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timely dissemination of this information in an accurate manner to the public.

“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न' 5 तरफ”

Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 7504 (1995): Gears - Cylindrical Gears - Accuracies -

Methods of inspection [PGD 31: Bolts, Nuts and Fasteners
Accessories]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”

है”
ह
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
 ( Reaffirmed 2005 )

Indian Standard
GEARS-CYLINDRICA~L GEARS-ACCURACIES-
MBTHODSOFINSPECTION
( First Revision )

UDC 621-833.1 : 620~111~1

Q BIS 1995

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

December 1995 Price Group 9

Gears Sectional Committee, Lhl 13

FOREWORD

This Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards, after -the
draft finalized by the Gears Sectional Committee had been approved by the Light Mechanical Engineer-
ing Division Council.
This standard was originally published in 1974. The present revision incorporates the latest internation-
ally accepted techniques for inspection of cylindrical gears which includes inspection of gear blanks of
meshing gears, inspection of teeth forms of gears pairs and the inspection of gear pairs in assembled
conditions. The gears are classified into 12 grades based on their accuracies. The revision also incor-
porates the methods for determining individual errors,_schematic for electronic pitch testing equipment,
schematic circuit for single flank testing and measurement of double flank total composite error
Assistance has been derived from the following standards while revising the standard:
i) DIN 3960 : 1987 ‘Definitions parameters and equations for involute cylindrical gears and gear
pairs’, issued by DIN. Dxutsches Institut fiir Normung, Germanv.
ii) DIN 3961 : 1978 ‘Tolerances for cylindrical gear teeth’, issued by DIN. Deutsches Institut ftir
Normung, Germany.
iii) DIN 3967 : 1978 ‘System of gear fits, backiash tooth thickness allowances, tooth thickness
tolerances, principles’, issued by DIN. Deutsches Institut fiir Normung, Germany.
IS 3681 : 1994 ‘Gears -- Cylindrical gears - Accuracies (Jivsi revision )’ may be referred for definitions
and notations.
In reporting the result of a test or analysis made in accordance with this standard, if the final value,
observed or calculated, is to be rounded off, it shall be done in accordance with IS 2 : 1960 ‘Rules for
rounding off numerical values ( revised )‘.
 IS 7504 : 1995

Indian Standard
GEARS - CYLINDRICAL GEARS -ACCURACIES
METHODS OF INSPECTION
( First Revision )
1 SCOPE SMax - Maximum tooth thickness
1.1 This standard covers the general plan for Win - Minimum tooth thickness
cylindrical gears of involute, modified involute flank
forms, comprising of gears with straight or inclined sb - Tooth thickness on base cylinder
teeth for connecting parallel shafts. Fn - Chordal tooth thickness
I.2 This standard covers the inspection methods for SC - Constant chordal tooth thickness
gear teeth oncylindrical gears of module 1 to 70 and
Y - Addendum modification co-efficient
with reference circle diameter up to 10 000 mm graded
in 12 gear tooth qualities. z - Number of teeth
2 REFERENCES zv - Virtual number of teeth
A - Factor (Table 7)
IS 3681 : 1994 ‘Gears - Cylindrical gears - Ac-
curacies (first revision)‘may be referred for definitions Cl - Factor (Table 8)
and notations. Factor (Table 9)
c2 -
3 SYMBOLS
OM - Measuring pin or ball diameter
a” _ Radial pitch distance (double flank pitch
distance) Ff - Total profile error
6 - Face width Fi’ - Single flank total composite error
d’ - Reference circle diameter F; - Double flank total composite error
4 - Top diameter, Blank diameter FP - Total cumulative pitch error
db - Base circle diameter Fpk - Cumulative pitch error over k pitches.
dM - Measuring circle diameter Fpz/a- Cumulative pitch error over 1/8%ofperiphery
ff - Profile form error Fs - Total alignment error
4’ - Single flank tooth to tooth composite error Fr - Radial run-out error
fi” _ Double flank tooth to tooth composite error IT - Tolerance grade

fP - Individual pitch error M - Tooth width

Base pitch error Ml - Tooth width for module 1
fv -
fu - Tooth to tooth pitch error MR - Dimension over pins or balls

fHa - Profile angle error Rp - Range of pitch errors

h-v - Flank line angle error Rs - Tooth thickness fluctuation t

cl - Pressure angle
fif - Longitudinal form error
Ii - Chordal height an - Normal pressure angle
& - Constant chordal height at - Transverse pressure angle

In - Normal backlash aw - Working pressure angle

k - Number of teeth measured awt - Transverse working pressure angle
m - Module aR - Pressure angle, pin or ball
ma - Normal plane module aRt - Transverse pressure angle, pin or ball
mt - Transverse module Helix angle
B -
Pb - Base pitch fib - Base helix angle.
s - Tooth thickness * - Tooth thickness semi-angle

