User Manual for KLINGELNBERG Cylindrical Gear GINA Software

User Manual
KLINGELNBERG
Cylindrical Gear GINA
Software
Kjhj khj k
03-007en-US, 2016-03-30
372008A
4
PREPARING FOR MEASUREMENT
Introduction
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4 Preparing for measurement

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Descriptions in this chapter apply predominantly to the function "Gear". The

menu «Gear» is therefore not indicated in each case. Functions for "Cluster"
are described in section Cluster.
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4.1 Introduction
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The following chart shows an overview of the program parts which have to be
checked or processed in preparation for a measurement. The user guidance with
the button [Continue] guides the user through all the necessary functions.
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Workpiece / protocol data Catalog
Workpiece / data
Machine / stylus Select / preset
Workpiece / profile (graph

lengths)
Workpiece / leads (graph lengths)
Check / Sel. of checks
Check / Tooth menu
Check / Measuring positions
Options / evaluation
Tolerance / profile / flank / pitch
Tolerance / ball dimensions
Machine / settings
Alignment / vertical positions
Alignment / workpiece axis position
Output / amplification
Output / evaluation instruction
38 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

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«Workpiece» Main Menu
4.3.2.2 Create new workpiece

1. Select the «Workpiece» menu or the {Catalog} symbol.
2. Enter the new drawing number in the <Drawing No.> text box.
þ The [Load] button label changes to [Set].
3. Click [Set].
þ If the data for the previous Drawing No. has not been stored, a prompt as-
king whether you want to store the data is displayed.
4. Answer the prompt.
þ The «Protocol data» window opens.
5. Complete the protocol data.
6. Click [Continue].
þ The «Gear data» window opens.
Input fields Description

<Type of profile> Choices:
– <Involute> Tooth flank is an involute
– <Spline> Plug-in toothing whose flanks are straight and
parallel to one another
– <Serration> Plug-in toothing whose flanks are straight
and at an angle to one another
For splines and serrations, the option with order number
590.087 must be installed.
<Tooth form> Choices:
– <symmetric> Gear with constant tip diameter and root
diameter
– <conical> Gear with constant tip diameter and conical
root diameter
– <taper> Gear with tapered envelope and conical tooth
form
– <beveloid> Gear as for <taper>, but with simplified data
input via the root cone angle
<Type of gear> Choices:
– <External> External gearing
– <Internal> Internal gearing
7. Mark the appropriate data.

8. Click [Continue].
þ The «Workpiece» «Data» window opens.
9. Complete the data.
þ The [Continue] button guides you through all the necessary windows.
10. To back up the data, click [Save] or «Program» «Save».
Result The new drawing number has been created.

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The new Drawing No. will not appear in the catalog until after the [Store] func-
tion has been executed.
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4.3.2.3 Tooth form

When a new gear is created, its form has to be specified.
Tooth form:
¡With a symmetrical tooth form, pitch diameter (da) and root diameter (dF) are
constant over the tooth width (b).
¡ With a conical tooth form, the root diameter decreases over the tooth height.
1.1
Fig. 11 Symmetrical tooth form Fig. 12 Conical tooth form
¡ With a tapered tooth form, the cylindrical gear becomes a bevel gear. Pitch
diameter (da) and root diameter (dF) decrease over the tooth width (b).
Fig. 13 Tapered and beveloid tooth form
¡ The design of workpieces with a beveloid tooth form is similar to that of the
tapered tooth form, but is described by the tilt angle (δ). The tilt angle corres-
ponds to the root cone angle of a bevel gear.
372008A 03-007en-US KLINGELNBERG Cylindrical Gear GINA 49

4
Tooth form:
symmetric
Serration
beveloid
tapered
conical
Spline
Input fields
<Identification lead> X X X X X X
<Modul> X X X X X
<No. of teeth> X X X X X X
<Tooth thickness> X X
<Tooth lead> X
<Helix angle> X X X X
<Lead direction> X X X X
<Measuring cone angle> X
<Tilt angle> X
<Gash angle> X
<Pressure angle> X X X
<Gear face width> X X X X X X
<Profile modification> X X X
<Base circle diameter> X
<Tip diameter> X X X X X X
<Smallest outside diam. of gear> X
<Largest outside diam. of gear> X
<Root diameter> X X X X X
<Effective root diameter> X X
<Workpiece clamping> X X
Input fields for the possible tooth forms
Further information on the parameters can be found in section Principles.

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4.3.3 Profile Graph Length

Profile corrections are intentional variations of the modification from the theoreti-
cal involute. The angular error and crowning can be specified for tip relief and root
relief.
In the «Workpiece» menu, click on «Profile».
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The graph length is calculated from the geometry data and suggested. The
graph length can be specified as a rolling path, angle of roll, diameter or radi-
us, depending on the menu settings under «Options» «Screen».
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Fig. 14 «Correction / Profile graph length» window
Fields Description
<Angular error> The angular error is entered numerically when the area is
activated.
The input field is only active for the evaluation range if the
button has been turned on.
<Crowning> Nominal value of the crowning used to calculate the total
error.
Crowning can be selected in the evaluation range inde-
pendently of angular error.
Angular error and crowning are mutually exclusive for the

4
Fields Description
tip relief and root relief.
Graph length The graph length is specified on the «Options» menu un-
der «Screen».
<Distance> Measuring length for tip relief, evaluation range, and root
relief.
<Tip relief> The tip relief can be measured when this check box is se-
lected.
<Range of eval.> The evaluation range is always active.
<Root relief> The root relief can be measured when this check box is
selected.
<left> Flank to be checked
<Arrow> These buttons transfer the data entered to the other flank.
The result becomes visible when the other flank is selec-
ted.
<right> Flank to be checked
<Calculate> Calculate graph lengths using the mating gear data.
<Default> Graph length is calculated and displayed when a 1:1 gear
set is presupposed.
Tab. 15 «Correction / Profile graph length» window
Points to note:
¡ The profile is modified separately for tip relief , evaluation range , and
root relief .
¡ Tip relief and root relief are only measured when the button on the left
is marked.
¡ The diagram in the middle is blue when the area is activated.
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The profile is measured from the root to the tip of the tooth. Standard measure-
ment height is 1/2 tooth width.
Fig. 15 Profile: Measuring range
Me End of measurement at tooth tip

Mk2 End of tip relief
Lk Measuring length, tip relief
Mk1 Transition from evaluation range to tooth tip
M2 End of evaluation range (~ tip circle)
L Measuring length, evaluation range
M1 Start of evaluation range (~ root circle)
Mf2 End of root relief
Lf Measuring length, root relief
Mf1 Start of root relief
Ma Start of measurement at tooth root
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An optional add-on to the program allows a possible broken edge at the tooth
tip to be taken into consideration. The measurement and evaluation is termi-
nated at position <fFamax>.
Determining default Functions used to calculate default values for the measuring range are located at
values the bottom of the window.
1. Select the <left> or <right> lead.

