Calculation of Gear Dimensions

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CALCULATION OF GEAR DIMENSIONS
TOP>Gear Knowledge>Gear Technical Reference>Calculation of Gear Dimensions
Gear dimensions are determined in accordance with their speci cations, such as Module (m), Number of teeth (z),
Pressure angle (), and Pro le shift coe cient (x). This section introduces the dimension calculations for spur gears,
helical gears, gear rack, bevel gears, screw gears, and worm gear pairs. Calculations of external dimensions (eg. Tip
diameter) are necessary for processing the gear blanks. Tooth dimensions such as root diameter or tooth depth are
considered when gear cutting.
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4.1 Spur Gears
Spur gears with locking hubs
Spur Gears are the simplest type of gear. The calculations for spur gears are also simple and they are used as the basis
for the calculations for other types of gears. This section introduces calculation methods of standard spur gears,
pro le shifted spur gears, and linear racks. The standard spur gear is a non-pro le-shifted spur gear.
(1) Standard Spur Gear

Figure 4.1 shows the meshing of standard spur gears. The meshing of standard spur gears means the reference circles
of two gears contact and roll with each other. The calculation formulas are in Table 4.1.
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Fig. 4.1 The Meshing of Standard Spur Gears

( = 20, z1 = 12, z2 = 24, x1 = x2 = 0 )
Table 4.1 Calculations for Standard Spur Gears
Example
No. Item Symbol Formula
Pinion (1) Gear (2)
1 Module m 3
2 Reference Pressure Angle Set Value 20 deg
3 Number of Teeth z 12 24
NOTE1
4 Center Distance a 54.000
5 Reference Diameter d zm 36.000 72.000

6 Base Diameter db d cos 33.829 67.658
7 Addendum ha 1.00m 3.000 3.000
8 Tooth Depth h 2.25m 6.750 6.750
9 Tip Diameter da d + 2m 42.000 78.000
10 Root Diameter df d 2.5m 28.500 64.500
NOTE 1 : The subscripts 1 and 2 of z1 and z2 denote pinion and gear
All calculated values in Table 4.1 are based upon given module m and number of teeth (z1 and z2). If instead, the
module m, center distance a and speed ratio i are given, then the number of teeth, z1 and z2, would be calculated using
the formulas as shown in Table 4.2.
Table 4.2 The Calculations for Number of Teeth
No. Item Symbol Formula Example

Pinion (1) Gear (2)
1 Module m 3
2 Center Distance a Set Value 54.000
3 Speed Ratio i 1.25
4 Sum of No. of Teeth z1 + z2 36
Note, that the number of teeth will probably not be integer values when using the formulas in Table 4.2. In this case, it
will be necessary to resort to pro le shifting or to employ helical gears to obtain as near a transmission ratio as
possible.
(2) Pro le Shifted Spur Gear

Figure 4.2 shows the meshing of a pair of pro le shifted gears. The key items in pro le shifted gears are the operating
(working) pitch diameters (dw) and the working (operating) pressure angle (w). These values are obtainable from the
modi ed center distance and the following formulas :
Fig. 4.2 The Meshing of Pro le Shifted Gears

( = 20, z1 = 12, z2 = 24, x1 = +0.6, x2 = +0.36 )
In the meshing of pro le shifted gears, it is the operating pitch circle that is in contact and roll on each other that
portrays gear action. Table 4.3 presents the calculations where the pro le shift coe cient has been set at x1 and x2 at
the beginning. This calculation is based on the idea that the amount of the tip and root clearance should be 0.25m.
Table 4.3 The Calculations for Pro le Shifted Spur Gears (1)
Example
Pinion (1) Gear (2)
1 Module m 3
2 Reference Pressure Angle 20 deg
Set Value
4 Pro le Shift Coe cient X 0.6 0.36
5 Involute w inv w 0.034316
6 Working Pressure Angle w Find from Involute Function Table 26.0886 deg
Center Distance
7 y 0.83329
Modi cation Coe cient
8 Center Distance a 56.4999
9 Reference Diameter d zm 36.000 72.000

10 Base Diameter db d cos 33.8289 67.6579
11 Working Pitch Diameter dw 37.667 75.333
ha1 ( 1 + y x2 ) m
12 Addendum 4.420 3.700
ha2 ( 1 + y x1 ) m
13 Tooth Depth h {2.25 + y ( x1 + x2 ) } m 6.370
14 Tip Diameter da d +2ha 44.840 79.400
15 Root Diameter df da 2h 32.100 66.660

A standard spur gear is, according to Table 4.3, a pro le shifted gear with 0 coe cient of shift; that is , x1 = x2 = 0.
Table 4.4 is the inverse formula of items from 4 to 8 of Table 4.3.
Table 4.4 The Calculations for Pro le Shifted Spur Gears (2)
Example
Pinion (1) Gear (2)
1 Center Distance a Set Value 56.4999
Center Distance
2 y 0.8333
Modi cation Coe cient
3 Working Pressure Angle w 26.0886 deg
Sum of Pro le Shift

4 x1 + x2 0.9600
Coe cient
5 Pro le Shift Coe cient x 0.6000 0.3600

There are several theories concerning how to distribute the sum of pro le shift coe cient (x1 + x2) into pinion (x1) and
gear (x2) separately. BSS (British) and DIN (German) standards are the most often used. In the example above, the 12
tooth pinion was given su cient correction to prevent undercut, and the residual pro le shift was given to the mating
gear.
(3) Rack and Spur Gear