1
IS 7504 : 1995
4 INSPECTION METHODS FOR
CYLINDRICAL GEARS
4.1 The logical order of manufacture of a gear pair is:
a) Machining the blanks of the two gears,
b) Cutting of the teeth of the hvo gears, and
c) Assembling the toothed wheels in operating
condition.
It is, therefore, normal to carryout the successive
inspection in corresponding order:
1. Inspection of the blanks of the two gears.
2. Inspection of the teeth of the two gearqand
3. Inspection of the assembly conditions of the two
gears.
5 INSPECTION OF THE GEAR BLARES
5.1 Reference Axis
In the case of pinions or wheels with bores, the axis of
the bore is adopted as the reference axis.
In the case of pinions on shafts, the reference axis shall
be the bearing axis of the bearings.
In order to facilitate the operations of machining,
inspection and assembly of toothed wheels, it is
recommended that radial and axial auxiliary reference
surfaces should be indicated clearly on the working
drawings ( see Fig. 1).
FIG.1 REFERENCE
SURFACES
\\
5.2 Tip Cylinder
5.2.1 Tip Dimne~er
The value of the tip diameter is not of essential impor-
tance. In cases where the apparatus for inspecting the
tooth thickness rests on the tip cylinder, allowance
should be made for the tip diameter error.
5.2.2 Radial Run-Out
This is the total range of movement of an indicator
stylus which is in contact with the tip cylinder during a
complete revolution of the gear (seeFig. 1). This check
is important only in the case where certain tooth inspec-
tion instruments rest on the cylinder.
5.3 Reference Surfaces
53.1 Radial Run-Out
This is the total range of movement of an indicator
stylus which is in contact with the radial cylindrical
reference surface during a complete revolution of the
gear.
53.2 Axial Run-Out (wobble)
This is the total range of movement of an indtcator
stylus which .is in contact with the axial reference
surface during a complete revolution of the gear.
5.4 Tolerauces on Gear Blanks
The tolerances on gear blanks shall be as given in
Table 1.
6 INSPECTION OF GEAR TEETH FOR ’
INDIVIDUALERRORS
6.1 Circular Pitch Errurs
Circular pitch errors called as pitch errors in short, ilre
measured on thereference circle or any other circle as
close to it as possible and concentric with respect to the
gear axis. The difference between the measuring circle
diameter & and the reference circle diameter d in-
fluences the measurement of the error by the factor
d&d and these errors aregenerally negligible.
The measured values are also affected by eccentricity
of the teeth with respect to reference axis and also by
profile error.
Inspection of the pitch by measuring the deviation from
the design value is normally performed only on high
precision gears where exact angular transmission is
indispensable, A tooth flank is butted against a fixed
anvil in the region of the reference circle while a
movable measuring feeler senses the corresponding
flank of the adjacent tooth. The differences between the
adjacent pitches csn be read from a dial indicator
( see Fig. -2 ).
Eccentricity of the teeth with reference to the gear axis
gives rise to an error curve of overall sinusoidal form.
When pitch measurement is carried out using a hand
operated comparator, the computation of the individual
pitch error, tooth to tooth pitch and total cumulative
pitch error is carried out as given in Table 2 and the
graph of the errors can be drawn from the values thus
computed.
The difference between the consecutive measured
values gives tooth to tooth pitch error, fU. Then the
algebraic mean value is calculated from all the
measured values. The difference between the measured
values and the mean valuegives individual ptich error,
ft The algebraic addition of individual pitch error fp
gives the cumulative pitch error. The total cumulative
pitch error Fp is given by the difference between
maximum and minimum values of cumulative pitch error.
The circular pitch errors can also be measured by using
electronic pitch testers. Individual pitch errors are
2
 Table 1 Tolerances on Gear Blanks (pm)
( Clause 5.4 )

I Quality 1 2 3 4 5 6 7 8 9 10

T
Bore ITl In IT3 IT4 IT4 IT6 IT6 IT6 IT7 ITa
error of form

Shaft In In IT3 IT4 IT4 IT5 ITS IT5 IT6 In IT8 IT8
error of form

Xp diameter IT6 IT6 IT7 IT7 IT7 IT7 IT7 IT8 Il?3 n-9 IT11 IT11
F
‘) Radial b-out of
Xp cylinder
Radial run-out of the 2.5 0.014 + 5 0.0&f, + 10 Usd, + 15 O.O4d, + 25
reference surface
Axial run-out of the
reference surface

w
NOTE-& - Blank diameter, mm.

‘) When the tip cylinder is used as a datum surface for a checking instrument.

i
 G SUPPORT

FIG.2 INS~YXX~ON
OFGEARTmm POR
INDMDUAL
ERRORS

measured Lvith an attachment for involute and helix
testers, which operates on the comparison pitch
measuring principle and at the same time defines a
mean value. Figure 3 shows a schematic of an
electronic pitch testing equipment. The attachment
compares the initial comparison pitch value ‘0’ of any
one pitch of the gear with all subsequent pitches. This
is achieved with the electric tracer ‘K’ which, with its
pair of styli ‘M’ switched to difference measurements,
measures values in relation to the initial datum value
‘0’. When the last measured value has been recorded,
electronic unit ‘R’ automatically evaluates the mean
value which k then drawn automatically as a straight
line through the previously recorded pitch diagram. The
actually recorded individual pitch errors are then read
Hoffalong the line.
6.1.1 Individual Pitch Error, fp
Individual pitch error,fpis the difference between the
actual value of a single transverse pitch and nominal
transverse pitch.
In a gear with z teeth there are z individual pitch errors
of the right flank and as many of the left flanks. The
errors, fP are obtained as the difference between the
individual measured value and the mean of all z’
measured values.
6.12 Cumulative Pitch Error, Fpk
This is the deviation of the actual dimension of a pitch
interval over k individual pitches from the correspond-
ing nominal value. The cumulative pitch error is
obtained as the algebraic sum of the k individual pitch
errors contained in the interval, provided the error of
measurement is sufficiently small.
k
Fpk-Zf
OP