4
2. Select the <Tip relief> and <Root relief> box if applicable, and enter the
corresponding angular error and crowning.
þ The curve with the areas to be measured in blue will change based on the
selections.
3. Enter the starting and finishing point of the measurement, or define the mea-
suring length.
4. Press the [Arrow] button to transfer the data to the other flank.
5. If necessary, calculate the graph lengths using the mating gear data, see next
chapter Calculation of graph lengths.
6. Clicking [Default] causes the graph lengths to be calculated again with a 1:1
gear set being presupposed.
7. Confirm the entries with [OK], [Apply] or [Continue].
Result The profile measuring range is recorded.

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4.3.3.1 Calculate profile graph lengths

Menu «Workpiece» / «Profile»
Button [Calculate]
Input fields Description

<No. of teeth> Number of teeth of the mating gear
Choices:
– <Profile modification factor> Factor for the profile modification
– <Center distance> Center distance in general (D d)/2
<Tip diameter> Tip diameter of the mating gear
<Reduction for d1> Measuring length d1 is reduced as a percentage.
Permissible range: 0% – 50%.
<Reduction for d2> Measuring length d2 is reduced as a percentage.
Permissible range: 0% – 50%.
<Graph lengths defined by> Graph length is defined with rolling path, angle of
roll, diameter or radius. Definition in menu «Opti-
ons» «Screen»
<Me> – <Ma> Measuring range
<M1> – <M2> Range of eval.
Tab. 16 «COMPUTE GRAPH LENGTHS» window
Procedure 1. Enter mating gear data such as number of teeth, profile modification factor (or
center distance) and tip diameter.
2. Enter percentage reduction of the measuring length.
3. Confirm with [OK].
þ The «Profile graph length» window opens again.
Result Measuring lengths are calculated and entered directly in the «Profile graph
length» window.

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4.3.4 Lead graph length
Menu «Workpiece» / «Lead»
Fig. 16 Lead «Correction / Lead graph length»
Input field Description

<Angular error> Button activates the angular error and the devia-
tion of the helix angle can be entered in µm.
<Crowning> Button activates the crowning and the value can
be specified for the Range of eval.
<Height> Measurement high in reference to gear face
width b
<Distance> Relief (lead) measuring range:
– <Lo> Top relief (lead) measurement path
– <L> Main eval. zone measurement path
– <Lu> Bottom relief (lead) measurement path
<be> End of check: Measurement is from bottom to
top
<Top-relief (lead)> Range of the top relief (lead):
– <bo2> End
– <Bo1> Start
<Range of eval.> Main eval. zone:
– <b2> End
– <b1> Start
<Bottom-relief (lead)> Range of the bottom relief (lead):
– <bu2> End

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Input field Description

– <bu1> Start
<ba> Check start is below
<left> Left flank
<right> Right flank
<Symmetrical reduction of ge- Specify in percent. Permissible range: 0% –
ar face width b> 20%. Measuring range and evaluation range
are reduced symmetrically.
1. Select the <left> or <right> lead.

2. If desired, then highlight Top relief (lead) and Bottom relief (lead) .
3. Set the shape of the crowning to be linear or crowned with the aid of the but-
tons.
þ Depending on the version, the illustrated curve changes in the middle.
4. Enter measurement heights.
5. If desired, then enter the reduction of the gear face width .
6. Use the respective button [Left arrow] or [Right arrow] to apply the values to
the other lead.
7. Confirm the entries with [OK], [Continue] or [Apply].
Result Graph lengths for checking the leads are recorded.
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The standard check is carried out on the reference circle.
Fig. 17 Lead: Measuring range

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Gear face width b

Start of check at bottom ba
Bottom-relief (lead) bu1 – bu2
Range of eval. b1 – b2
Top-relief (lead) bo1 – bo2
End of check at top be

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4.3.5 Extended data input

Depending on the installed options, additional inputs for measurements and eva-
luations are activated.
Menu «Workpiece» / «Special»
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4.3.5.1 Lead flutes

When this option is activated, the influence of the flute is eliminated in the evalua-
tion.
Fig. 18 Flute in the lead

Distance to start of flute Distance to start of flute
<Flute> When activates, the flute is ignored during

the measurement and evaluation.
<Starting point of flute> Distance from the vertical starting point
<End point of flute> Distance from the vertical starting point
Tab. 17 Add-ons for flutes in the lead

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4.3.5.2 Feed marks / hob valley

During the milling of cylindrical gears, periodic deviations can occur - depending
on the production method - which impair the evaluation.
Option The following option must be installed:
¡ Order No. 590.010, Compensation of feed marks
The inclination of the miller valleys to the tooth flanks is determined by a separate
measurement on several teeth. The miller feed is determined by comparing the
miller valleys on different teeth.
Prerequisites: The following prerequisites must be met:

