STD-AGMA LOQb-A-ENGL L597 Ml 0b87575 OO0S3L2 LA? mm ANSI/AGMA 1006-A97 AMERICAN NATIONAL STANDARD. Se Tooth Proportions for Plastic Gears ANSIAGMA 1006-A97 AGMA STANDARD Copyright by the American Gear Manufacturers Association SaSTD-AGMA LOOb-A-ENGL L997 MM OL87575 0005313 513 mm it Tooth Proportions for Plastic Gears American ANSI/AGMA 1006-A97 National Standard Approval ot an American National Standard requires veriication by ANSI thatthe require- ments for due process, consensus, and other criteria for approval have been met by the standards developer. Consensus is estabished when, in the judgment of the ANSI Board of Standards Review, substantial agreement has been reached by directly and materialy affected interests ‘Substantial agreement means much more than a simple majority, but not necessary una- rimity. Consensus requires that all views and objections be considered, and that concerted effort be made toward their resolution. “The use of American National Standards is completely voluntary: their existence does not in any respect preclude anyone, whether he has approved the standards or nat, from manuacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standards ‘The American National Standards Insttute does not develop standards and will in no circumstances give an interpretation of any American National Standard. Moreover, no person shall have the right or authority to issue an interpretation of an American National Standardin the name ofthe American National Standards Institute, Requests for interpre- tation of this standard should be addressed to the American Gear Manufacturers Association, CAUTION NOTICE: AGMA technical publications are eubject to constant improvement, revision, or withdrawal as dictated by experience. Any person who refers to any AGMA ‘Technical Publication should be sure that the publication isthe latest available from the ‘Association on the subject matter. [Tables or other selt-supporting sections may be quoted or extracted. Credit lines should read: Extracted from ANSVAGMA 1006-AS7, Tooth Proportions for Plastic Gears, with the permission ofthe publisher, the American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, Virginia 22914) Approved August 7, 1997 ABSTRACT This standard presents a new basic rack, AGMA PT, which, with its full round filet, may be preferred in many applications of gears made from plastic materials. It also expiains and illustrates the general concept of the basic rack, It contains a description, with equations and sample calculations, of how the proportions of a spur or helical gear may be derived from the design tooth thickness and the basic rack data. These equations and calculations use traditional AGMA symbols and inch units. In several annexes, there are discussions of pos- sible variations from this basic rack and also a procedure for defining tooth proportions without using the basic rack concept. Published by American Gear Manufacturers Association 1500 King Street, Suite 201, Alexandria, Virginia 22314 Copyright © 1997 by American Gear Manufacturers Association ‘All rights reserved, No part of this publication may be reproduced in any form, in an electronic Tetrieval system or otherwise, without prior writen permission of the publisher. Printed in the United States of America ISBN: 1-58589-684-7 Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD ANSVAGMA 1006-A97 Contents Page Foreword eee vieeeseeee iv Vo S00PE eee 1 2 Definitions and symbols 1 3 Tooth proportions and basic rack 3 4 Standard basic rack for plastic gears 3 Gear tooth proportions from basic rack data 8 Tables 1. Nomenclature: symbols and terms ore 2 Standard basic racks (based on unit pitch)... 4 Figures 1 AGMAPT basic rack (for Py oF Pay = 1) cee 8 2 Example of AGMA PT basic rack modified with tip relief : 5 3 Comparison of calculated bending stiesses at fillets from AGMA Fine-Pitch and AGMA PT basic racks ....... 6 (a) Effect of filet shape on mold fow .... 7 44(b) Effect of filet shape on fiber orientation close to surface (at mid—facewidth location) sa? (0) Etec of filet shape on filet surface temperature dung Keezing ........ 7 .4(¢) Comparison of shrinkage effect in undercut pinion with sharp and rounded fillets 8 5 Tooth outline features inttoduoed by tip rouncing on external gears ........ 11 Annexes ‘A Basic rack description and application on 8 Experimental basic racks for plastic gears - eel © Determination of tooth thickness and other design variables .............. 23 D Gear tip relief from a modified basic rack . or 27 E _Atternate practices for defining tooth proportions... 