2390 % Ss 'e's sss = Gear Measurements form profile, provided on it's circumferential surface is ca ower or motion, without slip, at a definite and constant velocity r2 applicetions where the distance between the axis of driving and driven shaft is short. Th ive (without slip) as compared to belt and chain drive. While transmitting the mot ‘¢ mounted on the shaft and are meshed with each other. When one gear rotates, the another meshe so rotates and thus the motion is transmitted from one shaft to another. The s s, transmission gear boxes, planetary drives ete. t in devices such as differenti The manufactured by casting, machining, stamping or by powder metallurgical pr ssses, method of production of gear by machining is most widely used in engineering pract 7.2: TYPES OF GEARS ‘The important types’of gears are as under ; Spur Gears Bevel Gears 3. Helical Gears 4. Worm and Worm Wheel 1. Spur Gears : Gears which transmit motion between parallel shafi and whose teeth are parallel to the axis of the shaft are called spur gear. This is the simplest form of geared drive as shown in fig. 7.1 Normally the teeth are of involute form. The efficiency of power transmission by these gears is very high (96 to 98% under average conditions). The disadvantage of these gears are that they are more noisy in operation any may wear out more readily than the other types. Fig, 7.1: Spur Gears 122Metrology and Instrumentation 2, Bevel Gears : Gears which transmit power between shafis, whose axes intersect each other if produced are called bevel gears. In these gears, the tec are cut on the conical surface. These are u forconnecting the driving and driven shaft whose a intersect and are generally at right angle. If the shaft are at right angle and wheels are of equal size, the g are called mitre gears. If the shafis are not at right an {ears are called angle bevel gear. Spiral toothed bevel gears are preferred to straight toothed bevels in certain applications, because they will run more smoothly and make less noise at high speeds 3. Helical Gears : Gears which transmit . power between parallel shafts but the teeth are parts of the helices, are called helical gears. The teeth of helical gears are inclined instead of being parallel with shaft Theinclined teeth ensures smooth action and more accurate maintenance of velocity ratio. It is as shown in fig. 7.3. The disadvantage of this gear is that a lateral thrust is set up due to inclination of teeth. A method of neutralising this lateral or axial thrust is to use double helical gears, also known as Herring bone gears. The helical gears are stronger and quicker in operation as ‘compare to spur gears. However some power losses takes place due to end thrust. 4. Worm and worm wheel : Worm and worm wheel are used when the power is being transmitted between nonparalle! and non-intersecting shafts. The worm gearing is used where a large speed reduction is required. One gear is known as worm gear and another gear is called worm : wheel. The threads of worm gear mesh with teeths of gear wheel. The advantage of worm gearing is the high gear ratio .¢. the high ratio of rotational speed or worm to the rotational speed of worm wheel.24 7.3: E-Series GEAR TERMINOLOGY Some important terms used in connection with gea as und 5 CIRCULAR THICKNESS. ores IRCULAR PITCH: DEDENDUM ADDENDUM 4 CIRCLE BASE CIRCLE WORKING DEPTH CIRCLE BOTTOM OF CLEARANCE TOOTH SPACE PITCH CIRCLE ROOT CIRCLE ‘S: Pictorial view of a portion of gear ADDENDUM CIRCLE PITCH CIRCLE DEDENDUM OF Ss ROOT CIRCLE "7 = Bea FILLET RADIUS CIRCULAR PicH WORKING i ee, "ADDENDUM. "woe DEPTH CENTRE DISTANCE Fig. 7.6 : Orthographic view of mating gear Pitch Circle: isan imaginary circle on which the teeth of the mating gears are meshed generated, The base circle on gear is ase Circle : It is the circle from which the involute form is only circle which is fixed and unalterable, It occurs only in involute gears, Root of the tooth: Its the junction ofthe tooth with the bottom of tooth space.Metrology and Instrumentation 20. at. 11 is outside surface of the tooth, which is perpendicular to the place the