¡ Tooth width (b) or the measuring range must cover at least 3 miller valleys.
¡ Miller valleys must be deep and long enough to allow feed and pitch to be de-
termined.
¡ If the pitch cannot be clearly determined, an error message is displayed.
Parameters Function
<Profile> If marked, the profile is measured in the mil-
ler valley.
<Spacing> Choices:
– <Point contact>
– <Lead>
– <No>
The spacing can be measured at various
points or over the lead.
Tab. 18 Parameters for feed marks
Profile A normal measurement is performed over the peaks and valleys of the involute
profile. If the field <Profile> is marked, the meausrement is performed in the miller
valley.
The symbol shown to the left is printed on the chart.
2.1
Fig. 19 Standard measurement Fig. 20 Measurement in the miller val-

ley

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Pitch The contact point for the pitch can be determined at various points or as a line:
¡ Point contact: While the pitch is being measured, the stylus measures at diffe-
rent T heights on adjacent teeth in order to follow the envelope spiral of the
feed. This option is recommended for workpieces produced with single-start
milling cutters. The symbol shown to the left is output on the chart.
¡ Lead: A continuous area is measured over at least 2 miller valleys and an
average line is formed from which the contact point for the pitch is determined.
This option is recommended for workpieces produced with multi-start milling
cutters. The symbol shown to the left with the tooth trace is output on the chart.
3.1
Fig. 21 Point contact Fig. 22 Tooth trace (helix) measure-

ment

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4.3.5.3 Undulation
Deviations in the surface of a workpiece are divided into the rough deviations
such as dimension, form, position and the fine deviations such as undulation and
roughness.
Option The following optional add-on must be installed:

¡ Order No. 590.000, Program in preparation
The distinction between undulation and roughness is defined by the limit wavel-
ength.
<Undulation> When activated, the undulation is mea-

sured.
– <Wavelength> Limit wavelength for undulation
Tab. 19 Add-ons

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4.3.5.4 Segment Gearing

Option The following optional add-on must be installed:
¡ Order number 590.107: Testing segment gearings
Missing teeth or missing spaces (block teeth) are determined and omitted at the
time of the pitch check.
In the «Workpiece» menu, click on «Special»
Input Fields Description

–Segment Gears– Table which specifies one tooth range per line for the associated
type of the segment gearing.
<1> … <n> The permitted lines are dependent on the total number of teeth in the
workpiece.
<Start Tooth no.> First tooth of a range
<End Tooth no.> Last tooth of a range
<Missed tooth> Range of missing teeth.
<Block teeth> Range of one block tooth
Tab. 20 «Special» window:
The spacing is interrupted for the segment gearing:

¡ When teeth are missing gaps will be found in the gearing.
¡ If spaces are filled with material, then one speaks of block teeth .
Fig. 23 Segment gearing

Missed tooth Block Tooth
Unusual features of the evaluation of the spacing are described in the chap-
ter Pitch chart for segment gearings.

4
Main Menu «Tolerance»
4.6.5 Tolerancing to AGMA, ISO and JIS

Tolerance acc. to DIN 3962 is the default setting. With an optional add-on it is al-
so possible to carry out evaluations according to other standards. The operation
corresponds to that for the evaluation according to DIN.
Option One of the following optional add-ons must be installed:

¡ Evaluation to AGMA 2019
¡ Evaluation to ISO 1326:1997
¡ Evaluation to JIS B 1702:1998
.
Parameters AGMA ISO JIS

«Profile» window
– <Angular error> fHa X X X
– <Total error> Vphi X X X
– <Form error> ffa X X X
– <Crowning> Ca Free Free Free
– <Tip relief> fKo Free Free Free
– <Root relief> fFu Free Free Free
«Lead» window
– <Angular error> Fhβ X X X
– <Total error> Vpsi X X X
– <Form error> ffβ X X X
– <Crowning> Cβ Free Free Free
– <Top-relief (lead)> fo Free Free Free
– <Bottom-relief (lead)> fu Free Free Free
«Spacing» window
– <Individual error> fp X X X
– <Total error> Fp X X X
– <Pitch-span var.> Fpz/8 X X X
– <Run-out> FrT X X X
– <Variation of tooth thick- Rs X X
ness>
Tab. 30 Parameters for tolerancing
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6
EVALUATION
Profile Chart and Lead
Example
Fig. 68 Chart for profile and lead
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EVALUATION
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6.2.1 Chart Legend
Fig. 69 Legend on Chart 1
Heading Profile/lead with symbol for clamping

Data of the check:
– Date and time of the check
– Gear face width
– Long test range La, evaluation range Lα for the profile
– Lead test range Lβ, evaluation range Lβ for the lead
– Evaluation start M1, start of the measuring range
– Number and diameter of the ball of the stylus
– Profile modification as factor or percentage
Data of the workpiece:
– Number of teeth is positive for external gearing, negative for internal gearing
– Module m
– Pressure angle α
– Helix angle β
– Base circle radius
– Base helix angle
Program version and number of the measuring center
Protocol data of the Drawing No.
– Designation
– Drawing No.
– Order / Serial number
– Customer number
– Location of check

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EVALUATION
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6.2.2 Profile data
Fig. 70 Profile evaluation on Chart 1
Designation for right and left lead

End evaluation range at head
Display for material (+) too much, (-) too little
Start evaluation range at the root
Numbers of the checked teeth. If several cuts have been checked, e.g. with torsion,
then these will be designated a (top), b (middle), c (bottom)
Variance: Difference between the smallest and the largest angular error without tor-
sion
The largest available measurement is output with quality level.
Tolerance values and associated quality levels. The data is dependent on the selec-
ted evaluation type in acc. with DIN, ISO, ...
Tooth root is at bottom
Scale: Horizontal and vertical scale are displayed with rectangles. The enlargement
of the variations are designated with Va (horizontal) and Vb (vertical).
Tooth tip is at top
Compensation of the axis position with number
Standard for the evaluation, here DIN 3962

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EVALUATION
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6.2.3 Evaluation of Lead
Fig. 71 Lead evaluation on Chart 1
Display for the sign of angle error in acc. with DIN, VDI or (+-+)
End of evaluation range at top
Display for material (+) too much, (-) too little
Start of evaluation range at bottom
Numbers of the checked teeth. If several cuts were checked, e.g. with torsion, then
these will be designated with a, b, c, etc. The check without torsion will thus be de-
signated with b.
Variance: Difference between the smallest and the largest angular error without tor-
sion (value after "B")
The largest available measurement is output with quality level.
Specification for the reference to the angular error (fHß):
<N:Z> total gear face width, <N:A> range of eval.,
<N:X> section 10 mm, 20 mm, 100 mm,
<N:80> Percentage of the evaluation range
Lead at bottom
Lead at top
Heading for evaluation of the lead or the creator
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EVALUATION
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6.2.4 Line of action chart