Table 2 Pitch Errors on Gears

( Clause 6.1 )

pitch No. Individual ;;IuhtAa4a;

‘%x? ‘izil%%f” Pitch Emu-
w fu,Irm fp.CM Fp7w
1 0 1 +l +l
2 +3 3 +4 +5
3 +5 2 +6 +I1
4 +l 4 +2 +13
5 -1 2 0 +13
6 -3 2 -2 +I1
7 -5 2 -4 +7
8 -3 2 -2 +.5
9 -6 3 -5 0
10 -3 3 -2 -2
11 -1 2 0 -2
12 +l 2 +2 0
-
NOTE - Mean value -+lO 22 - - 1 (Mean value to be rounded off to the nearest micrometer).
12

4
 Base or guide- body for H and J
Ckria side for eleck tracer K
Gvrier side for electric tracer L
I!kctric tracer for pitch tests, etc
F%ztric tracer for true nmning tests
Pair of tracer styli of K switched to
different measurements.
N Selector switch for separate tracer pressure
direction setting for M
0 Fine setting screw for adjusting the
distance betwken tracer styli of M
P Supporting ball pin or ball/type stylus of
L for true running teats
Q Measuring head adjustment swivelling and
locking members

2 Counting mechanism
R Computer for mean value evaluation
S Measured Glue store
T Stroke mechanism
iJ Stroke restriction
V Indicator instrument
W Ekctric tracer for involute tests, etc

FIG.3 ELECRCNW
PITQI
TEWNG E~JIPMENT

If the errors of all the pitch intervals are measured from Tooth to-tooth pitch errors are directly obtained from
a particular reference tooth profile or calculated from ciradar pitch measurements as the difference of
the individual errors& according to the above equation measurements offleighbouring pitches.
and then plotted against the corresponding teeth num- 65.7 Base Pitch Error, fp
bers, then the cumulative pitch errors are obtained as
per Fig. 4. Base pitch erroris the difference between the ac-1 and
nominal values of the base pitch. Deviations measured
6.13 Cumulative Pitch Ermr Over 118 of Periphery, in the transverse plane are denoted by fpt and in the
Fpzf8 normal plane by fpea.
This is the Amulative pitch error over-aniuterval of l/8 Insped~on is performed by means of a base pitch
circumference of the gear (k = z/8). measuting instrument which is pie-adjusted to setting
i.lA T&al Cumulative Pdch Errs, Fp gauges. Either portable or bench instruments can be
The maximum cumulative pitch errorin agear is called . employed. In both cases, measurement is independent
the total cumulative pitch error. It is indicatedwithout of the gear axis with no influence of radial run-out on
sign and is obtained from the cumulative pitch ermrs as the base pitch. -Se2Fii. 5.
the difference belweeu the algebraic maximum value The absolute value of the base pitch on the line of action
and the algebraic minimum value. ksn idicative of the pressure angle. Error in the base
piti Implies an error ln the pressure angle.
6.1.5 RangeofPitch Errors, Rp
For spur gears, error in the pressure angle can be -
This is the difference between maximum and minimum determined by means of the equation:
actual values of the transverse pitches of the right or left
flanks of a gear.
6.I.6 Tooth to Tooth P&h Errol fi For helical gears, the measured error of the base pitch
may be due to an error in the pressure angle or in the
The tooth to tooth pitch error is the difference between
helix angle or both. Measurement of the base pitch on
the actual values of two successive right or left the line of action is particularly important for the gears
tmnsverse pitches.
produced by si@e tooth cutters.

5
Is 7504 : 1995

’1 r-fu
FLANK F(O. 21 1 2 3 4 5 6 7 8 9101-l 12131415161718192021

PjTCH NO. rII

a- Individual pitch em+ marked as vertical blocks between the flnak numbers.
R, - Range of pitch exror, fU - Tooth to tooth pitch error
b-Total cumulative pitch error referred to flank 21.
Fp - Total cumulative pitch error.
c -Cumulative pitch error over intervals of every three teeth,&3 (k = 3) shown a5 vertical blocks in the middle of the flanks.