pitch cirele and perpendicular It is the radial distance between the pitch Itis the radial distance between the pitch circle a The difference between the dedendum and the add ou) he sum of addendum and dedendum of th h=h ¢ Depth : tis the greatest depth to which the tooth of oF Working depth = Addendum + Dedendum — Clearance Itis the thickness of the tooth measured on the pitch circle kness (S ‘h space : The width of the recess between the two adjacent teeth meas re ng th Je is called tooth space. ‘adius (r) : It is the radius which connects the root circle to th: The difference between tooth space and tooth thickness i Blank Diameter : The diameter of a gear blank is equal to the pitch circ dum, Pitch Circle Diameter (P.C.D.) : It is the diameter of pitch circle i.e. the circle which t rolling action would produce the same motion as the toothed gear wheel. It is representec Number of teeth N Diameteral pitch oP PCD. Diametral Pitch (D.P) : \t is the number of teeth on gear per mm of pitch circle diametet 1 Pitch (D.P. Number of teeth . N Pe PeND E> Sncidapamer &* DE PCD. Circular Pitch (C.P) :Itis the are distance on the pitch circle diameter from a point on on to the corresponding point on the adjacent tooth Circumference of pitch circle diameter Circular Pitch fees Number of teeth n*P.CD. cP. y Pitch Point: It isthe point of contact between the pitch circle of two gears in mesh,E-Series 22. Module (m) : It is the linear distance that e i spaced fons the teh ean tt each ooth of gear woud occupy ifthe gar tet wer } 10 Of PC.D. to number of teeth and is represented by Modul Bee. e Number of teeth ean Its reverse of diametral pitch and is the main parameter in fixing the dimensions of pear teeth 23. Cos agent Itis the common tangent at the pitch circle of the two mating gears atthe pitch 24, Common Normal . It is common normal to the two tooth profiles at the point of contact 25. Cenire distance It is the distance between centres of a pair of mating gears. It is equal to su radii of the pitch circles of the two gears. 26. Line of action - It is the common tangent of the two base circles which passes through the pitch Point of mating gears. e Pressure angle or Angle of obliquity ’ Itisthe angle which the common normal to the two teeth at the point of contact makes with the common tangent to the two pitch circles at the pitch point. It is as shown in fig. 7.7. The pressure angle determines the direction of pressure between the mating teeth. It also designates the shape of the involute WHEELS: teeth and size of the base circle. The larger pressure angles are advantageous Base because it will give strong tooth form CIRCLE | WHEEL A with less undercutting. The pressure angle is taken as 14.5° or 20°. Fig. 7.7 : Pressure Angle 7.4: SPUR GEAR MEASUREMENT The gears are manufactured by either reproducing method or generating method. In reproducing method. 2 formed involute cutter is used to cut gear teeth, The errors in this method may be due to errors in manufacturi of cutting tool, errors in positioning of the tool relative to the blank or errors due to incorrect indexing of gear blank. In generating method, the cutting tool forms the profile of several teeth simultaneously during constant relative motion of the tool and blank. The errors in gears may be due to errors in the manufacturing of tool or may be due to incorrect positioning of the tool or due to incorrect relative motion of the toll and blank during the cutting operation. These sources of error causes inaccuracies in lead, pitch, tooth thickness, profile and errors of composite nature. The accuracy of gears in geometrical form and shape has great influence over ‘smoothness of operation, durability and tendency of freedom from noise, So, itis very essential to measure and check every parameter of gears during manufacturing and before use, Following parameters are generally checked and measured. (@) Tooth thickness (b) Pitch of tooth (©) Tooth profilee@eeeveseeesees eset FF Metrology and Instrumentation (4) Composite error +.4.1 : TOOTH THICKNESS MEASUREMENT : Following methods ar neasurement of tooth thickness (a) Chordal thickness measurement by gear tooth vernier calliper : Th < us6dl to measure chordal thickness. This vernier calliper consists of two perp arms calle arm. Both arms consist of vernief scale, The horizontal vernier arm is used to mea: ickness of vertical vernier calliper is used to set the vernier at correct position. The tooth varies feo in chordal thickness method, the thickness of tooth is mea 1 ri sliding between the jaw, which can be set such that when it res’ nts of tooth at flank. The gear tooth vernier is as shown in fi VERTICAL SCALE \] HORIZONTAL SCALE | (i ae Lal MOVEABLE VERTICAL a L f MOVEABLE FIXED MEASURING J NOMENA Fig. 7.8 : Gear Tooth Vernier For the measurement of tooth thickness, set the addendum on the vertical slide of gear tooth vernier and then insert the j f the instrument on the tooth to be measured. Now adjust the horizontal vernier slide by the fine adjusting screw, so that the jaws just touch the tooth, The tooth thickness is measured by horizontal vernier slide. \ CHORD THICKNESS OF TOOTH Fig. 7.9: Measurement of Gea s r tooth th (b) Base Tangent method by David Brown Tan : ; ngent Comparator : The measur thickness by the use of gear tooth vernier is not very satisfactory because the observations ae : vernier readings and each is a function of other. The accuracy of measurement can be increskeqeia Y yy mex Meaurement over a number of oo la LOckiNG RING Fig. 7.11 : David Brown Tangent Comparator David Brown tangent comparator has two anvils : one is fixed and a ci attached with moving anvil and has limited movement on either side of 2 ngis ack. The measurement is taken over a convenient m ; 7.4.2: MEASUREMENT OF PITCH (By Zeiss Gear Measuring Machine) length of the chord of the pitch circle connecting two identically located po chordal pitch is measured at pitch circle by the use of Zeiss gear measuring umber of t. MOVING ANVIL eae ial MEASURING SPINDLE WEIGHT. Fig. 7.12 : Ze 's Gear Measuring Machine S@e@ 128 SteeMetrology and Instrumentation hive shock eased to mearure Zerss gear easing macline ea aniver (except involute profiles This machine cone et ata tangential wae acuninge catevage Tht ort twp anvils, one fixed and another movable anvil The ween antacid ith 9 Oia aie provision ofa fixed weight. the ans itsapph a pre sae anaarval deer tot onthe Flank Of gees, he Wan and ean be pr The gears can be ph Fhe meving, anvil ¢ are mounted on mandte! teh Bevin, “ba by the use of radial locator, while taking: the measur spindle which remain in contact with a fecler of dal gauge Initially the sere reading. 1 geat to be measured 1 mounted on mandnil and the anvils are properly located on chordal pitch 1s measured The other machines as Klingelnberg pitch measuring machine. Zeiss base pitch: " tangent base pitch tester and Keilpart hase pitch tester may be used to measure chordal pater 7.4.3 : MEASUREMENT OF TOOTH PROFILE BY INVOLUTE TESTER: The ugicaton profile of tooth is a very important parameter as oe on. for the uniform transmission of speed it must be ‘ perfectly involute. To obtain same pressure angle ali the gear teeth must be on single base circle. This represents the need of maintaining accurate profile. The profile of gear tooth is measured with” STRAIGHT: the help of involute tester or by tool maker's 0S: microscope. (The microscope has been explained in chapter - optical measuring devices). The involute tester is as shown in fig. 7.13 ‘An involute curve is defined as the locus lire of a point on straight line which rolls around a cylinder without slipping. The involute tester compares the actual profile of teeth wit theoretical involute formed by rolling a straight edge over base circle. The involute tester consists of a ground disk, whose diameter is equal to the base circle diameter of the gear under test. The ‘gear whose profile is to be checked is mounted ‘on same spindle on which the ground disk is fixed. A straight edge is made to contact the dise and is moved tangentially to it so that the disk rotates without slip. Due to this provision, any point on straight edge forms an involute according to the size of base