If the action line has been selected in menu «Check» / «Sel. of checks», the eval-
uation of the lead is deactivated. Instead the line of action is evaluated.
Fig. 72 Line of action evaluation on Chart 1

Data of the line of action

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EVALUATION
Topography measuring sheet
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6.3 Topography measuring sheet

If the topography has been selected in menu «Check» / «Sel. of checks», a chart
for topography is output.
Fig. 73 Topography measuring sheet

Left flank of the tooth Bottom
Top Root
Root Right flank of the tooth
Tooth tip

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EVALUATION
Pitch measuring sheet
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6.4 Pitch measuring sheet

The individual and cumulative variations of the left and right flank and the pitch
line run-out are depicted on the <Pitch> measuring sheet.
Example
Fig. 74 Pitch measuring sheet

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EVALUATION
Pitch measuring sheet
Characteristics:
¡ Underneath the measured data there is the table of the errors and the deter-
mined quality level.
¡ Measured values which exceed the tolerance are shown in boldface or color-
coded for color printers.
¡ The permissible value and the quality class are specified in the column to the
right of the measured data.
¡ Pitch measured values:
– Largest individual variation (fp max.)
– Pitch jump (fu max.)
– Range of pitch error (Rp)
– Total index variation (Fp)
– Total index var,within sector (Fpz/8)
¡ Pitch line runout measured values
– Pitch line runout (Fr)
– Special option: Eccentricity (e) or concentricity (Ƽ). This is the systematic
fraction defective for the Fr measuring curve. It is determined by means
of a compensatory calculation. The eccentricity corresponds to the
amplitude, and the concentricity corresponds to twice the amplitude of the
corresponding compensatory sine wave.
– Measurement over two balls (Mdk) and diameter of the measuring
ball (DM) (bottom right)
– The Mdknom and Mdkact values for the right-hand and left-hand lead are
output in the columns under the Mdk value.
¡ The evaluation of the tooth thickness and measurement over balls are output if
they have been selected in menu «Tolerance» / «Measurement over balls».
– Variation of tooth thickness (Rs)
– Base tangent length (Wk) and number of teeth to be measured
– If the Wk value is entered, the Wknom and Wkact values for the right-hand
and left-hand lead appear in the columns below.
– Measurement over one ball, measurement over two balls and measure-
ment over three balls

8
BASIC PRINCIPLES
Cylindrical Gears
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8 Basic principles
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8.1 Cylindrical Gears

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Cylindrical gears are gears with cylindrical pitch surfaces.
Fig. 109 Cylindrical gear with cylindrical pitch surfaces
Characteristics:
¡ Teeth can be located on the inside or outside of the cylinder. These are called:
– External gearing
– Internal gearing
¡ Teeth can be straight or helical
– Straight-tooth gear
– Helical gear
¡ The gear action involves 2 toothed gears rolling off one another. There are
three tooth forms: circular arc, cycloid, and involute. Only involutes are consi-
dered here.
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8.1.1 Normal module

The normal module is specified in drawings. It is the quotient of reference diame-
ter (d) and number of teeth (z):
M=d/z

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.2 Tooth forms

The teeth of the gears can have a symmetrical or conical form:
¡ With the symmetrical tooth form, pitch diameter and root diameter are
constant.
¡ With the conical tooth form, the root diameter changes over the gear face
width (b).
13.1
Fig. 110 Symmetrical Fig. 111 Conical

da Tip diameter dF Root diameter
b Gear face width
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8.1.3 Tapered gears

In the case of gears with a conical rather than cylindrical body, the outside diame-
ter decreases over the gear face width.
A distinction is made between:
¡ Tapered gears with a decreasing gear face width.
¡ Beveloid describes the same workpiece as the tapered gear, but with different
parameters (tilt angle = root cone angle).
Fig. 112 Tapered gear Fig. 113 Constant tooth depth

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.4 Plug-in gearing

With plug-in gearing, the teeth form a positive mesh with the mating gear. A dis-
tinction is made between:
¡ Splines (with straight, parallel flanks)
¡ Serrations (with straight, non-parallel flanks)
14.1
Fig. 114 Spline Fig. 115 Serration
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8.1.5 Lead Identification

The right or left flank is the flank an observer sees to his right or left when looking
in an established direction at a tooth pointed upward.
This definition applies to both external and internal gears. With a cylindrical gear
pair, the right flank works with the right flank and the left flank with the left, assum-
ing the same viewing direction
15.1
Fig. 116 External gearing Fig. 117 Internal gearing

Right flank Left flank
The software for this lead identification is set to ANSII.

According to the U.S. standard, the definition of lead identification is reversed
for external gears but the same for internal gears. The software can be optio-
nally changed.

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.6 Parameters
Fig. 118 Cylindrical gear parameters
Size Description
da Tip diameter
d Reference diameter
df Root diameter
db Base diameter
h Tooth depth
ha Addendum
p Pitch on the reference cylinder
s Tooth thickness on the reference cylinder
b Gear face width
α Pressure angle
Tab. 49 Cylindrical gear parameters
Pitch (p) is proportional to module (m) of the gear: P = π * m

The reference diameter is obtained by multiplying the module by the number of
teeth: d = m * z

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.7 Helix Angle

For straight-toothed cylindrical gears, the helix angle is ß = 0.
For helical cylindrical gears, the helix angle determines the lead:
¡ ß > 0 for right-hand teeth
¡ ß < 0 for left-hand teeth
16.1
Fig. 119 Right-hand ß > 0 Fig. 120 Left-hand ß > 0
For gears with internal gearing, the direction and the sign reverse.
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17.1
Fig. 121 External gearing Fig. 122 Internal gearing

right-hand lead right-hand lead
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Here Se without In the present software, the helix angle β is always specified without the sign of
sign of angle error angle error.
The input field <Lead direction> defines the lead:
¡ <Lead direction> = <right> for a gearing ascending to the right
¡ <Lead direction> = <left> for a gearing ascending to the left

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.8 Sign of Angle Error in acc. with DIN and VDI

The sign of angle error can be defined in acc. with DIN, VDI, or <+-+>. The sign of
angle error for DIN and VDI is the same for right-handed leads, but opposite for
left-handed leads.
For straight gear, the angle is handled mathematically in acc. with DIN but in
terms of absolute value in acc. with VDI.
DIN
Fig. 123 Sign of angle error in acc. with DIN
Right-handed Left-handed Line
VDI
Fig. 124 Sign of angle error in acc. with VDI