Table 4.5 presents the method for calculating the mesh of a rack and spur gear.
Figure 4.3 (1) shows the the meshing of standard gear and a rack. In this mesh, the reference circle of the gear touches
the pitch line of the rack.
Figure 4.3 (2) shows a pro le shifted spur gear, with positive correction xm, meshed with a rack. The spur gear has a
larger pitch radius than standard, by the amount xm. Also, the pitch line of the rack has shifted outward by the amount
xm.
Table 4.5 presents the calculation of a meshed pro le shifted spur gear and rack. If the pro le shift coe cient x1 is 0,
then it is the case of a standard gear meshed with the rack.
Table 4.5 The calculations of dimensions of a pro le shifted spur gear and a rack
Example
Spur gear Rack
1 Module m Set Value 3
2 Reference pressure angle a 20 deg
3 Number of teeth z 12
4 Pro le shift coe cient x 0.6

5 Height of pitch line H 32.000
6 Working pressure angle w 20 deg
7 Mounting distance a 51.800
8 Reference diameter d zm 36.000
9 Base diameter db d cos 33.829

10 Working pitch diameter dw 36.000
11 Addendum ha m(1+x) 4.800 3.000

12 Tooth depth h 2.25m 6.750
13 Tip diameter da d + 2ha 45.600

14 Root diameter df da 2h 32.100

One rotation of the spur gear will displace the rack l one circumferential length of the gears reference circle, per the
formula :
The rack displacement, l, is not changed in any way by the pro le shifting. Equation (4.2) remains applicable for any
amount of pro le shift.
Fig. 4.3 (1) The meshing of standard spur gear and rack
( = 20, z1 = 12, x1 = 0 )
Fig. 4.3 (2) The meshing of pro le shifted spur gear and rack
( = 20, z1 = 12, x1 = + 0.6 )
4.2 Internal Gears
Internal Gears are composed of a cylindrical shaped gear havingteeth inside a circular ring. Gear teeth of the internal
gear meshwith the teeth space of a spur gear. Spur gears have a convexshaped tooth pro le and internal gears have
reentrant shapedtooth pro le; this characteristic is opposite of Internal gears. Hereare the calculations for the
dimensions of internal gears and theirinterference.
(1) Internal Gear Calculations

Figure 4.4 presents the mesh of an internal gear and externalgear. Of vital importance is the working pitch diameters
(dw) andworking pressure angle (w). They can be derived from centerdistance (a) and Equations (4.3).
Table 4.6 shows the calculation steps. It will become a standardgear calculation if x1 = x2 = 0.
Fig.4.4 The meshing of internal gear and external gear

( = 20, z1 = 16, z2 = 24, x1 = x2 = +0.5 )
Table 4.6 The calculations of a pro le shifted internal gear and external gear (1)
Example
No. Item Symbol Formula External gear Internal
(1) gear (2)
1 Module m 3
2 Reference pressure angle 20 deg
Set Value
3 Number of teeth z 16 24
4 Pro le shift coe cient x 0 + 0.516
5 Involute function w inv w 0.061857
6 Working pressure angle w Find from involute Function Table 31.321258 deg
Center distance
7 y 0.4000
modi cation coe cient
8 Center distance a 13.2
9 Reference diameter d zm 48.000 72.000

10 Base diameter db d cos 45.105 67.658
11 Working pitch diameter dw 52.7998 79.1997
ha1 ( 1 + x1 ) m
12 Addendum 3.000 1.452
ha2 ( 1 x2 ) m
13 Tooth depth h 2.25m 6.75
da1 d1 + 2ha1
14 Tip diameter 54.000 69.096
da2 d2 2ha2
df1 da1 + 2h
15 Root diameter 40.500 82.596
df2 da2+ 2h

If the center distance (a) is given, x1 and x2 would be obtained fromthe inverse calculation from item 4 to item 8 of
Table 4.6. Theseinverse formulas are in Table 4.7.
Table 4.7 The calculations of pro le shifted internal gear and external gear (2)
Example
External gear (1) Internal gear (2)
1 Center distance a Set Value 13.1683
Center distance
2 y 0.38943

3 Working pressure angle w 31.0937 deg
Difference of pro le shift

4 X2 X1 0.5
coe cients
5 Pro le shift coe cient X 0 0.5

Pinion cutters are often used in cutting internal gears and externalgears. The actual value of tooth depth and root
diameter, after cutting,will be slightly different from the calculation. That is because thecutter has a pro le shift
coe cient. In order to get a correct toothpro le, the pro le shift coe cient of cutter should be taken
intoconsideration.
(2) Interference In Internal Gears

Three different types of interference can occur with internalgears: (a) Involute Interference, (b) Trochoid Interference,
and(c) Trimming Interference.
(a) Involute Interference

This occurs between the dedendum of the external gear and theaddendum of the internal gear. It is prevalent when the
number of teethof the external gear is small. Involute interference can be avoided bythe conditions cited below :
Where a2 is the pressure angle at a tip of the internal gear tooth.
wworking pressure angle
Equation (4.5) is true only if the tip diameter of the internalgear is bigger than the base circle :
For a standard internal gear, where = 20 , Equation (4.7) isvalid only if the number of teeth is z2 > 34.
(b) Trochoid Interference