3t F Generating spur gear geometry without racks 37 G Sample calculations 43 Bibliography : 7 47 STD-AGMA LODb-A-ENGL 1997 MM Ob47575 OOOS3L4 4ST a Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-AS7 AMERICAN NATIONAL STANDARD Foreword {The foreword, footnotes, and annexes are provided for informational purposes only and should not be construed as a part of ANSVAGMA 1006-AS7, Tooth Proportions for Plastic Gears] ‘AGMA has issued standards for gear tooth proportions over a period of many years. The most recent versions have been AGMA 201.02 (withdrawn 1995), Tooth Proportions for Coarse-Pitch Involute Spur Gears, and ANSVAGMA 1003-G98, Tooth Proportions for Fine-Pitch Involute Spur and Helical Gears. These standards and their predecessors were prepared in response to the need to standardize gear generating cutting tools such as hobs and shaper cutters. Without such standards, the variety of tools needed by gear shops: ‘would have become unlimited. The manufacture of gears by the molding process is not subject to the same practical constraints as manufacture by the gear cutting process. Every mold is inherently “non-standard”. The geometry of the mold cavity cannot follow a standard because of varying allowances for shrinkage. Furthermore, there are some methods for manufacturing ‘the mold cavity which do not depend on cutting tools and, even for those that do, special tools are generally required. Thus, tooth proportions for molded plastic gears need not follow those established for machined gears. ‘Some of the special properties of plastic materials influence the selection of gear tooth proportions as the two following examples illustrate: — The structure and orientation of plastic molecules, regardless of processing method, makes the strengths of the materials particularly sensitive to sharp internal comers. A substantially stronger tooth will result sharp filets at the base of the tooth are avoided. ‘The tooth proportions for gears made according to the AGMA fine-pitch standard noted above generally result in relatively sharp filets. - In certain applications, the higher expansion properties of plastic materials may create the need fora greater depth of engagement between mating gears than permitted by the other standard tooth forms. ‘As a result ofthis preference for a different tooth form, members of the plastic gear molding industry have adopted their own individual sets of tooth proportions. One set that has gained wide usage by plastic gear designers, and is often specified in place of the AGMA Fine-Pitch Standard, has been developed by William McKinley [1]. Because these tooth forms contain the preferential features for molded plastic gears and because they are already well recognized in the industry, they were used, with some changes, as models in the preparation of this standard. The first of the four variations in this set has a depth of engagement, or working depth, that is the same as in the above mentioned AGMA standards. The other three have increased depths of engagement in varying degrees. This standard has selected only the first variation, which is the one in widest use, as the model for the new tooth proportions. However, data similarly based on the other three variations are included in annex B ‘The tooth tormsin this standard are defined with the use of the basic rack concept. For those that might be unfamiliar with this concept, a detailed description of the basic rack is included as annex A. ‘Suggestions for improvement of this standard willbe welcome. They should be sent to the ‘American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, 22314. STD-AGMA LOOb-A-ENGL 1997 MM OL87575 0005315 395 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005a AMERICAN NATIONAL STANDARD PERSONNEL of the AGMA Plastics Gearing Committee Chairman: Laskin ...... =» Itving Laskin, PE, Vice Chairman: H. Yelle ACTIVE MEMBERS MA, Bennick ..... RTP Company R. Casavant ...... GW Plastics, Inc. D. Castor . Eastman Kodak Company CM. Denny Consultant DS. Elis ......... ABA-PGT, Inc. K. Gitchel Universal Tech. Systems, Inc. JW. Kelley Shell Chemical Company R.kleiss ......... Kleiss Engineering S. Legautt ‘Seitz Corporation A Milano Seitz Corporation ASSOCIATE MEMBERS J. Ambrosina ..... IDEO Product Development M.K. Anwar ....... Allied Devices Corporation D. Bailey ......... Rochester Gear, nc. RE. Bergmann... Gear Research Institute F.Boss........... DSM Engineering Plastics K Buyukataman ... UTC Pratt & Whitney A Conrad GW Piastics, Inc. P Danish . ITT Automotive P.Davoli ......... Politecnico di Milano WI. Derry ........ Lewis Research, Inc. E.Dorman ........ Winzeler, Inc. L Faure .. cM. C. Fleenor Bay Designs, Inc. M. Fletcher ....... Hoechst Celanese D. Fritzinger ...... Power Wheels RJ. Galipeau ..... Plastics Technology T.Grula .......... DuPont Company PM. Hughes Hoechst Celanese SLeGault ‘Seitz Corporation S.D. Pierson . JLT. Ril. M. Schireson L Siders: Z Smith .. M. Thompson A Ulrich M. Wichmann EH. Williams, Ill JH. Winzeler, Jt. RB. Lowis. J Lovell G. Martello JH. Monger M. Octrue M. Oliveto KR. Price E. Reiter D. Rosenfeld . R. Santandreu NAR. Schott J. Simonelli. Lu. Smith RE. Smith . Z Solstarecz ©. Tacey R. Weder .. M. Wikinson P.Wyluda ‘ANSVAGMA 1006-A97 - Ecole Polytechnique de Montréal ABA-PGT, Inc. Black & Decker, inc. - OSM Engng. Plastics, Inc. Lexmark . Hoechst Celanese Corp. - UFE, Inc. UFE, Inc, DuPont Polymers - UNP Engng. Plastics, inc. Winzeler, Inc. Lewis Research, Inc. Spaulding Composites Co. BF Goodrich Spec. Chem. Process Gear Company cETIM DSM Engng. Plastics, Inc. Eastman Kodak Company ATS Precision Comp. Div. . DSM Engng. Plastics, Inc. - Consultant «Institute for Plastic Innovation Emerson Power Trans. Co. Invincible Gear Company - RE. Smith & Company, Inc. Seitz Corporation DuPont Polymers CW. Tool - Mikron GW Plastics Hoechst Celanese STD-AGMA LOOL-A-ENGL 1997 MM Gb87575 OOOSILb 222 ml Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-AS7 AMERICAN NATIONAL STANDARD (This page is intentionally left blank.) STD-AGMA LOOb-A-ENGL 1997 MM Ob87575 OO0S3L7 169 a Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005STD-AGMA LOODb-A-ENGL 1597 MM Ob67S75 OOOS3L8 OTS am ‘AMERICAN NATIONAL STANDARD American National Standard — Tooth Proportions for Plastic Gears 1 Scope 1.1 Basic rack ‘This standard defines a basic rack for spur and helical plastic gears. However, the specific basic rack can be applied to any type of gear which employs the basic rack concept to help define its geometry. NOTE: This basic ack is an optional aternative tooth- er AGMA basic racks. Itwilloften be preferred for those applications in which tooth bending strength is a major factor in the design of plastic gears. A detailed description of the basic rack concept, including its features and its application to various types of gears, is given in annex A. The data for three other basic racks, differing pri- marily in depth of engagement, are given in annex B. 1.2 Gear tooth proportions This standard shows how basic rack dimensions determine the tooth proportions of the gear once the tooth thickness has been established. Specific values of the gear tooth thickness and the resulting ‘gear tooth proportions are not covered by this standard. However, many ofthe considerations that gointo such a selection are discussed in annex C. ‘The tip relief from a modified basic rack is discussed in annex D. ANSVAGMA 1006-AS7 1.3 Non-tradi Proportions nal practices for defining tooth ‘Annexes E and F describe some non-traditional Practices currently used to help achieve gear designs that are optimum for their applications. ‘Their use with molded plastic gears has been made more convenient by modem methods of mold cavity manufacture. These practices include modifying standard basic racks, creating custom designed basic racks, and designing tooth proportions without reference to basic racks. In the annexes, the description of each method is accompanied by potential advantages and design cautions. An example of one procedure for the last method, designing without reference to basic racks, is presented in annex F. 2 Definitions and symbols 2.1 Definitions ‘The terms used in this standard conform to ANSI/ AGMA 1012-F90, Gear Nomenclature, Definition of Terms with Symbols. Terms used in this standard which require elabora- tion and concepts which are specific to plastic gears are covered where they are first used 2.2 Symbols The symbols used in the tables and formulas are shown in table 1. NOTE: The symbols and definitions used in this standard may differ trom similar items in other AGMA standards. The user should not assume that familiar ‘symbols can be used without a careful study of these definitions. Table 1 - Nomenclature: symbols and terms ‘Symbol Term First Used ‘ape [Addendum of basic rack Figure OreR Effective addendum of the basic rack (distance from pitch line to start of the circular- | Figure 2 arc tip modification) bee __|Dedendum of basic rack Figure 1 Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005 (continued)ANSVAGMA 1006-A97 AMERICAN NATIONAL STANDARD. Table 1 (concluded) ‘Symbor Term First Used Trea [Form dedendum of basic rack (distance from pitch line to start of filet radius) Figure 7 car _| Clearance of basic rack Figure 1 a ‘Standard pitch diameter of gear (reference diameter) Eq1 4s Base circle diameter of gear Eqs ae Form diameter of gear Eq6 4 Inside diameter of internal gear Eq9 do Outside diameter of external gear Eq3 dos __ | Effective outside diameter Eq29 de Root diameter of gear Eq4 Jusr | Working depth of basic rack Figure 1 hap | Whole depth of basic rack Figure 1 IN Number of teeth of gear 54 per _| Circular pitch of basic rack Figure 1 Ps Diametral pitch Gis 5 Pat | Normal diametral pitch Cis 5 ‘Rree | Radius of the circular-arc tip modification on the basic rack Figure 2 rar _| Fillet radius of basic rack Figure 1 7 Tip radius of gear Eq 28 oR ‘Space width of basic rack Figure 1 t ‘Tooth thickness at standard pitch diameter 54 or Tooth thickness of basic rack Figure 1 4 ‘Tooth thickness at inside diameter of spur internal gear; inside tip land &q 12 he Normal tooth thickness at standard pitch diameter 54 fy Normal tooth thickness at inside diameter of helical internal gear; normal inside tip | Eq 27 land ho Normal tooth thickness at outside diameter of helical external gear; normal top land | Eq 23 hoe _| Effective normal top land with tip rounding Eq 34 teor | Remaining normal top land with tip rounding Eq 92 » ‘Tooth thickness at outside diameter of spur external gear; top land Eqe oe Effective top land with tip rounding &q30 tor Remaining top land with tip rounding Eq 28 @ Transverse tooth thickness at inside diameter of intemal helical gear Eq 25 40 Transverse tooth thickness at outside diameter of external helical gear Eq21 y Rack shift Eq2 v Helix angle at standard pitch diameter 54 w Helix angle at inside diameter of internal helical gear Eq26 Wo Helix angle at outside diameter of external helical gear Eq22 6 Profile angle of basic rack; pressure angle at standard pitch diameter of spur gear; | Figure 1 normal pressure angle at standard pitch diameter of helical gear o Pressure angle at inside diameter of spur internal gear Eq 4x0 _| Normal pressure angle at outside diameter of helical external gear Eq3i 40 Pressure angle at outside diameter of spur gear Eq7 e Transverse pressure angle at standard pitch diameter of helical gear Eqi7 a Transverse pressure angle at inside diameter of intemal helical gear Eq24 4r0_| Transverse pressure angle at outside diameter of external helical gear Eq20 2 STD-AGMA LOOb-A-ENGL 1957 MM 0b87575 OOUS3L5 TI) a Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD 3 Tooth proportions and basic rack Itis general practice to establish a system of tooth proportions by defining a basic rack. The actual tooth outline for a gear with a specified number of teeth and value of tooth thickness will be generally determined by the generating action of this rack- shaped outline. (Some features of the tooth outline may be determined by additional considerations. See 5.8.1, 5.8.2 and 5.8.3.) A description of this basic rack concept and how itis appiied to various types of gears is given in annex A. 4 Standard basic rack for plastic gears A standard basic rack is established in this AGMA standard. Plastic gears with tooth forms defined by this basic rack will mesh properly with both AGMA, fine-pitch and ISO coarse-pitch gears. (Three ANSI/AGMA 1006-A97 experimental basic racks with greater working depths are defined in annex B.) NOTE: This basic rack is an optional aternative to other AGMA basic racks. It wil often be preferred for ‘those applications in which tooth bending strength is a ‘major factor in the design cf plastic gears. See 4.4 4.1 Designations This basic rack is designated as: ‘AGMA Plastic Gearing Toothform, abbreviated as: AGMA PT. 4.2 Proportions The basic rack is shown in figure 1. The figure identifies al the features described in A.2. Values of the dimensional features are listed in table 2 along with comparative values for the AGMA fine-pitch standard and the ISO mostly coarse-pitch standard. All of these values are referenced to unit pitch ‘Actual values are found by dividing the table values by the diametral pitch, Dimensional features: ‘agg = addendum June = working depth form dedendum ps learance "oR dedendum kar = whole depth =circuiarpitch = fillet radius sop = space width ‘gg = tooth thickness profile angle Figure 1 - AGMA PT basic rack (for P OF Pag = 1) STD-AGMA LOOL-A-ENGL 1997 MM Ob87575 OOUS320 753 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-A97 AMERICAN NATIONAL STANDARD Table 2 - Standard basic racks (based on unit pitch) ‘ANSVAGMA 1003-GS3 TSO 53 (1874) Basic rack feature AGMA PT fine-pitch coarse pitch [Profile angle, $77 20 deg. 20 deg. 20 deg. Circular pitch, par 3.14160 3.14160 3.14160 Tooth thickness, ts 1.57080 1.57080 1.57080 ‘Addendum, ape 1.00000 1.00000 1.00000 Whole depth, As 2.33000 2.20000 (+0.00200)? 