FIG.4 DEIERMNKIION
OFPrm ERROR(Eg : 21)

MEASURING F
ER SUPPORT

BASE

FIG.5 Mars UREMENTOF

BASEPm ERROR

l
 Is 7504 : 1995

4.2 FlankDeviations tester,flank test graph as shown in Fig. 7 can be

obtained.
6.2.1Inspection of the involute Profile
This inspection, together with the pitch measurement is
of foremogt importance in the schedule of individual
error tests, since for the correct meshing and the
measurement ofgears it is essential that the tooth flanks
are really involutes.
The formof the profile can be opticallyenlarged and
compared with the drawing of an involute, especially
in case of fme pitches. The diftkulty lies in determining
the position of the proftie in relation to the base circle.
Usually the test is made by means of an apparatus which
generates the true involute by roiling a straight edge on
a base circle disc and records the deviations of the
actual tooth profile to an enlarged scale on graph paper.
See Fig. 6. The diameter of the base circle disc follows
from the equations:
For spur gears:
\ STRAIGHT EDGE
db = z.m cosa
For helical gears:

d,=z.m=
cos&
By plotting the flank deviations with the help of a flank FE. 6 IXSPECXON
OFTCIOIXPROFILE

Profile Flank Line

Total profile error, Ff Total alignment error, Fp

Profile angle errorha Flank line angle error&

-

0 3 Profile form error,fi Longitudinal form error faf

BB Intermediate actual profile Intermediate actual flank line

AA,A’A’ Nominal profile Nominal-flank lines which envelop the actual flank
R’B’, B”B” Actual profile Actual helical lines which envelop the actual flank
C’c’, C”C” Nominal profile Nominal flank lines which cut the actual flank lines at the beginning
and end point of the teat range
FIG. 7 FLANKDIZVIATONS
ANDTESTGRAPH

7
IS 7504 : 1995
6.2.1.1 Totalprofile err06 Ff
In a test graph, as shown in Fig. 7, the total profile error,
Ff is the measurement made perpendicular to the paper
feed direction between the parallel lines AA and A' A',
drawn in the direction of the paper feed within the profile
test region through tbe extreme point of the test graph. Tbe
desired modifications from the involute form are taken
into consideration by corresponding deviations of the
lines AA and A’A’ from tbe straight line.
6.2.1.2 Pnzjile form error, ff
In a test graph as shown in Fig. 7, the profile form error
ff is the measurement taken perpendicular to the paper
feed direction between the lines B’B’ and B’B” which
am parallel to the actual involute BB. Line BB is drawn
to average the involute curve which touches tbe test
curve within the profile test region.
62.13 Profile angle err03 fia
In a test graph as shown in Fig. 7, the profile angle error,
fHa, is the measurement taken perpendicular to the
direction of paper feed between the lines C’C’ and
C”C” parallel to AA, which cut the line BB at the start
and end point of the profile test region respectively.
6.2.2 Inspection of Tooth Alignment Errors
623.1 Total alignment error Fp
For measuring the tooth alignment errors, Fig. 8 shows
an apparatus that imparts the gear, a rotation cor-
responding to the helix angle set on the apparatus. This
rotation, combined with the movement of tbe feeler
parallel to tbe gear axis, results in a vertical straight line
diagram, if tbe acutal helix angle coincides with the
design value.
In a test graph as per Fig. 7, the total alignment error
Fg is the distance, measured perpendicular to the paper
feed direction, between the parallel lines AA and A’A’
which are drawn iu the direction of paper feed within
the flank line test region through the extreme points of
the test graph. The intended deviations from tbe helix
line form ‘are taken into account by corresponding
deviations of the lines AA and A’A’ from the straight
line.
62.2.2 Longitudinal form error, fpf
The longitudinal form error, fbf of a tooth flank is the
distance between the two helix lines with the actual
lead, which touch and envelop the actual flank line
within the flank line t&t region taking into account the
intended deviations from the helix line form.
6.2.2.3 Flank line angle error, fHp
For all the defi‘irritions and calculations concerning the
gear pair, 3 flank line angle for an external gear is
considered a:, pcsitive when it is right banded with
respect to a helix line witb the nominal lead and it is
considered negative wbcn it is left handed with respect
to a helix line with the nominal lead. In case of an
iuternal gear, the signs are opposite. Thus in case of a
spur ge;lr mating, equal errors with opposite signs csn-
ccl each other out.
8
FIG.8 A~PARKIUS
FORMENSWUNG
TOOTH
,~GNMENTERROR
Hence, there are two different definitions for tbe sign
of the Eat& line angle error. In all production docu-
ments, test reports, etc, the direction of the effect of the
errors should be clearly indicated.
In a test graph, as shown in Fig. 7, the flank line angle
error,fHg is the distance measured perpendicular to the
direction of the paper feed, between the lines C’C’ and
C”C” which are parallel to the 1ineAA and cut the line
BB at the end of the Eank line test region.
6.3 Radial Run-Out-Error, Fr
Radial run-out error, Fr of a gear is tbe radial positional
difference of a measuring piece (Ball, cylinder or
wedge), placed successively in all the tooth spaces,
which touches the tooth flanks near the reference circle,
while tbe gear is mounted on its guide axis, free to
rotate. Fr is used to designate the maximum difference
between the measurements at the gear peripbery.
The simple method to measure the radial run-out error
of small and medium diameter gears consists of succes-
sively introducing a ball or roller into all the tooth
spaces, whilst the-gear is supported between centres.
The relative depths attained by tbe ball iu the tooth
spaces are mad from a dial indicator. See Fig. 9.
6.4 Tooth Thkkness Measurement
The measurement of tooth thickness is to guarantee the
observance of a specified backlash for a given cenire
distance taking into account, tbe inevitable tooth errors:
a) Measurement independent of the axis is applied
mainly for setting up the gear production
machine. It should be noted that tbe specifying
of the tooth thickness consistent with a likewise
specified backlash at the theoretical centre dis-
tance postulates that all mothererrors are withirr
their respective limits, particularly the radial
and axial run-out. Thus the measurement of
 FIG. 9 MFASJREMENTOF
RADLAL
RUN-OUTERROR