This refers to an interference occurring at the addendum ofthe external gear and the dedendum of the internal gear
duringrecess tooth action. It tends to happen when the differencebetween the numbers of teeth of the two gears is
small.Equation (4.8) presents the condition for avoiding trochoidalinterference.
Here
where a1 is the pressure angle of the spur gear tooth tip:
In the meshing of an external gear and a standard internal gear = 20 , trochoid interference is avoided if the
difference of thenumber of teeth, z2 z1, is larger than 9.
(c) Trimming Interference

This occurs in the radial direction in that it prevents pulling thegears apart. Thus, the mesh must be assembled by
sliding thegears together with an axial motion. It tends to happen whenthe numbers of teeth of the two gears are very
close. Equation(4.11) indicates how to prevent this type of interference.
Here
This type of interference can occur in the process of cutting aninternal gear with a pinion cutter. Should that happen,
there isdanger of breaking the tooling.Table 4.8 (1) shows the limit for the pinion cutter to preventtrimming
interference when cutting a standard internal gear,with pressure angle 0 = 20, and no pro le shift, i.e., x0 = 0.
Table 4.8 (1) The limit to prevent an internal gear from trimming interference
There will be an involute interference between the internal gearand the pinion cutter if the number of teeth of the pinion
cutter ranges from 15 to 22 (z0 = 15 to 22).Table 4.8(2) shows the limit for a pro le shifted pinion cutter toprevent
trimming interference while cutting a standard internalgear. The correction (x0) is the magnitude of shift which
wasassumed to be: x0 = 0.0075z0 + 0.05.
Table 4.8 (2) The limit to prevent an internal gear from trimming interference
There will be an involute interference between the internal gearand the pinion cutter if the number of teeth of the pinion
cutter ranges from 15 to 19 (z0 = 15 to 19).
Fig.4.5 Involute interference and trochoid interference
Fig.4.6 Trimming interference
4.3 Helical Gears
A helical gear such as shown in Figure 4.7 is a cylindricalgear in which the teeth ank are helicoid. The helix angle
inreference cylinder is , and the displacement of one rotation isthe lead, pz.
The tooth pro le of a helical gear is an involute curve from anaxial view, or in the plane perpendicular to the axis. The
helicalgear has two kinds of tooth pro les one is based on a normalsystem, the other is based on a transverse
system.
Pitch measured perpendicular to teeth is called normal pitch, pn.

And pn divided by is then a normal module, mn.
The tooth pro le of a helical gear with applied normal module,

mn, and normal pressure angle n belongs to a normal system.
In the axial view, the pitch on the reference is called thetransverse pitch, pt . And pt divided by is the
transversemodule, mt.
These transverse module mt and transverse pressure angle t atare the basic con guration of transverse system
helical gear.
In the normal system, helical gears can be cut by the same gearhob if module mn and pressure angle at are constant,
no matterwhat the value of helix angle .
It is not that simple in the transverse system. The gear hobdesign must be altered in accordance with the changing of
helixangle , even when the module mt and the pressure angle at arethe same.
Obviously, the manufacturing of helical gears is easier withthe normal system than with the transverse system in the
planeperpendicular to the axis.
When meshing helical gears, they must have the same helixangle but with opposite hands.
Fig.4.7 Fundamental relationship of a helical gear (Right-hand)
(1) Normal System Helical Gear

In the normal system, the calculation of a pro le shifted helicalgear, the working pitch diameter dw and transverse
workingpressure angle wt is done per Equations (4.15). That is becausemeshing of the helical gears in the
transverse plane is just likespur gears and the calculation is similar.
Table 4.9 shows the calculation of pro le shifted helical gears inthe normal system. If normal pro le shift coe cients
xn1, xn2 arezero, they become standard gears.
Table 4.9 The calculations of a pro le shifted helical gear in the normal system (1)
Example
Pinion(1) Gear(2)
1 Normal module mn 3
2 Normal pressure angle n 20 deg
Reference cylinder helix
3 30 deg
angle
Set Value
Number of teeth & helical
4 z 12 (L) 60 (R)
hand
Normal coe cient of
5 xn + 0.09809 0
pro le shift
Transverse pressure
6 t 22.79588 deg
angle
7 Involute function wt inv wt 0.023405
Transverse working
8 wt Find from involute Function Table 23.1126 deg
pressure angle
Center distance
9 y 0.09744
11 Reference diameter d 41.569 207.846
12 Base diameter db d cos t 38.322 191.611
ha1 ( 1 + y xn2 ) mn
14 Addendum 3.292 2.998
ha2 ( 1 + y xn1 ) mn
15 Tooth depth h { 2.25 + y ( Xn1 + Xn2 ) } mn 6.748
16 Tip diameter da d + 2ha 48.153 213.842
17 Root diameter df da 2h 34.657 200.346

If center distance, , is given, the normal pro le shiftcoe cients xn1 and xn2 can be calculated from Table 4.10. These
are the inverse equations from items 5 to 10 of Table4.9.
Table 4.10 The calculations for a pro le shifted helical gear in the normal system (2)
Example
Pinion (1) Gear (2)
1 Center distance a Set Value 125
Center distance
2 y 0.097447

Transverse working
3 wt 23.1126 deg
pressure angle
Sum of pro le shift

4 xn1+ xn2 0.09809
coe cient
5 Normal pro le shift coe cient xn 0.09809 0

The transformation from a normal system to a transversesystem is accomplished by the following equations :
(2) Transverse System Helical Gear

