm NASA gear #20 (polished) tooth 15/right, =0.059m/0.08mm « -175mm (filtered:@ RDI103.FIL prone seeemetenrenpept anny antenna 100 pm wo RDIVO9-FIL hnpaseatneanith yvenernmtaetayprnnssn anata n/nacen ten ey YY 100 wm © RDI106-FIL Prryriodiitivn ony snenryranynar apn ary 100 pm 1mm, y= 3.175mm (filtered: Ra=0.106umm/0.08: NASA gear #23 (polished) tooth15/eft, @ RDII2-FIL [heat tnyvoan arginine tpn ryote ny Ayn hranenery Aan 4 100 am NASA gear #23 (polished) tooth15/right, I Iam NASA gearf23 (polished) tooth /left, x=-.1mm, y= 3.175mm (filtered: Ra=0.063.m/0.08mm cuto! I 1am NASA gear #23 (polished) tooth 1/right, x=-.1mm, y= 3.175mm (filtered: Ra=0.064ym/0.08mm c. I Jam ;mm cul ym ‘=-.1mm, y= 3.175mm (filtered: Ra=0.073.m/0.08mm c