2.25000 Fillet radius, re 0.43032 0.00000°) 0.38000 Dedendum, bar 1.33000 1.20000 —_(+0.00200)2) 1.25000 Working depth, haze 2.00000 2.00000 2.00000 Clearance, can 0.33000 0.20000 (+0.00200)2) 0.25000 Form dedendum, bra‘) 1.04686 1.20000 __(+0.00200)?) 1.05261 Space width, 1.57080 1.57080 1.57080 NOTES: 1) qs also the pressure angle at standard pitch diameter of. iameter of helical gear. ce, the corner is made with a small radius.” bran Is the distance from pitch line to start of filet radius. 2° after dividing the table value by the diametral pitch, add the value in parentheses. 9) ANSYAGMA 1003~G3s states: “A zero filet radius implies a sharp comer on the tip of the generating tool. In actual ‘spur gear or the normal pressure angle at standard pitch 4.3 Optional modifications Certain modifications may be made to these basic racks without deviating from their essential charac ter. When any such change is desired, a description in an appropriate form must be included in the gear specifications, 4.3.1 Profile modification It is sometimes desirable to make slight modifica- tions to the involute profile of the gear. One such example is tip relief. This is the removal of a small sliver of material along a portion of the involute leading to the tooth tip. Tip relief will often benefit gear action by reducing the abrupt action accompa- ying load transfer between adjoining teeth, especially when the teeth are deflecting under a heavy load. Such modification to the tooth profile can be introduced by an appropriate modification to the straight-sided flank of the basic rack tooth. ‘When thisis desired, a drawing of the modified basic rackis required as part of the gear specifications. An ‘example of such a modification applied tothe AGMA PT tooth form is shown in igure 2. Annex D provides, equations for calculating the effect of this, modification on certain features of the generated tooth, 4.3.2 Tooth-tip diameter modification It is sometimes necessary to change the outside diameter of external gears or the inside diameter of STD-AGMA LOOb-A-ENGL 1997 mm Ol Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005 internal gears from the diameters defined by the basic rack. Some of these considerations are discussed in 5.8.1 and annex C. Such adjustments do not significantly depart from the standard basic rack and do not require a special basic rack drawing showing the modification. The specification of the outside or inside diameter is, by itself, sufficient to define the modification 4.4 Comparison to other AGMA basic racks This new basic rack is similar to the other listed ‘AGA basic racks. Gears derived from all of them will generally operate together. However, there are differences which, for the new basic rack, may result in plastic gear designs of enhanced load capacity and, particularly in the case of molded plastic gears, also of greater accuracy. 4.4.1 New features Of all the features compared in table 2, the most significant is the increase in filet radius. The new radius, corresponding to a full-round radius, is the maximum radius possible while at the same time maintaining a form dedendum value greater than 1.0. This form dedendum greater than 1.0 insures ‘compatibility with the other AGMA basic racks. The remaining new features, that is, the whole depth, dedendum, and clearance, are geometry changes needed to accommodate the larger fillet radius. b87575 OOOS32% bIT aAMERICAN NATIONAL STANDARD ANSVAGMA 1006-A97 rap = tip relief radius 7pR {dendum to start of tip relief radius Figure 2 - Example of AGMA PT basic rack modified with tip reliet 442 Generated fillet form and stress concentration The trochoid-shaped ileton a generated gear tooth is determined in part by the basic rack filet radius. This filet radiusis the tip radius ofthe generating tool as shown in annex A. The larger this basic rack radius, the larger the radii along the troichoid curve land the less sharp the “corner” represented by the fillet When load is applied to a gear tooth, it produces maximum bending moments inthe filet area. Stress ‘concentration around relatively sharp filet comers increases the resulting bending stress. The less sharp this filet, the lower the maximum local stress land the greater the capacity ofthe tooth to withstand the applied load. This is especially true under the condition of repeated loads typical of gear applications. ‘Some features of the new basic rack influence the fillet stresses