Table 4.11 shows the calculation of pro le shifted helical gearsin a transverse system. They become standard if xt1 =
xt2 = 0.
Table 4.11 The calculations for a pro le shifted helical gear in the transverse system (1)
Example
Pinion(1) Gear(2)
1 Transverse module mt 3
Transverse pressure
2 t 20 deg
angle
3 30 deg
angle Set Value
4 z 12 (L) 60 (R)
hand
Transverse pro le shift
5 xt 0.34462 0
coe cient
6 Involute function wt inv wt 0.0183886
Transverse working
7 wt Find from Involute Function Table 21.3975 deg
pressure angle
Center distance
8 y 0.33333

10 Reference diameter d zmt 36.000 180.000

ha1 ( 1 + y xt2 ) mt
13 Addendum 4.000 2.966
ha2 ( 1 + y xt1 ) mt
14 Tooth depth h { 2.25 + y ( Xt1 + Xt2 ) } mt 6.716

Table 4.12 presents the inverse calculation of item 5 to 9 of Table 4.11.
Table 4.12 The calculations for a pro le shifted helical gear in the transverse system (2)
Example
Pinion (1) Gear (2)
1 Center distance a Set Value 109
Center distance
2 y 0.33333

Transverse working
3 wt 21.39752 deg
pressure angle
Sum of pro le shift

4 xt1+ xt2 0.34462
coe cient
5 Transverse pro le shift xt 0.34462 0
coe cient

The transformation from a transverse to a normal system isdescribed by the following equations :
(3) Helical Rack

Viewed in the transverse plane, the meshing of a helicalrack and gear is the same as a spur gear and rack. Table
4.13presents the calculation examples for a mated helical rack withnormal module and normal pressure angle.
Similarily, Table4.14 presents examples for a helical rack in the transversesystem (i.e., perpendicular to gear axis).
Table 4.13 The calculations for a helical rack in the normal system
Example
Pinion Rack
1 Normal module mn 2.5
3 10 deg 5749
angle
Number of teeth & helical Set Value
4 z 20 (R) (L)
hand
Normal pro le shift
5 xn 0
coe cient
6 Pitch line height H 27.5
Transverse pressure
7 t 20.34160 deg
angle
9 Reference diameter d 50.92956

10 Base diameter db d cos t 47.75343
11 Addendum ha mn ( 1 + Xn ) 2.500 2.500
12 Tooth depth h 2.25mn 5.625


The formulas of a standard helical rack are similar to those ofTable 4.14 with only the normal pro le shift coe cient
xn = 0.
To mesh a helical gear to a helical rack, they must have thesame helix angle but with opposite hands.
The displacement of the helical rack, l, for one rotation of themating gear is the product of the transverse pitch and
number ofteeth.
According to the equations of Table 4.13, let transverse pitchpt = 8 mm and displacement l = 160 mm. The transverse
pitchand the displacement could be resolved into integers, if thehelix angle were chosen properly.
Table 4.14 The calculations for a helical rack in the transverse system
Example
Pinion Rack
1 Transverse module mt Set Value 2.5
2 Transverse pressure t 20 deg
angle
3 10deg 5749
angle
4 z 20 (R) (L)
hand
Transverse pro le shift
5 xt 0
coe cient
6 Pitch line height H 27.5
8 Reference diameter d zmt 50.000

9 Base diameter db d cos t 46.98463
10 Addendum ha mt ( 1 + Xt ) 2.500 2.500
11 Tooth depth h 2.25mt 5.625


In the meshing of transverse system helical rack and helicalgear, the movement, l, for one turn of the helical gear is
thetransverse pitch multiplied by the number of teeth.
4.4 Bevel Gears
Bevel gears, whose pitch surfaces are cones, are used to driveintersecting axes. Bevel gears are classi ed according
to theirtype of the tooth forms into Straight Bevel Gear, Spiral BevelGear, Zerol Bevel Gear, Skew Bevel Gear etc. The
meshing ofbevel gears means the pitch cone of two gears contact and rollwith each other.Let z1 and z2 be pinion and
gear tooth numbers; shaft angle ;and reference cone angles 1 and 2 ; then:
Fig. 4.8 The reference cone angle of bevel gear
Generally, a shaft angle = 90 is most used. Other angles(Figure 4.8) are sometimes used. Then, it is called bevel
gearin nonright angle drive. The 90 case is called bevel gear inright angle drive.When = 90, Equation (4.20)
becomes :
Miter gears are bevel gears with = 90 and z1 = z2. Theirtransmission ratio z2 / z1 = 1.
Figure 4.9 depicts the meshing of bevel gears.The meshing must be considered in pairs. It is because thereference
cone angles 1 and 2 are restricted by the gear ratioz2 / z1. In the facial view, which is normal to the contact line
ofpitch cones, the meshing of bevel gears appears to be similar tothe meshing of spur gears.
Fig. 4.9 The meshing of bevel gears
(1) Gleason Straight Bevel Gears

A straight bevel gear is a simple form of bevel gear havingstraight teeth which, if extended inward, would come
togetherat the intersection of the shaft axes. Straight bevel gears can begrouped into the Gleason type and the
standard type.
In this section, we discuss the Gleason straight bevel gear. TheGleason Company de nes the tooth pro le as: tooth
depth h =2.188m; tip and root clearance c = 0.188m; and working depthhw = 2.000m.
The characteristics are :
** Design speci ed pro le shifted gears

