Micro-Geometry: Involute Modifications

Can involute modifications be used to optimise the transmission error of a

gear pair?

It is an established practice to apply involute modifications to gear teeth to improve running

smoothness (Figure 1). The amount of tip relief is easy to determine - enough to allow for
tooth deflection and manufacturing
tolerances. However, the extent of a) Long relief b) Short relief
tip relief (how far down the tooth it Amount Amount

is applied) is also a critical factor but Extent Extent

this is more difficult to determine. = pb x (εα-1) = 0.5pb x (εα-1)

In this study, gear pairs with an

identical amount of tip relief were
used to test the effect of varying the
extent of tip relief on transmission pb = Transverse base pitch
εα = Transverse contact ratio
error (T.E.).
Figure 1. The two types of tip relief
This is a normal document. Measurements were carried out on a back-to-
Electric Motor back test rig (Figure 2) using a unique optical
measuring system that measured quasi-static
and dynamic T.E. at speed. The test data
Optical System were correlated against the theoretical
Torsion Rods
predictions of RomaxDesigner (Figure 3).

Predicted Long Measured Long

Predicted Intermediate Measured Intermediate
Predicted Short Measured Short

Drive Gearbox 25
Test Gearbox

20
Figure 2. Test rig schematic layout
Peak to Peak TE (um)

15

10
It is clear from the results that:
• Long relief is suitable for full design 5

load 0
• Short relief is suitable for light design 0 20 40 60 80
load % Design Load

• Intermediate relief is suitable for Figure 3. Predicted vs. measured T.E.

loads in between the two

Intermediate relief can be selected by varying the extent of tip relief between long and short
to suit the appropriate operating conditions.

Romax Technology has established a method for involute gear tooth

optimisation, according to the operating conditions, which has been
experimentally validated.