and, hence, the bending strength ofthe generated tooth. On one hand, its slightly larger dedendum tends to increase the bending moment at the root of the tooth. However, this slight harmful effect is generally more than compensated by the combined beneficial effect of the wider tooth base and the reduced stress concentration resulting from the larger filet radius. Figure 3, derived from Boundary Element!) analysis, ‘compares the stress levels at two versions of a Pinion fillet, one generated by the AGMA Fine-Pitch basic rack and the other by the AGMA PT basic rack. This figure compares the two filets for a 12 tooth pinion enlarged in accordance with ANSAGMA 1003-G93, Tooth Proportions for Fine-Pitch Gears. For each fillet, the figute shows three plots of induced stress levels at the base of the tooth. The innermost plot, labelled "Lewis", gives the stress as calculated by the elementary Lewis equation without consideration of stress concentration. The next plot, labelled "Dolan & Broghamer’, adds the effect of stress concentration @s commonly estimated in ‘AGMA gear strength calculations. The third plot shows the stresses as determined by the Boundary Element Method"). In each case, the filet form determined by the PT Basic Rack shows lower stress levels than that determined by the AGMA ‘7_The Boundary Element Analysis was performed within The External Gear Profile Generation Program, 1987, Ohio ‘State University STD-AGMA LOOb-A-ENGL 1997 MM Ob87575 OOOS322 Sab am Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-A97 Dolan & Broghamer (@)AGMA Fine-Pitch basic rack AMERICAN NATIONAL STANDARD Load (D)AGMA PT basic rack Pinion Data: 24 diametral pitch, 12 teeth, 0.0811 inch tooth thickness Figure 3 - Comparison of calculated bending stresses at fillets from AGMA Fine-Pitch and AGMA PT basic racks ‘Sharp comers in plastic materials ‘According to the above explanation, the full-radius feature of a basic rack is to be preferred in gears of ‘any material when bending strength is a majorfactor ingear design. Thisis widely recognized and has led tothe common practice of using maximurn filet radi in basic racks for heavily loaded gears made from a variety of materials. This approach is especially important for gears made from plastic materials. The relatively low strength of plastics as compared to other engineering materials, their relatively low fracture toughness, and theit other notch-sensitive properties make plastics particularly susceptible to stress concentrations, 4.43.1 Machined plastic gears Plastic gears are machined from stock materials generally made by an extrusion or casting process. ‘The machined filet surface with an unfavorable molecular structure can be especially vulnerable to the higher stress at relatively sharp filets. When machined plastic gears are used as proto- types, this can cause part failure that will not fairly represent the performance of the molded part. 4.4.3.2 Molded plastic gears The plastic molding process can create conditions which reduce material strength at the gear tooth filets and which are influenced by the size of the fillet radius. These conditions are described below and shown in figure 4: — Plastics flowing into a mold develop a flow pattern which is mostly determined by the shear stress induced during the flow process. Sudden transitions, such as flow around sharp comers or ‘abrupt velocity change, can produce flow irregu- larities (resembling but not identical to turbuient flow) near the part surface, These are quickly frozen in place, see figure 4(a). The result is molded-in stresses which reduce tooth strength. ‘Afterwards, the action of time, temperature, or ‘chemical exposure can lead to relief of these ‘stresses with an accompanying distortion in gear ‘geometry. ~ With fiber reinforced plastics, there is an add- fed concem from this type of mold-filing flow. With a smooth, continuous flow process, the fibers in the material near the surface of the part align in the flow direction. However, when the flow encounters a relatively sharp comer, the fibers tend to position themselves in a radial pattern pointing to the comer, see figure 4(t). Thus the fibers do not fully reinforce the critical comer, and may introduce potential failure paths. Further- more, poorly oriented fibers can produce non-uniform shrinkage and poor tooth geometry. STD-AGMA LOOb-A-ENGL 1997 MM Ob87575 OO0S323 4b2 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD = Fundamental to molding stable, stress-free parts are designs which encourage uniform cool- ing in the mold. Sharp comers, such as those at minimal radius root