In the Gleason system, the pinion is positive shifted andthe gear is negative shifted. The reason is to distributethe
proper strength between the two gears. Miter gears,thus, do not need any shift.
** The tip and root clearance is designed to be parallel
The face cone of the blank is turned parallel to the rootcone of the mate in order to eliminate possible lletinterference
at the small end of the teeth.
Fig. 4.10 Dimensions and angles of bevel gears
Table 4.15 shows the minimum number of the teeth to prevent undercut in the Gleason system at the shaft angle =
90.
Table 4.15 The minimum numbers of teeth to prevent undercut
Table 4.16 presents equations for designing straight bevel gearsin the Gleason system. The meanings of the
dimensions andangles are shown in Figure 4.10 above. All the equations inTable 4.16 can also be applied to bevel
gears with any shaftangle.
The straight bevel gear with crowning in the Gleason system iscalled a Coni ex gear. It is manufactured by a special
GleasonConi ex machine. It can successfully eliminate poor toothcontact due to improper mounting and assembly.
Tale 4.16 The calculations of straight bevel gears of the Gleason system
Example
Pinion(1) Gear(2)
1 Shaft angle 90 deg
2 Module m 3
Reference pressure Set Value
3 20 deg
angle
5 Reference diameter d zm 60 120
6 Reference cone 1 26.56505 deg 63.43495 deg
angle 2
7 Cone distance R 67.08204
8 Facewidth b It should not exceed R / 3 22
ha1
9 Addendum 4.035 1.965
ha2
10 Dedendum hf 2.188m ha 2.529 4.599
11 Dedendum angle f tan^-1(hf / R ) 2.15903 deg 3.92194 deg

a1 f2
12 Addendum angle 3.92194 deg 2.15903 deg
a2 f1
13 Tip angle a + a 30.48699 deg 65.59398 deg
14 Root angle f f 24.40602 deg 59.51301 deg
15 Tip diameter da d + 2ha cos 67.2180 121.7575
16 Pitch apex to crown X R cos ha sin 58.1955 28.2425
17 Axial facewidth Xb 19.0029 9.0969
18 Inner tip diameter di 44.8425 81.6609
The rst characteristic of a Gleason Straight Bevel Gear thatit is a pro le shifted tooth. From Figure 4.11, we can see
thetooth pro le of Gleason Straight Bevel Gear and the same ofStandard Straight Bevel Gear.
Fig. 4.11 The tooth pro le of straight bevel gears
(2) Standard Straight Bevel Gears

A bevel gear with no pro le shifted tooth is a standard straightbevel gear. The are also referred to as Klingelnberg bevel
gears.The applicable equations are in Table 4.17.
Table 4.17 The calculations for a standard straight bevel gears
Example
Pinion(1) Gear(2)
2 Module m 3
Reference pressure Set Value
3 20 deg
angle
6 Reference cone 1 26.56505 deg 63.43495 deg
angle
2
8 Facewidth b It should not exceed R / 3 22
ha1
9 Addendum 4.035 1.965
ha2
10 Dedendum hf 2.188m ha 2.529 4.599
11 Dedendum angle f tan^-1(hf / R ) 2.15903 deg 3.92194 deg

a1 f2
12 Addendum angle 3.92194 deg 2.15903 deg
a2 f1
13 Tip angle a + a 30.48699 deg 65.59398 deg
14 Root angle f f 24.40602 deg 59.51301 deg
These equations can also be applied to bevel gear sets withother than 90 shaft angles.
(3) Gleason Spiral Bevel Gears

A spiral bevel gear is one with a spiral tooth ank as in Figure4.12. The spiral is generally consistent with the curve of a
cutterwith the diameter dc. The spiral angle is the angle between ageneratrix element of the pitch cone and the
tooth ank. Thespiral angle just at the tooth ank center is called the mean spiralangle m. In practice, the term spiral
angle refers to the meanspiral angle.
Fig.4.12 Spiral Bevel Gear (Left-hand)
All equations in Table 4.20 are speci c to the manufacturingmethod of Spread Blade or of Single Side from Gleason. If
agear is not cut per the Gleason system, the equations will bedifferent from these.
The tooth pro le of a Gleason spiral bevel gear shown here hasthe tooth depth h = 1.888m; tip and root clearance c =
0.188m;and working depth hw = 1.700m. These Gleason spiral bevelgears belong to a stub gear system. This is
applicable to gearswith modules m > 2.1.
Table 4.18 shows the minimum number of teeth to avoidundercut in the Gleason system with shaft angle = 90
andpressure angle n = 20.
Table 4.18 The minimum numbers of teeth to prevent undercut =35
If the number of teeth is less than 12, Table 4.19 is used todetermine the gear sizes.
Table 4.19 Dimentions for pinions with number of teeth less than 12
Table 4.20 shows the calculations for spiral bevel gears in the Gleason system
Table 4.20 The calculations for spiral bevel gears in the Gleason system
Example
Pinion (1) Gesr (2)
2 Module m 3
Set Value
4 Mean spiral angle m 35 deg
Number of teeth and
5 z 20 (L) 40 (R)
spiral hand
Transverse pressure
6 t 23.95680
angle
1
26.56505 63.43495
8 Reference cone angle
2 deg deg
10 Facewidth b It should be less than 0.3R or 10m 20
ha1
11 Addendum 3.4275 1.6725
ha2
12 Dedendum hf 1.888m ha 2.2365 3.9915