8
BASIC PRINCIPLES
Cylindrical Gears
<+-+>
Fig. 125 Sign rule in acc. with <+-+>
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The depiction of the lead angular error is set up in the «Options» / «Evaluations»
menu.
Example:
¡ in acc. with DIN fHβ = -3.5
¡ in acc. with VDI fHβ = R3.5
¡ in acc. with <+-+> fHβ = -3.5

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.9 Transverse plane / normal plane

With straight gears the transverse plane is the same as the normal plane. With
helical gears we have:
mn = ms * cos β where: mn < ms
If a parameter refers to an evaluation instruction in the transverse plane, an "s" is
appended, in the normal plane an "n" is appended.
Fig. 126 Transverse plane and normal plane
S-S Transverse plane N-N Normal plane

ts Pitch in the transverse plane tn Pitch in the normal plane
ms Module in the transverse plane mn Module in the normal plane
αs Pressure angle αn Pressure angle
β Helix angle b Gear face width
sk
Tab. 50 Transverse plane and normal plane

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.10 Line of action

A line of action of the involute surface is an intersection line of the tooth flank with
a tangential plane developed from the base cylinder. If 2 gears mesh together
perfectly, then flank and mating flank contact one another on the common lines of
action, the lines of contact.
Fig. 127 Line of action

Lines of contact Base cylinder
With straight gearing, the line of action runs parallel to the gearing centerline.
The line of action of helical gearing is inclined by the base helix angle ß to the
gear axis.

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.11 Relief and crowning

Depending on the load, the gear may be deformed resulting in a shift of the tooth
meshing zones to the edges of the tooth flanks. Profile and lead are then
changed so that the teeth mesh wioth one another more smoothly.
The form of the flanks can be modified within certain limits by "reliefs" or uniformly
by symmetrical or asymmetric "crowning".
Fig. 128 Reliefs

Root relief Bottom relief
Tip relief Top relief

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.12 Top and bottom relief

In the case of reliefs, the average line is determined from the measured data with-
in the associated evaluation range.
Fig. 129 End relief
fo Top relief
fu Bottom relief
bu1 Bottom relief (start)
bu2 Bottom relief (end)
b1 Start of evaluation
b2 End of evaluation
bo1 Top relief (start)
bo2 Top relief (end)
Tab. 51 Relief parameters

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.13 Root relief and tip relief

In the case of reliefs in the tip and root of the tooth, the average line is determined
from the measured data within the associated evaluation range.
Fig. 130 Root relief, tip relief
Best-fit line

Extended average line from evaluation range M1 – M2

fKo Tip relief
fFu Root relief
Mf1 Start of root relief
Mf2 End of root relief
M1 Start of evaluation of graph
M2 End of evaluation of graph
Mk1 Start of tip relief
Mk2 End of tip relief
Tab. 52 Tip relief and root relief parameters

8
BASIC PRINCIPLES
Cylindrical Gears
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8.1.14 Profile modification

A profile modification occurs when the distance between the cutting tool and the
gear is increased or decreased.
This results in changes in e.g.:
¡ Form of the tooth flanks
¡ Contact area at the flanks
¡ Tooth thickness
Fig. 131 Profile modification

Profile modification > 0 Profile modification < 0
Profile modification = 0 Undercut
Base circle Reference circle
The size of the profile modification is dictated by the "profile modification factor" x
and is a multiple of the normal module.
Profile modification = x * m n
According to DIN 3960, the profile modification with external gearing is positive if
the modification is away from the centre of the gear. It is negative if the modifica-
tion is towards the centre of the gear.
Reference circle The reference circle is a mathematical quantity. The reference circle diameter cor-
responds to module times number of teeth.
V-circle A cylindrical gear with profile modification is also referred to as a V-gear. An X-
zero gear is a cylindrical gear without profile modification. The modified reference
circle of a V-gear is referred to as the V-circle.
Pitch circle For an X-zero gear, the reference circle is the same as the pitch circle. For a V-
gear the reference circle is the same as the V-circle, but the pitch circle is modi-
fied. The diameter of the pitch circle is equal to the reference circle diameter plus
double the modification.

8
BASIC PRINCIPLES
Types of check
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8.2 Types of check

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8.2.1 Topography
For the topographical evaluation, a tooth flank is measured on several sections
towards the profile and lead. A perspective representation of the tooth surface is
then created from the measurement results. The number of measurements to-
wards the profile and lead determines the resolution of the representation.
Fig. 132 Measurement of the topography
Settings:
¡ Menu «Check» / «Tooth menu»
– Define number of profiles and leads to be checked.
¡ Menu «Check» / «Measuring positions», tab «Topography»
– Define positions of the first and last profile and the leads.
– The distance between the grid points is divided uniformly over the evalua-
tion.

8
BASIC PRINCIPLES
Types of check
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8.2.2 Torsion check

The torsion check detects distortion in the tooth, e.g. due to the heat treatment.
18.1
Fig. 133 Leads Fig. 134 Profile
The profile is measured at 3 different heights over the tooth width, e.g. root, mid-
dle and tip. The lead is measured at 3 different diameters, e.g. usable root circle,
V-circle and usable tip circle.
The measuring positions are defined in the menu «Check» / «Measuring posi-
tions», tab «Torsion». The measurement results can be output on the chart for
profile and leads or separately (option).