tooth thickness, independent of the axis can be

regarded as a form of acceptance test only on
condition that other errors (radial run-out in
particular) are also inspected and remain within
the limits specified.
b) The measurement of tooth thickness with refer-
ence to the axis, usually-included in the accep-
tance test schedule,supplies the most important
information for the determination of the effec-
--S-i
tive tooth thickness, namely, the tooth thickness

cl
of an imaginary gear concentric with the axis,
which encloses all the errors of the gear.
The theoretical tooth thickness measured on the
AL
h\/\
REFERENCE CIRCLE

reference cylinder is:

-J)--

The tooth thickness fluctuation, R, is the

difference between the maximum and minimum FIG. 10 MEAWREMENT
OF Too-m THKKNES~
ON
tooth thickness s of a gear: hFERENCE&'LINDEB

4 = %,- &I
Ii-m+;m(l-c0s~)fx.m
6.4.1 Measurement tif the Tooth Thickness by Means of
Gear Tooth Calipers
in -which y) = $ t F (in radians)
a) Meizsurement on the reference cylinder ”
Refer Fig. 10. Measurement on the reference
cylinder is given b-y: -$ -$ for ~gears without addendum
<-mqsin11, modifications.

9
IS 7504 : 1995

For spurgears: zv = z points of the periphery. All individually measured tooth

invat
For helical gears : zv = z -
inv a
For backlash allowance ‘$ the dimension S is
to be reduced by &
For corrected gears the dimension & must be
reduced by the appropriate amount.
b) Inspection by constant chord method
Refer Fig. 11, in this case, the measurement is
not taken on the reference cylinder, but a little
~higher, which has a detrimental effect when the
~pressure angle is large and/ or the number of
teeth is low.
YC-m. cos2a[t*Zr.tana]
widths must lie within the tolerances in accordance
with tooth thickness fluctuation, R,
Measurement is possible in case of both spur and helical
gears. In case of helical gears, measurement has to be
made~in the normal plane.
NOTE - * sign used in the formulae given in the text
means plus sign for’positive correction and minus sign for
negative correction and the absolute value of x’is to be
substituted in the formulae.
6.43.1 General formulae
The general formida for nominal dimension A4of tooth
width is:
M=mncc6 a,[(k-05)x+z. inv at]
+ 2r.mn.sina.. .. . ..(1)
To ensure the contact between the measuringjaws
and tooth flanks is made near half the tooth depth,
k must be calculated from:

1
tmw
1
EC-m 1 - Ic sina cosa f x . cos2a k_f
4 --2Etanan- inv at + 0.5 .....(2)
[ I II cos2Bb
For module = 1 and a - 20°, & - 1.387 05
k must always be rounded off to a whole number.
and & = 0.747 58. The transversti working pressure angle awt on the
cylinder with the diameter (d + 2x.mn) can be
calculated from:
Z
cosawt-cosat .....(3)
z+2r.cosp
The helix angle on the base cylinder is computed
from:
tanfib - tar+ cosat .....(4)
The transverse pressure angle is calculated from:
tana,
tanat = - ....
cosS
BASE ClRCLf
6.4.2.2 Gears wtihoutprofile correction

a) Spur gears
The odoth width ‘M’ in case of a spur gear is
calculated from:
M - m cosa [(k - 0,0.5) n + z&v a]
.. ...(a)
The number of teeth measured is computed
from the formula:

k=z - ao + 0,OS (rounded off to whole

6.4.2 Tooth Width Measurement with theAid of M-Test 180°
Dimension number) ......(7)
In case of spur gears, without profile correc-
The tooth width M is the distance betweeri two parallel tion with module = 1; the value of k and the
planes each touching a right and left flank in the vicinity width ikft for the pressure angles a = 14.9,
of the pitch circle, measured over k teeth. See Fig. 12. lS”, 2@ and 30’ can be obtained from the
Its particular advantage is that it permits measurement Tables 3 to 6. With any given module, the
of the tooth width independent of the outside diameter. tooth width is computed from:
Since the variations in the pitch also come into the ......(8)
M = M1.m.
measurement, it is necessary to measure at several

10
 Is 7504 : 19YJ
Tabk3 Tooth Width of Gears Without Profile Correction, Module = 1, PressureAngle = 14.F’
( Clause6.4.2.2 )
z = number of teeth in gear blank, k = number of teetb measured, MI = tooth width for module 1
p, - m.n cos14.5” = 3.041527. m
a = 14.50
IS 7504 : 1995
Table 4 Tooth Width of Gears Without Profile Correction, Module = 1, Pmssure Angle = 15”
( Chse 6.4.2.2 )
z = ,number of teeth in gear blank, R = number of teeth measured, Ml = tooth width for module 1
pe = m.3c.cosW = 3.034 546.m

a = 15O

t i i

/~/~!‘~757 )l159! 14 ! 41.9109 !!209! 18 ! 54.3461 1

112 ) 10 ) 29.4935 11162 1 14 1 41.9287

115 1 10 1 29.5113 11165 1 14 1 41.9465

/+j+%%j’~! 17.0821 ll116! 10 ! 29.5173 !!~166! 14 ! 41.9525 ]