1.90952 3.40519
13 Dedendum angle f tan^-1( hf / R )
deg deg
a1 f2 29.97024 1.90952
14 Addendum angle
a2 f1 deg deg
29.97024 65.34447
15 Tip angle a + a
deg deg
24.65553 60.02976
16 Root angle f f
deg deg
All equations in Table 4.20 are also applicable to Gleason bevelgears with any shaft angle. A spiral bevel gear set
requiresmatching of hands; left-hand and right-hand as a pair.
(4) Gleason Zerol Bevel Gears

When the spiral angle bm = 0, the bevel gear is called a Zerolbevel gear. The calculation equations of Table 4.16 for
Gleasonstraight bevel gears are applicable. They also should takecare again of the rule of hands; left and right of a
pair must bematched. Figure 4.13 is a left-hand Zerol bevel gear.
Fig. 4.13 Left-hand zerol bevel gear
4.5 Screw Gears
Screw gearing includes various types of gears used to drivenonparallel and nonintersecting shafts where the teeth of
one orboth members of the pair are of screw form. Figure 4.14 showsthe meshing of screw gears.Two screw gears
can only mesh together under the conditionsthat normal modules (mn1) and (mn2) and normal pressure angles(n1,
n2) are the same.
Fig.4.14 Screw gears of nonparallel and nonintersecting axes
Let a pair of screw gears have the shaft angle and helix angles1 and 2 :
If the screw gears were pro le shifted, the meshing wouldbecome a little more complex. Let w1, w2 represent the
workingpitch cylinder ;
Table 4.21 presents equations for a pro le shifted screw gearpair. When the normal pro le shift coe cients xn1 = xn2
= 0, theequations and calculations are the same as for standard gears.
Table 4.21 The equations for a screw gear pair on nonparallel and Nonintersecting axes in the normal system
Example
Pinion (1) Gear (2)
3 20 deg 30 deg
angle
Set Value
4 z 15 (R) 24 (R)
hand
Normal pro le shift
5 xn 0.4 0.2
coe cient
Number of teeth of an
6 zv 18.0773 36.9504
Equivalent spur gear
Transverse pressure 21.1728 22.7959
7 t
angle deg deg
8 Involute function wn inv wn 0.0228415
Normal working pressure

9 wn Find from involute function table 22.9338 deg
angle
Transverse working 24.2404 26.0386
10 wn
pressure angle deg deg
Center distance
11 y 0.55977
13 Reference diameter d 47.8880 83.1384
dw1
15 Working pitch diameter 49.1155 85.2695
dw2
20.4706 30.6319
16 Working helix angle w
deg deg
17 Shaft angle w1 + w2 or w1 w2 51.1025 deg
18 Addendum ha1 ( 1 + y xn2 )mn 4.0793 3.4793
ha2 ( 1 + y xn1) mn
19 Tooth depth h {2.25 +y ( xn1 + xn2) } mn 6.6293

Standard screw gears have relations as follows:
dw1 = d1
dw2 = d2
w1 = 1
w2 = 2
(4.24)
4.6 Cylindrical Worm Gear Pair
Duplex Worm Gears
Cylindrical worms may be considered cylindrical type gearswith screw threads. Generally, the mesh has a 90 shaft
angle.The number of threads in the worm is equivalent to the numberof teeth in a gear of a screw type gear mesh.
Thus, a onethreadworm is equivalent to a one-tooth gear; and two-threads equivalent to two-teeth, etc. Referring to
Figure 4.15, for areference cylinder lead angle , measured on the pitch cylinder,each rotation of the worm makes the
thread advance one leadpz.
There are four worm tooth pro les in JIS B 1723-1977, as de nedbelow.
Type I The tooth pro le is trapezoidal on the axial plane.
Type II The tooth pro le is trapezoid on the plane normal tothe space.
Type III The tooth pro le which is obtained by inclining theaxis of the milling or grinding, of which cutter shapeis
trapezoidal on the cutter axis, by the lead angle tothe worm axis.
Type IV The tooth pro le is of involute curve on the plane ofrotation.
KHK stock worm gear products are all Type III. Worm pro les (Fig 4.15). The cutting tool used to process worm gears
iscalled a single-cutter that has a single-edged blade. The cuttingof worm gears is done with worm cutting
machine.Because the worm mesh couples nonparallel andnonintersecting axes, the axial plane of worm does
notcorrespond with the axial plane of worm wheel. The axial planeof worm corresponds with the transverse plane of
worm wheel.The transverse plane of worm corresponds with the axial planeof worm wheel. The common plane of the
worm and wormwheel is the normal plane. Using the normal module, mn, ismost popular. Then, an ordinary hob can
be used to cut theworm wheel.
Fig. 4.15 Cutting Grinding for Type III Worm
Table 4.22 presents the relationships among worm and wormwheel with regard to axial plane, transverse plane,
normalplane, module, pressure angle, pitch and lead.
Fig. 4.16 Cylindrical worm (Right-hand)
Table 4.22 The relations of cross sections of worm gear pairs
Worm
Axial plane Normal plane Transverse plane
Transverse plane Normal plane Axial plane

Worm wheel

Reference to Figure 4.16 can help the understanding of therelationships in Table 4.22. They are similar to the
relationsin Formulas (4.16) and (4.17) in that the helix angle besubstituted by (90 deg ). We can consider that a
worm withlead angle is almost the same as a helical gear with helixangle(90 deg ).
(1) Axial Module Worm Gear Pair