8
BASIC PRINCIPLES
Types of check
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8.2.3 Ball Dimension

The ball dimension is an indirect measure of tooth thickness. A measurement ball
with diameter DM is positioned in a tooth space such that it is in contact with both
tooth flanks. This ball is adjusted mathematically with the measuring center.
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1-ball dimension The 1-ball dimension, also referred to as radial 1-ball dimension, is the distance
between:
¡ Gear axis and the innermost point of an internal gearing
¡ Gear axis and the outermost point of an external gearing
19.1
Fig. 135 Internal gearing Fig. 136 External gearing

DM Ball diameter Mrk Radial 1-ball dimension
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2-ball dimension 2 balls are positioned on the flanks of the two tooth spaces located the furthest
apart from each other.
The 2-ball dimension is also called diametric 2 ball dimension. On a gear with ex-
ternal gearing, it is the largest external dimension over the two balls; on a gear
with internal gearing, it is the smallest internal dimension between the two balls.
20.1

DM Ball diameter Mdk Diametric 2-ball dimension

8
BASIC PRINCIPLES
Types of check
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3-ball dimension The 3-ball measurement was used in the past with odd numbers of gear teeth
when the 2-ball dimension could not be determined manually.
21.1

DM Ball diameter Mdk 3-ball dimension
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8.2.4 Base tangent length

The base tangent length was determined in the past using a micrometer gauge.
The base tangent length W k of an external gearing is the length over k teeth, of an
internal gearing the length over k tooth gaps. The number of teeth (k) was select-
ed such that the plates of the micrometer gauge could be positioned tangentially
and as close as possible to the V-circle.
22.1
WK Base tangent length over k teeth or gaps

dM Diameter of the measuring circle for base tangent length
dV V-circle diameter
Tab. 53 Base tangent length
As the base tangent length does not precisely contact the V-circle, the exact con-
tact diameter must be entered for measurement of the pitch.

8
BASIC PRINCIPLES
Evaluation
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8.3 Evaluation
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The pages that follow contain definitions of relevant terms for the presentation of
deviation parameters.
This guide covers standard evaluations only and does not take account of
customer-specific factory standards.
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8.4 Circular Pitch Variation

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Circular pitch variations are measured on the reference circle or a measurement

circle centered with respect to the gear axis and located as close to the reference
circle as possible. The difference between measurement circle diameter dM and
reference circle diameter d affects the deviation measurements by a factor dM/d
and is generally negligible.
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8.4.1 Individual Pitch Variation fp

Individual pitch variation fp is the difference between the actual dimension of an
individual transverse pitch and the nominal dimension pt.
On a gear with <z> teeth, there are <z> individual pitch variations of the right
flanks and just as many variations of the left flanks. The fp variations are calcula-
ted as the difference between the individual measured values and the average of
all <z> measured values.
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8.4.2 Range of Pitch Error Rp

The range of pitch error (pitch fluctuation) Rp is the difference between the largest
and the smallest actual dimension of the transverse pitches pt on the right or left
flanks of a toothed gear.
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Fig. 143 Pitch parameters
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fp Individual pitch deviation

fu Pitch jump
Rp Range of pitch error

8
BASIC PRINCIPLES
Circular Pitch Variation
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8.4.3 Tooth Spacing Error fu

A tooth spacing (pitch) error fu is the difference between the actual dimensions of
two successive transverse pitches of the right or left flanks on the toothed gear.
During circular pitch measurements, pitch errors are calculated as the difference
between the measured values of two adjacent pitches.
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8.4.4 Cumulative Pitch-Span Variation Fpk

Cumulative pitch-span variation Fpk is the sum of individual pitch deviations fp. k is
is the number of pitches formed via the sum.
Cumulative pitch-span variation Fp z/8 is the largest cumulative deviation occurring
on one-eighth of the tooth count.
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8.4.5 Total Pitch Variation Fp

The greatest cumulative pitch-span variation on a toothed gear is designated total
pitch variation Fp. It is unsigned and is calculated as the difference between the
largest and the smallest pitch-span variation values.
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Fig. 144 Total pitch variation
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8.4.6 T.S. total index error over CF Fpz/8

Tooth space total index error over CF (pitch-span variation) Fpz/8 is the largest var-
iation of the actual dimension with respect to the nominal dimension of a pitch
span over z/8 single pitches.

8
BASIC PRINCIPLES
Profile Deviations
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8.5 Profile Deviations

Involute gears have involutes only in the transverse section. For this reason, tooth
profile deviations are only measured in the transverse section.
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8.5.1 Total Profile Deviation

Total profile deviation Fα (or Fa) of a tooth flank is the distance between the two
nominal profiles AA and A“A“ that touch and enclose the tooth flank inside the
profile evaluation range.
The desired deviations in the form of an involute are allowed for by corresponding
deviations of the lines AA and A’ A’ from straight lines.
Fig. 145 Total profile deviation
Fα Total profile deviation

Lα Profile evaluation range
AA, A’’A’’ Nominal profiles enclosing the actual flank
Tab. 54 Parameters for total profile deviation

8
BASIC PRINCIPLES
Profile Deviations
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8.5.2 Profile Form Deviation

Profile form deviation ffα of a tooth flank is the distance between the two involutes
of the actual base circle that touch and enclose the actual profile inside the profile
evaluation range. Desired deviations from the form of the involutes are allowed for
by deviations from the straight lines.
Fig. 146 Profile form deviation
ffα Profile form deviation

BB Centering line for actual involute
B’B’, B’’B’’ Parallel lines enveloping centering line for actual involute
Tab. 55 Parameters for profile form deviation
The profile form deviation also includes the wave depth of the profile ripple. The
profile ripple is a deviation that recurs periodically with the rolling angle.

8
BASIC PRINCIPLES
Profile Deviations
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8.5.3 Profile Angle Deviation

Profile angle deviation fHα is the distance between the two nominal profiles
C’C‘ and C‘‘C‘‘ that intersect the centering profile – that is, the nominal profile mo-
dified by a helical component – at the starting point and end point, respectively, of
the profile evaluation range. Profile angle deviation fHα is generally given in μm
as the linear measure associated with profile test range Lα.
Profile angle deviation fHα is positive when the involute of the actual base circle
rises toward the material-free side compared with the nominal profile in the direc-
tion of increasing working lengths.
Profile angle deviation fHα is negative when the involute of the actual base circle
slopes down toward the material side in the direction of increasing working
lengths.
Fig. 147 Profile angle deviation
fHα Profile angle deviation

BB Centering line for actual involute
C’C’, C’’C’’ Nominal profiles intersecting the profiles at the test range starting
point and end point, respectively.
Tab. 56 Parameters for profile angle deviation

8
BASIC PRINCIPLES
Profile Deviations
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8.5.4 Depth Crowning

Depth crowning Cα modifies the shape of the profile.
This figure shows how the values for Fα, fHα , and ffα are determined from the profile
test diagram while taking account of the specified crowning CαSoll (Cα setpoint).
Fig. 148 Depth crowning

LAE Profile evaluation range, including tip area
LAF Profile measuring range (range of the tooth profile in which the measured values
were recorded)
P1, P2 Highest and lowest point, respectively, at which the enveloping setpoint parabola
is placed from both sides (a determining factor for the value of total deviation Fα)
P1, P3 Highest and lowest point, respectively, at which the enveloping actual parabola is
placed from both sides (a determining factor for the value of form deviation ffα)
Tab. 57 Parameters for depth crowning
For the evaluation, a regression parabola is calculated in the evaluation range.