12012 4.6706 117016

12312 4.6884 117317

35 13 / 7.7943 1185 18 1 23.2640 ll1351~12 1 35.6992 111851 16 1 48.1344 11235)20 j 60.5697

/ 42 1 4 1 10.8704 IL

45 ( 4 1 10.8882 11 95 1 8 1 233234 jj145( 13 ) 38.7932 11195) 17 1 51.2284 I1245 1 21 1 6

 IS 7504 : 1995
Table 5 Tooth Width of Gears Without Profile Correction, Module = 1, Pressure Angle = 20’
( Clause 6.4.2.2 )
z = number of teeth in gear blank, k = number of teeth measured, MI = tooth width for module 1
pe = m.n ws20° - 2.952 133.m
a-20"

t-,mf$$ 38.5262 /1166! 19 ! 56.9393 !!216! 2.5 ! 75.3524 1

t-\-j’@ ! 47.6768 lj187! 21 1, 63.1377 1)237! 27 ! 81

141 1 5 1’ 13.8588 11 91 Ill 1 32.2719 IL

 I!S7504:1995
‘hble 6 Tooth Width of Gears Without Profile Cormction, Module = 1, Pressurp Angle = 30”
( Cluuse 6.4.2.2 )
z = number of teeth in gear blank, k = number of teeth measured, MI = tooth width for module 1
p,-m.ncos300= 2.720 698.m
a-300

795930 11211 I36 I 106.4068

73931

5465 11 186 1 32 1 94360 2 ii236 1 40 1 118.453 3 1

187 1 32 1 94.406 8 237 1 40 1 118.4998
138 17 1 19.4534 43.5466 11138b41 703603 ljl88l 32 ( 94.45331rUign

46.4068 11411241 70.4999 11191)32 1 94.59301241 ,l 1 121.4067 1

/+!-%%j#%%ii&42!24! 705465 !!192!33! 97.3602 jl242141 l-:21.4533 1

145 ] 8 1 225000 1195 116 ] 465930 )]145)25 1 73.4068 )I195133 1.97.4

33 1 97.5464 11246 ( 42 1 124.360 2 j

150 1 9 1 25.4534 \\100\ 17 1 49.5465 Ill50126 1 76.3602 j1200) 34 \ 100.4533 1[12itjy .2 1 124.5464 1

14
 I!3 7504: 1995
kOOT CIRCLE

FIG. 12 MEASUREMFN OF Tocrrn WIDTH

where A = (k - 0.5)~. cosas

b) Helical gears
Cl Anv at. cosan
In case of helical gears the tooth width is com-
puted from: The values of A for various values of k are given in
j%fI ma.cosaa [(k - 0,O.S) rt + z.inv at] .....(9) Table 7. The values of Cl for various helix angles
and the number of teeth is measured from: p and various pressure angles an can be obtained
from Tabb 8. The minimum face width 6 required
t.mattan2
Bb ......(lO) for M-measurement is calculated from formula 19.
R;
6.433 Gears withprofile correction
for &-- 200, k can be obtained from Fig. 13. a) Spur gears
By introducing, constants that can be tabulated, The nominal dimension M of the tooth width of
formula 4 can be simplified as follows: a spur gear with profile correction factor n over
M-ma(A+z.Cl) .....(n) k teeth is: .

All dimensions in millimetres.

FIG. 13 NUMBER OFTEEIHMEASUREMENT FOR g, I u)O

15
 Table 7 FactorA
( Clause 6.4.2.2 )

M - mcosa[ (k - 0,5) x + zinva] + 2xmsina The effective pressure angle aw on the diameter
. ......(12) (d + 2xm) is computed from:
Number of teeth measured, k is computed from: z
cosaw =eosa- .....(15)

I
2+2X
tana,,,-2Ztsna-inva +OS .....(13) b) Helical gears
The nominal dimension M~of the tooth width of a
By introducing constant C2, the formula 12 can be helical gear with profile correction over k teeth
simplified as: according to formula 1 is:
M-m.(Mt +C2) .....(14) M = mn cosa” [(k~- 0,s) x + z.inv at]
Value of C2 can be obtained from Table 9.
+ 2xmn sin an .....(16)
Value of Ml can be obtained from Tables 3 to 6.