Table 4.23 presents the equations, for dimensions shown inFigure 4.16, for worm gears with axial module, mx, and
normalpressure angle n = 20.
Fig. 4.17 Dimentions of cylindrical worm gear pair
Table 4.23 The calculations for an axial module system worm gear pair
Example
Worm(1) Wheel (2)
1 Axial module mx 3
2 Normal pressure angle ( n ) ( 20 deg )
No. of threads, Set Value Double
3 z 30 (R)
no. of teeth Thread (R)
Coe cient of Pro le
4 zt2 0
shift
d1 ( Qmx) NOTE1
5 Reference diameter 44.000 90.000
d2 z2mx
Reference cylinder lead
6 7.76517 deg
angle
ha1 1.00 mx
8 Addendum 3.000 3.000
ha2 ( 1.00 + xt2 ) mx
9 Tooth depth h 2.25 mx 6.750
da1 d1 + 2ha1
10 Tip diameter 50.000 99.000
da2 d2 + 2ha2 + mx NOTE2
11 Throat diameter dt d2 + 2ha2 96.000
12 Throat surface radius ri 19.000
df1 da1 2h
df2 dt 2h
NOTE 1.
Diameter factor, Q, means reference diameter of worm, d1, over axialmodule, mx.
Q = d1 / mx
NOTE 2.
There are several calculation methods of worm wheel tip diameter da2 besides those in Table 4.25.
NOTE 3.
The facewidth of worm, b1, would be su cient if: b1 = mx (4.5 + 0.02z2)
NOTE 4.
Effective facewidth of worm wheel bw =
So the actualfacewidth of b2bw + 1.5mx would be enough.
(2) Normal Module System Worm Gear Pair

The equations for normal module system worm gears are basedon a normal module, mn, and normal pressure angle,
n = 20.See Table 4.24.
Table 4.24 The calculations for a normal module system worm gear pair
Example
Worm(1) Wheel (2)
2 Normal pressure angle n ( 20 deg )
No. of threads,
3 z Double (R) 30 (R)
No. of teeth
Set Value
Reference diameter of
4 d1 44.000
worm
Normal pro le shift
5 xn2 0.1414
coe cient
Reference cylinder lead
6 7.83748 deg
angle
Reference diameter of
7 d2 90.8486
worm wheel
ha1 1.00 mn
9 Addendum 3.000 2.5758
ha2 ( 1.00 + xn2 ) mn
10 Tooth depth h 2.25 mn 6.75
da1 d1+ 2ha1
11 Tip diameter 50.000 99.000
da2 dt2+ 2ha1 + mn
12 Throat diameter dt d2 + 2ha2 96.000
13 Throat surface radius ri 19.000
df1 da1 2h
df2 dt 2h
NOTE : All notes are the same as those of Table 4.23.
(3) Crowning of the Tooth

Crowning is critically important to worm gears. Not only can iteliminate abnormal tooth contact due to incorrect
assembly, butit also provides for the forming of an oil lm, which enhancesthe lubrication effect of the mesh. This can
favorably impactendurance and transmission e ciency of the worm mesh.There are four methods of crowning worm
gear pair :
(a) Cut Worm Wheel with a Hob Cutter of Greater Reference Diameter than the Worm.
A crownless worm wheel results when it is made by using ahob that has an identical pitch diameter as that of the
worm.This crownless worm wheel is very di cult to assemblecorrectly. Proper tooth contact and a complete oil lm
areusually not possible.
However, it is relatively easy to obtain a crowned worm wheelby cutting it with a hobwhose reference diameter
isslightly larger than that ofthe worm.
This is shown in Figure 4.18.This creates teeth contact inthe center region with spacefor oil lm formation.
Fig.4.18 The method of using a greater diameter hob
(b) Recut With Hob Center Position Adjustment.

The rst step is to cut the worm wheel at standard centerdistance. This results in no crowning. Then the worm
wheelis nished with the same hob by recutting with the hob axisshifted parallel to the worm wheel axis by h. This
results in acrowning effect, shown in Figure 4.19.
Fig.4.19 Offsetting up or down
(c) Hob Axis Inclining From Standard Position.

In standard cutting, the hob axis is oriented at the proper angleto the worm wheel axis. After that, the hob axis is
shiftedslightly left and then right, , in a plane parallel to the wormwheel axis, to cut a crown effect on the worm
wheel tooth.
This is shown in Figure 4.20. Only method (a) is popular.Methods (b) and (c) are seldom used.
Fig. 4.20 Inclining right or left
(d) Use a Worm with a Larger Pressure Angle than theWorm Wheel.
This is a very complex method, both theoretically andpractically. Usually, the crowning is done to the worm wheel,but
in this method the modi cation is on the worm. That is,to change the pressure angle and pitch of the worm
withoutchanging base pitch, in accordance with the relationships shown in Equations 4.25 :
In order to raise the pressure angle from before change, wx, toafter change, x , it is necessary to increase the axial
pitch, pwx, toa new value, px, per Equation (4.25). The amount of crowningis represented as the space between the
worm and worm wheelat the meshing point A in Figure 4.22. This amount may beapproximated by the following
equation :
Where
d1 : Reference diameter of worm
k : Factor from Table 4.25 and Figure 4.21
Table 4.25 The value of factor k
Axial pressure angle x

