PPT4 - Engineering Inspection and Quality Control PDF

Engineering Inspection and
Quality Control
By
Dr. Sukanta Roy
Associate Professor, Department of Mechanical Engineering, National Institute of Technology Mizoram
Adjunct Associate Professor, Faculty of Engineering and Science, Curtin University Malaysia
PhD (IIT Guwahati), MTech (NIT Silchar), BEng (NIT Agartala) , MASME, MIE CEng (India), SFHEA (UK)
Erasmus Mundus Post-Doctoral Fellow (ECN, France)
Post-Doctoral Fellow (IRPHE/AMU, France)
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Engineering Inspection and Quality Control | Dr. Sukanta Roy | National Institute of Technology Mizoram
Metrology of Gears
Types of Gears
Spur gears
These gears are the simplest of all gears. The gear teeth are cut on the
periphery and are parallel to the axis of the gear. They are used to
transmit power and motion at a lower speed of rotation.
Spur Gears are the simplest type of gear. They consist of a cylinder or
disk with the teeth projecting radially, and the edge of each tooth is
straight and aligned parallel to the axis of rotation. These gears can be
meshed together correctly only if they are fitted to parallel shafts.
Spur gears
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Metrology of Gears
Helical gears
The gear teeth are cut along the periphery, but at an angle to the axis of the
gear. Each tooth has a helical or spiral form. These gears can deliver higher
torque since there are a greater number of teeth in a mesh at any given point
of time. They can transmit motion between parallel or non-parallel shafts.
Helical gears offer a refinement over spur gears. The leading edges of the teeth
are not parallel to the axis of rotation but are set at an angle. Since the gear is
curved, this angling causes the tooth shape to be a segment of a helix. Helical
gears can be meshed in parallel or crossed orientations. The former refers to
when the shafts are parallel to each other; this is the most common
orientation. In the latter, the shafts are non-parallel, and in this configuration
the gears are sometimes known as "skew gears".
Whereas spur gears are used for low-speed applications and those situations
where noise control is not a problem, the use of helical gears is indicated when Helical gears
the application involves high speeds, large power transmission, or where noise
abatement is important.
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Metrology of Gears
Types of Gears
Herringbone gears
These gears have two sets of helical teeth, one right-hand and the other
left-hand, machined side by side.
Herringbone gears
Worm and worm gears

A worm is similar to a screw having single or multiple start threads,
which form the teeth of the worm. The worm drives the worm gear or
worm wheel to enable transmission of motion. The axes of worm and
worm gear are at right angles to each other.
Worm and
worm gears
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Metrology of Gears
Bevel gears
These gears are used to connect shafts at any desired angle to each other.
The shafts may lie in the same plane or in different planes.
It is shaped like a right circular cone with most of its tip cut off. When
two bevel gears mesh, their imaginary vertices must occupy the same
point. Their shaft axes also intersect at this point, forming an arbitrary
non-straight angle between the shafts. The angle between the shafts can
be anything except zero or 180 degrees. Bevel gears with equal numbers Bevel gears
of teeth and shaft axes at 90 degrees are called miter gears.
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Metrology of Gears
Hypoid gears
These gears are similar to bevel gears, but the axes of the two connecting
shafts do not intersect. They carry curved teeth, are stronger than the common
types of bevel gears, and are quiet-running. These gears are mainly used in
automobile rear axle drives. The pitch surfaces appear conical but, to
compensate for the offset shaft, are in fact hyperboloids of revolution. Hypoid
gears are almost always designed to operate with shafts at 90 degrees.
Hypoid gears
Depending on which side the shaft is offset to, relative to the angling of the
teeth, contact between hypoid gear teeth may be even smoother and more
gradual than with spiral bevel gear teeth, but also have a sliding action along
the meshing teeth as it rotates and therefore usually require some of the most
viscous types of gear oil to avoid it being extruded from the mating tooth
faces.
This style of gear is most commonly found driving mechanical differentials,
which are normally straight cut bevel gears, in motor vehicle axles.
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Metrology of Gears
Rack & Pinion
rack is a toothed bar or rod that can be thought of as

