AGMA Webinar Series

Analytical Gear Chart Interpretation:

Reading Between the Lines
PART ONE

Dwight Smith
President, Cole Mfg. Systems, Inc.

May 10, 2012

Dwight Smith

Dwight Smith, President of Cole Mfg. Systems, Inc., 
has a wide range of experience in gear manufacturing, 
workholding, metrology, analysis, and project 
management. 
He has been developing and presenting the Gear Basic 
training sessions throughout North America since 
1989. Smith serves as chairman of the AGMA 
Nomenclature Committee and is an instructor for the 
Basic Gear School for AGMA. 
His company, Cole Mfg. Systems, Inc., represents 
complementary gear‐related equipment 
manufacturers.

American Gear Manufacturers Association

 Gear – Primary Elements

• Definition of primary gear tooth elements

– Profile (Involute)
• Deviation from the involute curve
– Helix (Lead)
• Deviation from true helix angle
– Pitch (Index)
• Distance along a curve from one tooth to
next at same diameter
– Runout
• Radial deviation over a ball occurring
once per revolution
 Analytical Gear Measurement

Pitch
(Cumulative Pitch, Single Pitch, Index)

Helix
(Lead, Tooth Alignment)

Profile
(Involute)
Pitch Inspection
Index Tangent to Base Circle Diameter

Base
Tangent Line

Rotary
Base Circle Motion
Diameter
Index Test
Index Test- Total Error
Index Test – Single Pitch Error

Single
Pitch
Error
 Gear Index and Pitch Terms
Index and pitch 4

expected

actual
probe

fp

Fp

1 5 10 19
 Index Test Calculations

(Pitch)
Index – Computerized printout
 Pitch vs. Runout
Cumulative Pitch Single Pitch
ATTENTION: Runout determined by
analytical inspection is NOT a direct
substitute for “Runout by Composite
Test”.
Helix Inspection
 Helix (Lead) Test

Test
Results

Lead (Helix)
Test
 Gear Tooth Helix Chart
Helix
Tooth #1

top

bottom

bottom top
 How Helix is Depicted on the Chart

Plus helix
deviation

Reverse
Drive

Forward Drive

• The helix trace will appear straight if

deviations are not present.

• If the helix deviation differs from

the nominal surface, the trace will
trend or slope one or the other
direction depending if the gear is Face
left hand or right hand. Width

• In the case shown, a right hand

gear has a plus helix deviation
Helix traces

Actual tooth Desired Tooth

Gear Helix Chart Creation

•
 (-) (+) (-) (+) (+) (-) (+) (-)

Left Right
Left Right Flank Flank
Flank Flank
Left Hand Helix
Right Hand Helix
For a left hand helix, if the
For a right hand helix, if the measured helix is more right,
measured helix is more right, the measured value is
the measured value is positive. negative.
If the measured helix is more If the measured helix is more
left, the measured value is left, the measured value is
negative positive.
Helix Variation
Helix Traces with Variation
 Trouble Guide-Hobbing
NOT Good Why Causes
VARIATION
Good Lead • Individual • Axial runout of
tooth traces clamping fixture
are not • Damage to locating
parallel to face
each other
• Chip buildup

• OFF HELIX
• Individual
• Slippage of part
tooth traces
parallel but • Fixture alignment
leaning • Dull hob cutter
Profile Inspection
 Profile Test

Test Involute Profile

Results Test
 Involute Inspection with Error -Tangent to Base Circle

Error

Perfect
Trace Rotary
Base Circle
Motion
Diameter
Tooth #1
 Gear Involute Trace Creation

Scale for deviations

from true involute,
Deg of roll
200x, 400x, or 800x
scale

36
Base circle diameter
33
30
27
24
21
tooth
18
15
12
9
6
3
0 18 21 24 27
Root 15 30
12
9 33
6
.004 mm 3
0
AGMA 2000-A88, Fig. 9-19
Trace Characteristics Evaluated

Helix
Fß = Total deviation
fHß = Slope deviation
ffß = Form deviation

Profile
F = Total deviation
fH = Slope deviation
ff = Form deviation
Helix Slope Deviation (fHβ)
Helix slope deviation is the
amount of deviation from a
nominal helix over the
evaluation range.
(From AGMA + ANSI 2015-1-A01)
Helix Form Deviation (ffβ)
Helix form deviation is the
divergence from a best fit
curve along the helix.
(From AGMA + ANSI 2015-1-A01)
Helix Deviation, Total (Fβ)
The total amount of error
including angle and form
errors.

(From AGMA + ANSI 2015-1-A01)

 End of
evaluation

Helix Crown (Cβ)

evaluation range
The amount of material
above the fitted angle Cβ
+
error line to the highest
point of the fitted curve.
(Not part of AGMA 2015)

SAP

Helix Crowning
Profile Slope
Deviation (fH)
Profile slope deviation
is the amount of
deviation from a
nominal involute
profile over the
evaluation range.
(From AGMA + ANSI 2015-1-A01)
Profile Form
Deviation (ff)
Profile form deviation
is the divergence of
the measured profile
from a best fit line or
curve.
(From AGMA + ANSI 2015-1-A01)
Profile Deviation, Total
(F)
The total amount of error
including slope and form
errors.
(From AGMA + ANSI 2015-1-A01)
 End of
evaluation

Profile Barreling (C)

evaluation range (L)

Profile barreling is the
distance from the best fit
curve to the slope C
+
deviation line. This is
sometimes called involute
crown.
(Not part of AGMA 2015)
SAP

Profile barreling
 OD
Variation
from
Runout
Relocate part on
inspection arbor
Don’t Miss the Next AGMA Webinar

June 7, 2012
1:00‐2:30 PM Eastern

Analytical Gear Chart Interpretation: 
Solving Manufacturing Problems
Dwight Smith
President, Cole Mfg. Systems, Inc.

Picking up from Part One, this webinar reviews chart interpretation and applies
inspection data to understand the causes and cures of manufacturing errors. Many
chart examples are used to understand cause and effect.

American Gear Manufacturers Association

AGMA 2012 ‐ Education Calendar

January 24-26 Gearbox CSI: Forensic Analysis of Gear & Bearing Failures, Concordville, PA

April 16-20 Basic Training for Gear Manufacturing, Chicago, IL

May 15-17 Gear Materials - Selection, Metallurgy, Heat Treatment, and Quality Control, Milwaukee, WI

June 11-13 Gear Failure Analysis, Big Sky, MT

June 19-21 Gearbox System Design: The Rest of The Story…Everything But The Gears and Bearings,
Clearwater Beach, FL

Sept 17-19 Gear Failure Analysis, Big Sky, MT

Oct 1-5 Basic Training for Gear Manufacturing, Chicago, IL

Nov 13-15 Gear Manufacturing & Inspection ― Methods, Practices, Application & Interpretation for the
Design Engineer, Las Vegas, NV - MM

Dec 4-6 Detailed Gear Design – Beyond Simple Service Factors (Not for the Faint-Hearted! Alexandria, VA

Visit www.agma.org for full details and registration.

American Gear Manufacturers Association

 Certificate of Participation
The American Gear Manufacturers Association
certifies that

has attended the AGMA Webinar

Analytical Gear Chart Interpretation: Reading Between the Lines

Presented by: Dwight Smith, President of Cole Manufacturing Systems, Inc.

May 10, 2012 1.5 hours

A M E R I C A N G E A R M A N U F A C T U R E R S A S S O C I A T I O N