The two intersection points on the parabola are connected to the boundary lines
of the evaluation range, thereby producing a chord.
The distance between a parallel line and the chord gives depth crowning Cα.

8
BASIC PRINCIPLES
Tooth Trace Deviations
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8.6 Tooth Trace Deviations

The tooth trace is the intersection between the tooth flank and the reference cy-
linder. Deviations of the tooth trace from its nominal form are measured tangenti-
ally to the base cylinder in sequential transverse sections.
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8.6.1 Total Tooth Trace Deviation

Total tooth trace deviation Fβ of a tooth flank is the distance between the two
nominal profiles that touch and enclose the tooth flank inside the tooth trace eva-
luation range.
Desired deviations from the ideal helix are allowed for by corresponding devia-
tions of the lines AA and A“A“ from straight lines.
Fig. 149 Total tooth trace deviation
Fβ Total tooth trace deviation

Lβ Tooth trace evaluation range
b Face width
AA, A’’A’’ Nominal tooth traces enclosing the actual flank
Tab. 58 Parameters for total tooth trace deviation

8
BASIC PRINCIPLES
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8.6.2 Tooth Trace Angle Deviation

Tooth trace angle deviation fHβ is the distance in a transverse section plane
between the two nominal tooth traces that intersect the helix with the actual lead
at the starting point and end point of the evaluation range.
It is generally given in μm as the linear measure associated with tooth trace test
range Lβ.
Fig. 150 Tooth trace angle deviation
fHβ Tooth trace angle deviation

b Face width
BB Centering line for actual tooth trace
C’C’, C’’C’’ Nominal tooth traces intersecting the tooth traces at the test range
starting point and end point
Tab. 59 Parameters for tooth trace angle deviation

8
BASIC PRINCIPLES
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8.6.3 Tooth trace angle deviation

Tooth trace angle deviation ffβ is the distance between the two helices and the
actual lead, which touch and enclose the actual flank within the tooth trace test
range, The ripple of the tooth trace is taken into consideration.
Fig. 151 Tooth trace angle deviation
ffβ Tooth trace angle deviation

Lβ Evaluation range on the tooth trace
b Gear face width
B–B Averaging line of the tooth trace
B’–B’, B”–B” Enveloping lines parallel to B–B

8
BASIC PRINCIPLES
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8.6.4 Helix Crowning

Helix crowning modifies the tooth profile in its face width.
This figure shows how the values for Fβ, fHβ, and ffβ are determined from the tooth
trace test diagram while taking account of the specified crowning CαSoll (Cα set-
point).
Fig. 152 Helix crowning
b Face width
P1, P2 Highest and lowest point, respectively, at which the enveloping setpoint parabola
is placed from both sides (a determining factor for the value of total tooth trace
deviation Fβ)
P1, P3 Highest and lowest point, respectively, at which the enveloping actual parabola is
placed from both sides (a determining factor for the value of tooth trace form de-
viation ffβ)
Tab. 60 Parameters for helix crowning
Note that crowning Cβ must be referenced to evaluation range Lβ . The highest

point is determined by placing a parallel line on the regression curve.
To determine fHβ the chord of the regression parabola should be used; ffβ, the re-
gression parabola is used.
Tooth trace deviation angle fHβ is calculated from the value f’Hβ measured inside
evaluation range Lβ by extrapolating to face width b.

8
BASIC PRINCIPLES
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8.6.5 Pitch Line Runout Fr

The pitch line runout (concentricity variation) is determined by means of a measu-
ring element (sphere, cylinder, or V head) introduced into the tooth spaces. The
measuring element contacts the tooth flanks near the X-circle. The radial position
difference of the measuring element is measured for each tooth space.
Fr denotes the greatest difference among the measured values.
Fig. 153 Pitch line runout (concentricity variation)
Concentricity variation is caused primarily by the following:

¡ Eccentricity of the gear teeth in the plane of measurement perpendicular to the
gear axis
¡ Uneven space widths due to pitch variations in the right flanks and left flanks
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8.6.6 Calculated Runout (Not DIN-Compliant)

Unlike runout Fr calculated to DIN, the value for the right and left flank is output
individually in this case.
The tolerances and quality ratings are taken for both flank sides from the input for
runout Fr.
About the calcula- As the calculated runout, twice the fundamental vibration amplitude of the cumu-
tion lative pitch-span variation is output.
The concentricity variation in a tooth space is calculated as the difference
between the cumulative pitch-span variation of the left flank of tooth <l> and the
cumulative pitch-span variation of the right flank of tooth <l+1> divided by twice
the tangent of the mean pressure angle.

8
BASIC PRINCIPLES
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8.6.7 Tooth Thickness Variation Rs

The tooth thickness variation Rs is the difference between the largest and small-
est tooth thickness s on a toothed gear.
Fig. 154 Tooth thickness variation

8
BASIC PRINCIPLES
Roughness Basics
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8.7 Roughness Basics

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8.7.1 Cut-Off
The variation of a surface from its ideal geometry is divided into rough geomet-
rical variations -- dimension, form, and position -- and fine geometrical variations -
- waviness and roughness. The difference between waviness and roughness is
determined by the cut-off (cutoff filter) λc. Thus, the cutoff filter is used to generate
the roughness profile from the raw data.
According to VDI/VDE Guideline 2615, the Klingelnberg roughness measurement,
based on the probe section method, is suitable for measuring tooth flanks.
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8.7.2 Roughness Parameters