Fig. 4.21 The value of factor (k)
Table 4.26 shows an example of calculating worm crowning.
Table 4.26 The calculations for worm crowning
No. Item Symbol Formula Example

1 Axial module mwx 3
2 Normal pressure angle wn 20 deg
NOTE:
Number of threads of
3 z1 This is thedata beforecrowning. 2
worm
Reference diameter
4 d1 44.000
of worm
Reference cylinder
5 w 7.765166 deg
lead angle
6 Axial pressure angle wx 20.170236 deg
7 Axial pitch Pwx mwx 9.424778

8 Lead PwZ mwx z1 18.849556
It should be determined by
Amount of
9 CR considering the size of tooth 0.04
crowning
contact.
10 Factor k From Table 4.26 0.41
* After crowning
11 Axial pitch Px 9.466573
12 Axial pressure angle x 20.847973 deg
13 Axial module mx 3.013304
Reference cylinder
14 7.799179 deg
lead angle
15 Normal pressure angle n tan^-1(tanx cos ) 20.671494 deg

16 Lead Pz mxz1 18.933146 deg

(4) Self-Locking Of Worm Gear Pairs

Self-locking is a unique characteristic of worm meshes thatcan be put to advantage. It is the feature that a worm
cannotbe driven by the worm wheel. It is very useful in the designof some equipment, such as lifting, in that the drive
can stopat any position without concern that it can slip in reverse.However, in some situations it can be detrimental if
the systemrequires reverse sensitivity, such as a servomechanism.
Self-locking does not occur in all worm meshes, since itrequires special conditions as outlined here. In this
analysis,only the driving force acting upon the tooth surfaces isconsidered without any regard to losses due to bearing
friction,lubricant agitation, etc. The governing conditions are asfollows :
Let Ft1 = tangential driving force of worm
Then,
Ft1 = Fn (cos n sin cos ) (4.27)
If Ft1 > 0 then there is no self-locking effect at all. Therefore,
Ft1 0 is the critical limit of self-locking.
Let n in Equation (4.27) be 20, then the condition:

Ft1 0 will become :
(cos 20 sing mcosg) 0
Figure 4.22 shows the critical limit of self-locking for leadangle g and coe cient of friction m. Practically, it is very
hardto assess the exact value of coe cient of friction . Further,the bearing loss, lubricant agitation loss, etc. can add
many sideeffects. Therefore, it is not easy to establish precise self-lockingconditions.
However, it is true that the smaller the lead angle , the morelikely the self-locking condition will occur.
Fig.4.22 Position A is the point of determining crowning amount
Fig. 4.23 The critical limit of self-locking of lead angle g and coe cient of friction m
Related links :
Basic Gear Terminology and Calculation A page of The ABCs of Gears / Basic Guide B
Online Shopping of Metric Gears in UK & Europe via RAR Gears website Delivery in 2-3 days !
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Calculation of Gear Dimensions - KHK Gears

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4.1 Spur Gears

Spur gears with locking hubs

(1) Standard Spur Gear

Fig. 4.1 The Meshing of Standard Spur Gears

Table 4.1 Calculations for Standard Spur Gears

5 Reference Diameter d zm 36.000 72.000

Table 4.2 The Calculations for Number of Teeth

No. Item Symbol Formula Example

4 Sum of No. of Teeth z1 + z2 36

(2) Pro le Shifted Spur Gear

Fig. 4.2 The Meshing of Pro le Shifted Gears

5 Involute w inv w 0.034316

9 Reference Diameter d zm 36.000 72.000

11 Working Pitch Diameter dw 37.667 75.333

Table 4.4 is the inverse formula of items from 4 to 8 of Table 4.3.

1 Center Distance a Set Value 56.4999

3 Working Pressure Angle w 26.0886 deg

Sum of Pro le Shift

5 Pro le Shift Coe cient x 0.6000 0.3600

(3) Rack and Spur Gear

4 Pro le shift coe cient x 0.6

11 Addendum ha m(1+x) 4.800 3.000

4.2 Internal Gears

(1) Internal Gear Calculations

Fig.4.4 The meshing of internal gear and external gear

5 Involute function w inv w 0.061857

9 Reference diameter d zm 48.000 72.000

11 Working pitch diameter dw 52.7998 79.1997

Difference of pro le shift

(2) Interference In Internal Gears

(a) Involute Interference

Where a2 is the pressure angle at a tip of the internal gear tooth.

wworking pressure angle

(b) Trochoid Interference

where a1 is the pressure angle of the spur gear tooth tip:

(c) Trimming Interference

Fig.4.5 Involute interference and trochoid interference

Fig.4.6 Trimming interference

4.3 Helical Gears

Pitch measured perpendicular to teeth is called normal pitch, pn.

The tooth pro le of a helical gear with applied normal module,

Fig.4.7 Fundamental relationship of a helical gear (Right-hand)

(1) Normal System Helical Gear

7 Involute function wt inv wt 0.023405

10 Center distance a 125.000

11 Reference diameter d 41.569 207.846

12 Base diameter db d cos t 38.322 191.611

13 Working pitch diameter dw 41.667 208.333

Sum of pro le shift

(2) Transverse System Helical Gear

6 Involute function wt inv wt 0.0183886

10 Reference diameter d zmt 36.000 180.000

12 Working pitch diameter dw 36.3333 181.6667

Table 4.12 presents the inverse calculation of item 5 to 9 of Table 4.11.

Sum of pro le shift

(3) Helical Rack