circle If any stylus of indicator is in the plane of straight edge and contacts the tooth flank at the base circle, then it will represent the Fig. 7.13 : Involute Tester deviation of actual profile with theoretical profile If a magnification lever (not shown in fig 7.13) is fitted with stylus to magnify the movement of styl lever will remain stationary for profile of exactly involute shape. The variation from straight line will indi STRAIGHT EDGE INDICATOR the error.rv thickness error, eccentricity. The presence of thes manufactured gear (master gear) periodic err nots, Causes interference in smooth and noise oF, runout, radial runout and ess operation. Ifan accurately ston withthe gears having these errors, then dhore these errors there isa variation in the ¢ wera Beat and master gear. The master gears are used compare the gears and it provides basis of checking of errors when t. n rolled with the gear under test. The master gears are ‘manufactured iim manganese tool steel or good quality steel. These gears mre Sabilized to release internal stresses, The Parkinson gear tesee es shown in fig. 7.14 is used to check these errors ELECTRONIC RECORDER ELECTRONIC TRANSOUCER PICK UPS ‘MECHANICAL DIAL INDICATOR OF MASTER GEAR VARIED CENTRE DISTANCE sees GEAR GEAR UNDER TEST] CALIBRATED ' SPRING VERNER SCALE VERNER SCALE BASE Fig. 7.14 : Parkinson Gear Tester =e i ine is when two gears are in mesh with each other then, due to Fen cere ghia in tw eee disance. The Parkinson —- ool Peace jindles, one is fixed and other is mounted on spring loaded sliding carriage. The ae el aac spindle and the gear, to be measured is mounted on another spindle, The twe desire applied bya calibrated spring atached with eaiage. The gear ae free Sea ea. wher ihe gears are rotated by hand, the movements of the sliding ary it incictceThesevaribons are he mesa of irregularities in the gear, which can eoaearereree A: recorder, Following are some of he Iinlatioogeai tester. pe ac, be used only to know acceptance or rejection of gear but does not find out detailed i) This teste: ee crrcectcn. suB134 Metrology and Instrumentation (ii) It does not clearly indicate the type of error present in gear under test (iii) Only small size gears (below 150 mm) may be tested with the help of this tester. (iv) Accuracy of measurement is of the order + 0.001 mm. EXERCISE | SUBJECTIVE QUESTIONS : What is gear ? Explain different types of gears used in various appliances. Explain the terminology of gears. What are the different elements of the sput gear which are checked for the accuracy of gears 7 Explain with neat sketch the construction and working of gear tooth vernier. Explain following methods used to measure tooth thickness. @ __ Chordal thickness method ©) Base tangent method 6. Explain Zeiss gear measuring machine used to measure gear tooth pitch. How the profile of gear is checked by the use of involute tester ? Explain with sketch. 1 8. Explain working of Parkinson gear tester. SUBJECTIVE QUESTIONS : A. Fill in the blanks : A wheel having teeth of uniform form, provided on the surface is called. The gears used to transmit motion between parallel shaft and having teeth parallel to the axis of shaft is called... gear. 3. The general form ofa teeth is. i ‘The gears used to transmit motion between shafts whose axes are intersection are called. gears. 5. If the two shafis are at right angle and the size of two gears is same, then such bevel gears are called... gear. 6. _ The gears which transmit power between parallel shafts but the teeth are in the part of helix, are Called ene BOE. 7. csussseeuneneiS generally used to convert rotary motion into rectilinear motion. 8. The involute teeth are mostly used but when there is heavy and impact load, used. 9. Theeircle from which he involute form of gear is generated is called. ‘The imaginary circle on which the teeth ofthe mating gears are meshed is calle... The circle which limits the top of the gear is called circle. The radial distance between pitch circle and addendum circle is called, The radial distance between pitch circle and bottom of the tooth is called.