a sector gear with an infinitely large radius of
curvature. Torque can be converted to linear force by
meshing a rack with a pinion: the pinion turns; the
rack moves in a straight line. Such a mechanism is
used in automobiles to convert the rotation of the
steering wheel into the left-to-right motion of the tie
rod. Racks also feature in the theory of gear
geometry, where, for instance, the tooth shape of an Rack & Pinion
interchangeable set of gears may be specified for the
rack (infinite radius), and the tooth shapes for gears
of particular actual radii are then derived from that.
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Metrology of Gears
Base circle: It is the circle from which the involute form is

generated. Only the base circle of a gear is fixed and
unalterable.
Outside circle: It marks the maximum diameter of the gear up

to which the involute form is extended. It is also called the
addendum circle. In addition, it is the diameter of the blank
from which the gear is cut out.
Pitch circle: It is the imaginary circle on which lies the centres of the
pitch cylinders of two mating gears.
Root circle: It is the circle corresponding to the minimum diameter of the gear profile. However, the involute profile
is limited only up to the base circle of a spur gear.
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Metrology of Gears
Addendum: It is the radial distance between the addendum

circle and the pitch circle.
Dedendum: It is the radial distance between the pitch circle

and the root circle.
Face: The portion of tooth lying between the addendum circle

and the pitch circle is called the face.
Flank The portion of tooth lying between the pitch circle and
the dedendum circle is called the flank.
Circular pitch It is the distance between corresponding points of adjacent teeth measured
along the pitch circle.
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Metrology of Gears
Diametrical pitch It is expressed as the number of teeth per

unit diameter of the pitch circle.
Module It is simply the metric standard for pitch. It is the linear

distance (in mm) that each tooth of the gear would occupy if the
gear teeth were spaced along the pitch diameter.
Accordingly, if the pitch circle diameter of the gear is D and the
number of teeth is N, then the module m is given by D/N and is
expressed in mm.
The Indian Standards Institute (ISI) has recommended the following modules (in mm) in order of preference:
First choice: 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20
Second choice: 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14, 18
Third choice: 3.25, 3.75, 6.5
Tooth thickness It is the arc distance measured along the pitch circle from its intercept with
one flank to that with the other flank of the same tooth.
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Metrology of Gears
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Metrology of Gears
Line of Action and Pressure Angle

The mating teeth of two gears in the mesh make contact with each other
along a common tangent to their base circle. This line is referred to as the
‘line of action’. The load or the so-called pressure between the two gears is
transmitted along this line.
The angle between the line of action and the common tangent to the pitch
circles is known as the pressure angle. Using trigonometry, it can be shown
that the pressure angle is also given by the angle made between the
normal drawn at the point of contact of line of action to the base circle and
the line joining the centres of the gears.
Standard: 14.5 deg or 20 deg

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Metrology of Gears
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Gear Tooth Measurement
Since the tooth thickness is measured as the length of an arc, it is difficult to measure it directly. It is
generally measured at pitch circle and is, therefore, the pitch line thickness of the tooth. In the most
cases, it is sufficient to measure the chordial thickness, i.e., the chord joining the intersection of the
tooth profile with the pitch circle.
There are various methods of measuring gear tooth thickness:
i) Chordial Thickness method (measurement of tooth thickness by gear tooth vernier caliper)
ii) Constant chord method
iii) Base tangent method
iv) Measurement over rollers
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Chordial Thickness method
Vernier gear tooth caliper Chordial thickness method
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Chordial thickness method
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Depth of tooth
Chordial thickness method
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Thank you
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Engineering Inspection and

Worm and worm gears

rack is a toothed bar or rod that can be thought of as

Base circle: It is the circle from which the involute form is

Outside circle: It marks the maximum diameter of the gear up

Addendum: It is the radial distance between the addendum

Dedendum: It is the radial distance between the pitch circle

Face: The portion of tooth lying between the addendum circle

Diametrical pitch It is expressed as the number of teeth per

Module It is simply the metric standard for pitch. It is the linear

Line of Action and Pressure Angle

Standard: 14.5 deg or 20 deg

There are various methods of measuring gear tooth thickness:

Vernier gear tooth caliper Chordial thickness method

Chordial thickness method

Chordial thickness method

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