The number of output values can be defined by Klingelnberg Service.
Value Description
Ra Arithmetic mean of the profile ordinates
Rz Mean of 5 individual roughness depths
Rt Roughness depth: largest profile distance in the vertical direction in the total
measurement section
Rmax Largest occurring individual roughness depth
R3z Base roughness depth: R3z corresponds to the mean calculated from the
third-highest profile peak and the third-lowest profile valley in an individual
measurement section.
Rq Mean roughness value: squared mean of all values in the roughness profile
Rpc Number of peaks in the roughness profile
Rk Core roughness depth: depth of the core profile
Rpk Reduced peak height: averaged height of the peaks emerging from the core
area.
Rvk Reduced groove height: averaged depth of the grooves emerging from the
core area.
MR Material percent (= percentage contact area tp): Percent ratio of material-filled
length to total measurement section (lm)
MR1 Smallest percentage of material in the core profile
MR2 Greatest percentage of material in the core profile
Tab. 61 Overview of roughness parameters

8
BASIC PRINCIPLES
Roughness Basics
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8.7.2.1 Traceline Length

The distance covered during the roughness measurement, called the traceline
length (Lt), is divided into the run-up section (lv), the total measurement sec-
tion (lm), and the run-out section (ln).
Fig. 155 Traceline length
The run-up section (lv) and run-out section (ln) are used to accelerate and decel-
erate the probe and to build up the filter. For the evaluation, only the values in the
range of the total measurement section (lm) are applied.
In accordance with the standard, the total measurement section is divided into
five individual measurement sections (le), whereby the length of each individual
section corresponds to the cut-off of the cutoff filter λc being used.
To calibrate the roughness probe, a measurement section of 4.8 mm is used;
thus, the cutoff filter is 0.8 mm. If other traceline lengths are also included in the
measurement program, the program will automatically select the correct cutoff fil-
ter.

8
BASIC PRINCIPLES
Roughness Basics
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8.7.2.2 Roughness Parameters

The diagram below shows profile depth measurements over the measurement
section (lm).
Fig. 156 Roughness Parameters
Z1 – Z5 The greatest profile depth (individual roughness depth) in an individual meas-

urement section (le).
Rmax Largest occurring individual roughness depth
Rt Roughness depth: largest profile distance in the vertical direction in the total
measurement section
lm Total measurement section
le Individual measurement section
Mean roughness va- Ra is the arithmetic mean of the sum of all values constituting the profile variation
lue Ra within the total measurement section (lm).
Averaged Rz is the arithmetic mean calculated from the 5 individual roughness depths Z1 –
roughness depth Rz Z5.
Rz is a dimension for the average jaggedness of the surface, since outliers are
only taken into account as follows: 1/5 = 20%.
The following formula generally holds true: Rt ≥ Rmax ≥ Rz ≥ Ra

8
BASIC PRINCIPLES
Roughness Basics
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8.7.2.3 Standard Values

For standards-compliant measurement, the cutoff wavelength and the associated
length of the individual measurement sections are determined according to the
following table:
Aperiodic Profiles Cutoff Wavelength Individual Measu-

rement Section
Rz Ra λc Rz
0.025 – 0.1 µm 0.006 – 0.02 µm 0.08 mm 0.025 – 0.1 µm
0.1 – 0.5 µm 0.02 – 0.1 µm 0.25 mm 0.1 – 0.5 µm
0.5 – 10 µm 0.1 – 2 µm 0.80 mm 0.5 – 10 µm
10 – 50 µm 2 – 10 µm 2.5 mm 10 – 50 µm
50 – 200 µm 10 – 80 µm 8.0 mm 50 – 200 µm
Tab. 62 Standard roughness values
Rz Mean of 5 individual roughness depths

Ra Arithmetic mean of the profile ordinates
λc Cutoff wavelength
Le Individual measurement section of roughness profile
Lm Total measurement section: individual measurement section times 5
Tab. 63 Description of parameters
Parameters for common gearings on the tooth flanks:

¡ Roughnesses Ra = 0.1 – 2.0 µm
¡ Traceline length Lt = 4.8 mm
¡ Cutoff filter λc = 0.8 mm
The results of the roughness measurement are output in the standard measuring
sheet (see the section on roughness measurement results) found in chapter 5.
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4 Preparing for measurement

Descriptions in this chapter apply predominantly to the function "Gear". The

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Workpiece / protocol data Catalog

Machine / stylus Select / preset

Workpiece / profile (graph

Check / Sel. of checks

Check / Tooth menu

Check / Measuring positions

Tolerance / profile / flank / pitch

Tolerance / ball dimensions

Alignment / vertical positions

Alignment / workpiece axis position

Output / evaluation instruction

38 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

4.3.2.2 Create new workpiece

Input fields Description

7. Mark the appropriate data.

Result The new drawing number has been created.

48 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

4.3.2.3 Tooth form

Fig. 11 Symmetrical tooth form Fig. 12 Conical tooth form

Fig. 13 Tapered and beveloid tooth form

372008A 03-007en-US KLINGELNBERG Cylindrical Gear GINA 49

Further information on the parameters can be found in section Principles.

50 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

4.3.3 Profile Graph Length

In the «Workpiece» menu, click on «Profile».

Fig. 14 «Correction / Profile graph length» window

372008A 03-007en-US KLINGELNBERG Cylindrical Gear GINA 51

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52 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

Fig. 15 Profile: Measuring range

Me End of measurement at tooth tip

372008A 03-007en-US KLINGELNBERG Cylindrical Gear GINA 53

Result The profile measuring range is recorded.

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54 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

4.3.3.1 Calculate profile graph lengths

Input fields Description

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372008A 03-007en-US KLINGELNBERG Cylindrical Gear GINA 55

4.3.4 Lead graph length

Menu «Workpiece» / «Lead»

Fig. 16 Lead «Correction / Lead graph length»

Input field Description

56 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

Input field Description

1. Select the <left> or <right> lead.

Result Graph lengths for checking the leads are recorded.

The standard check is carried out on the reference circle.

Fig. 17 Lead: Measuring range

372008A 03-007en-US KLINGELNBERG Cylindrical Gear GINA 57

Gear face width b

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58 KLINGELNBERG Cylindrical Gear GINA 03-007en-US 372008A

4.3.5 Extended data input

Menu «Workpiece» / «Special»

4.3.5.1 Lead flutes

Fig. 18 Flute in the lead

<Flute> When activates, the flute is ignored during