0) EVEN NUMBER OF TEETH b) ODD NUMBER OF TEETH

FIG. 14 DLMENSION
OVERBAUDORPINSFORE-AL GEARS

16
 IS 7504 : 1995

Table 8 Factor C,
( Chse 6.4.2.2 )

,
B a, - 14.50 an - 1.5’
0” 0.0053 68 0.005 940

lo 0.005 370 0.005 943

2” 0.005 378 0.005 950 24O 0.006 988 0.007 723 0.018 113

3O 0.005 390 0.005 967 25O 0.007 153 0.007 914 0.018526

4” 0.005 407 0.005 982 0.014 103 1 1 25O56’40” 1 0.007 317 1 0.008092 1 0.018 942

5O 0.005 428 0.006 007 26’ 0.007 327 0.008 102 0.018 968

6’ 0.005 455 0.006 036 27” 0.007 515 0.008 310 0.019 440

7” 0.005486 0.006 071 0.014 307 11 a0 ! 0.0~7716 1 0.008531 0.019 944

7” lo’ 51“ 0.005 493 0.006 078

8” 0.005 522 o.cKl6 112

9O 0.005 564 0.006 155

lo” 0.005 614 0.006 212

10°48’25” 0.005 657 0.006 259

14028’40” 0.005 899 0.006 527 0.015 355 11 38O 1 0.010721 1 0.011849 0.027 431

18’12’36” 0.006 238 0.006 900

190 0.006 323 0.006 994

z
k the number of teeth measured, computed horn cosa, = cosa, .. . ..(18)
formula 2 is: z+2xcos~

2 bna, By using tactors A, Cl, Cz the following formula is

k=- - - 2:‘tatq -_inv a, + 0.5 .....(17) obtained:
Jc cos2p, M=m,(A+z.Cl+Cz)
[ 1 .....(19)
where
k, for a, = 20’ can be obtained from Fig. 13.
A = (k - 0.5)x cosa,, according to Table 7,
The transverse working pressure angle awr~on the Ct = cosa,,.invat according to Table 8, and
diameter (d + 2xmn) follows from:
C;?= &.sina, acwrdingto Table 9.

17
 Table 9 Factor C,

( Clause 6.4.2.3)

” In the case of negative profile correction a minus sign (-) must be placed before the values c’z.

18

To ensure that two parallel planes touch the flanks,
the face width must be:
b 2 iti sin& + b co@, ... ..(20)
tat& = tang. cosar
where !q,.t = Constant line overlap or width of the
measuring surface in tooth width measurement.
For gears without chamfering
&f z 1.2 + 0.018M
bkj > 2.0 + 0.03M
Summary of the important formulae~for the tooth width
measurement with the aid of M-test dimension for spur
and helical gears are furnished in Table IO.
6.4.3 Tolerance on M-Test Dimension
The upper allowance and tolerance on M-test dimension
can be obtained by multiplying the upper tooth thickness
allowance (A,,) and tooth thickness tolerance (7’,, values
from Tables 7and 8 of IS 3681 : 1995, respectively by
cosa,.
6.4.4 Tooth ThicknessMeasurement Over Pins or Balls
Tooth thickness can be determined by taking the meas-
urement over pins or balls placed in diametrically
opposite tooth spaces as shownin Fig. 14 and Fig. 15.
This method is suitable for both external and internal
spur and helical gears. The size of the balls or pins should
be selected in such a way that they touch the tooth flanks
on or approximately near the reference circle.
The theoretical dimension,Mu over the pins or balls can
be calculated from Table 11. The selection of pin orball
diameter and the calculation procedure for other
parameters are given in Table 12.
The tolerance on dimension, MR over pins or balls can
be obtained by multiplying the upper tooth thickness
allowance (A,,) and tooth thickness tolerance. (Ta
values loom Tables 7 and 8 of IS 3@31 : 1995, respec-
tively by a factor given by --- * rotated with a left and right flank of thegears always in
sinaRt . wsf3
6.5 Blue Bearing Test (TR4)
Due to various gear errors and inIluence of working
conditions..a near flank will not have full bearinn on the
mating flank & a gear mesh. The blue bearing t&t indi-
cates the bearing zone of one flank with its mating flank.
a) EVEN NUMBER OF TEETH
FIG. 15 DIMENSION
OVERBALLSORPINSFOR INERNALGEARS
19
IS 7504 : 1995
7 INSPECTION OF GEAB TEETH IN
ASSEMBLY CONDITIONS
7.1 Single Flank Total Composite Error Testing
In this test two gears are meshed and rotated at the
prescribed centre distance with either the right or left
flanks in constant contact. See Fig. 16. The single flank
composite errors of the right flank are generally
different from those of left flank of the same gear. The
deviations of the’ rotating positions of the gear with
respect to nominal positions given by the positions of
the mating gear and by the ratio of the number of teeth
are measured starting lrorn a start position. For this, a
comparative measuring device is required where the
error free rotating angle positions are obtained. The
errors are generally indicated as paths along with
circumference of a measuring circle, for example, the
reference circle or base circle. The errors can also be
given in angles.
7.1.1 Single Flank Total Composite Errol; Fi’
In a circular test graph as shown in Fig. 17, the single
flank total composite error, Fi’ is the difference between
the maximum and minimum distance of the recorded
test graph from the axis of rotation of the test chart,
namely, F,’ is the difference between the maximum
and minimum Y-axis of the test graph.
7.12 Single Flank Tooth to Tooth Composite Error, fi’
The single flank tooth to tooth composite error,j’ is the
maximum difference that occurs in the rotating posi-
tions deviations within a rotating angle corresponding
to the period of a tooth contact.
7.2 Double Flank Total Composite Error Testing
In this test two gears are meshed with each other and
contact at the same time (two Sank contact) under the
inlIuence of a force acting in the direction of the centre
distance. See Fig. 18. In this process, the changes of the
centre distance arc measured. The centre distance found
in the double flankcomposite error testing is designated
as a”.
b) ODD NUMBER OF TEETH
 Table 10 Summary of Important Formulae for the Tbotb Width Measurement
(Clause 6.4.2.3)

Gear Prome Tooth Width, ‘M Number of Teeth

Measured, t
spur gears M=m.M1 According to
Gears without profile Tables 3 to 6
correction Helical gears M-m.(A +r.Cl) Aaxrding to
Fig. 13
spur gears
Gears with profile
crorrecGon Helical gears

Ml = according to Tables 3 to 6
A = according to Table 7
Cl = according to Table 8
C2 = according to Table 9

‘) check whether the value of k read from Tables 3 to 6 and also from Fig. 13 are tbe same. If the value is not same, use
the fomitiae 12 and 13 of 642.3 to evaluate M and k.

73.1 Double Flank To& Composite Errq fi” the distance between the highest and lowest points of
an averaging line.
Refer Fig. 19. The double flank total composite error,
Fi” is the diEerence between the maximum and mini- 7.2.3 Double Flank Tooth to Tmth Composite
mum working centre distance within one test rotation. Err04 X”
7.22 Radial Run-Ou Fr
The double flank tooth to tooth composite error, fi”
The radial run-& error& is the longwave component is the difference between the maximum and mini-
of the test diagram. This component can be obtained by mum working centre distance that occurs within a
drawing zm averaging line thereby suppressing the turning angle corresponding to the period of a tooth
short-wave components. The radial run-out error, Fr is contact.

21 = DRIVING GEAR 22 = DRIVEN GEAR

23 = f,(-12) puuu/s
22 -
FIG.16 BLOCKDIAGRAM
OFCIR~JKFDXSINGLE
FLANKTFS~ING
 Table 11 Calculation of Theoretical Dimension Over Pins or Balis, MR
( Clause 6.4.4 )

External Geam Internal Gears

Dimension
Spur Gears Helical Gears Spur Gears kklical Gears

With
even COSci, a=%
MR-ms =+DM Mtt-q.z- MR-mzz-DM bfR’m$-- hi
No.of +DM
a=R co% R *=Rt
teeth
Dimension
over pins With
or balls odd No.
of teeth
MR-ms -D, MR'T.Z
MR-mz +44 MR-m,s +DM wsaR
axaRt
-DM
CosuR waRt
 Table 12 Calculation of dR,aR, aRt and q~
( Chzuse 6.4.4 )

Gears Exterual Gears Internal Geals

Spur gears DM - 1.728m D, - 1.44m 1)

Pin or ball touching the tooth n 2rtanat)
aR sc 2x tana 1)
flanks above the reference circle kaR’inva+~COSQ--f- invaR - inva _2!L+_*
22 2 mzcosa 22 z
(without correction) --
Helical gears DM - 1.72&n,, D, - 1.44%
dR _7C, bin% 1) dR L aanq, 1)
Inv a,, - inv% + invaRt - invat +----f-
mnzoxa, 22 Z m,zccsa, 25 Z

spur gears DM - mz sinq/cxw$t D, - mz sinv/waR

Pin or ball touching the tooth
flanks on the reference circle

w aR+a-3

Helical gears m, z sin *cosa, mn z sim+xosq,

DM- D,-
cosaRt . co=t cDsaRt . *=I

%-a,+* “Rt’%-q .

spur gears
DM=nm.cbsa

invaR=inta*+”
Pin or ball touching the tooth
flanks below the reference circle
Helical gears
DM

2r tAna, 1)
inva& = inva, f -
Z

‘) Use + sign for positive correction and - sign for negative correction. Substitute the apolute value of x in the equations.
 IS 7504 : 1995

1 ROTATION OF THE GEAR UNDER TESt

40
so
20

10 . . . . . . . . . . . . . . . . . . . . . .

0 llIllIllllllllIllll111111
125242322212019181716151413121110 9 6 7 6 5 4 3 2 125

-c-- DIRECTION OF CHART FEED

FIG. 17 SINGLE TOTALQMP~SI’IEERROR

FLANK DMGRAM

8 INSPECTION OF XNVOLUTE RACKS - Double flank composite error, and

8.1 Corresponding to the measurement of external - Profile.
gears, the racks are checked.for following values:
- Tooth thickness, For the inspection of tooth thickness, the measurement
- Penetrating depth of a pin or ball (corresponding with balls or pins is the most accurate procedure. Refer
Fig. 20.
to runout of a gear),

I I

FIG.18 TIWINGONDOUBLE
FLANKTOTALCOMFYBITE
ERROL

23
IS 7504: 1995

U)
) fl” fr

b)

FIG.19 DOUBLJZ
FLANKTOTAL
COMWSITE
ERROR
DIAGRAM

The dimension MR, over pins or balls is given by the

formula:
The pin or ball diameter, &+.t can be calculated from
DM = $&- (Round off to a standard pin or~ball
”
diameter)
For double flank composite error testing of racks of
limited length, double flank checking machines with
suitable attachments are employed.
Measuring microscopes and profile projectors are
suitable for profile and pitch inspection of racks.

T
b

FIG.20 INSPECXJON
OFTOOTH
THKKNFSS

24
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