fillets, define a region with a constricted path for heat conduction, see figure (0). The results a region which remains hot well after the adjacent material has cooled. This ‘condition is further intensified by a similar heat ‘conduction problem which raises the temperature in the corresponding sharp external corner of the mold. The non-uniform cooling rates in the plas- tic generate shrinkage forces which develop voids or high localized stresses near the tooth foot. Furthermore, these uncontrolled and unstable forces can distort the tooth profile in an Unpredictable manner. A maximum radius at the filet minimizes the temperature differential and ANSVAGMA 1006-AS7 the resulting shrinkage stresses, profile distortion, and surface material strength loss. Another kind of molding problem associated with an undercut tooth profile often appears with gears having a limited number of teeth designed with inadequate basic rack offset. A relatively sharp comer atthe filet emphasizes the undercut condition. During shrinking in the mold, the undercut can cause “hang-up” on the corre- sponding projections in the mold cavity restricting the free shrinkage in the combined radial and circumferential directions. Figure 4(d) shows the effect of shrinkage on two identical, except for f let shape, undercut pinions. This "hang-up" condition is clearly shown on the pinion with the sharper comer and not, in this example, on the Gf Figure 4(a) - Effect of fillet shape on mold flow Radial - pattern <1 I~ Je Tangential a pattern Figure 4(b) - Effect of fillet shape on fiber orientation close to surface (at mid-facewidth location) Hot spots with unstable shrinkage ‘Temperature profiles Figure 4(c) - Effect of fillet shape on fillet surface temperature during freezing STD-AGMA DOOb-A-ENGL 1997 MM Ob8757S OOOS324 379 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-97 AMERICAN NATIONAL STANDARD Mold cavity i Molded pinion | i with shrinkage ! \ | 1 I 1 I I | ! Hang-up effect { I I ‘Sharp fillet Rounded fillet Figure 4(d) - Comparison of shrinkage effect in undercut pi 5 Gear tooth proportions from basic rack data ‘Aimostaall ofthe features defining a spur gear can be derived from the standard basicrack or the specified iametral pitch, Ps, and a few items of primary gear data. This is also true for a helical gear, with the specified diametral pitch of the basic rack becoming ‘the normal diametral pitch, Pyz, of the gear and the profile angle of the basic rack becoming the normal Profile angle, ¢, of the gear. Sample calculations illustrating the use of the equations in this section are supplied in annex G. 5.1 Primary gear data for spur gears — number of teeth, 1; = tooth thickness, 1 ‘5.2 Derived gear data for external spur gears 5.2.1 Outside diameter Asso see 5.8.1.1. The standard pitch diameter (reference diameter) of the gear, d, is: oft) where Nv isnumber of teeth of gear; Pz isdiametral pitch Rack shift, y. See A.7.1 and figures A7 and A.8. 1 ty Tang. (2) where with sharp and rounded fillets 1 is tooth thickness at the standard pitch ciameter; tax _ is the tooth thickness of the basic rack; © _ is the profile angle of the basic rack; pres- sure angle at the standard pitch diameter of ‘a spur gear; normal pressure angle at the standard pitch diameter of a helical gear. Outside diameter of the external gear, do, is: do = d+ 2y + Jape -8) where ‘agp_is addendum of basic rack. 5.2.2 Root diameter ‘The root diameter of the gear, de, is: de = d+ 2y~2boe old) where bp is dedendum of basic rack. 5.2.3 Form diameter ‘The base circle diameter of the gear, de, is de = dcosd 6) ‘The form diameter of the gear, de, is: where bear is form dedendum of basic rack (distance ‘from pitch line to start of fillet radius). NOTE: This equation applies only for gears that are not ‘undercut. The condition of no undercuts met the term in brackets is equal to or greater than zero. The ‘analytical method for finding the form diameter for undercut gears is beyond the scope of this document. STD-AGMA LOOb-A-ENGL 1997 MM Ob87575 OO0S325 235 mw Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD 5.2.4 Top land The involute pressure angle at the outside diameter of a spur gear, do, is: 4 ¢0= o=[#] ” ‘The tooth thickness at the outside diameter of a spur external gear, of top land, 10, is: fo = deff + inve~invoo] (8) 5.25 Fillet form ‘The form of the filet can be found by graphically reproducing the generating action of the basic rack ‘The analytical method is beyond the scope of this document. See {2}, [3], [4] and [5] in the Bibliography. 5.3 Derived gear data for internal spur gears 5.3.1 Inside diameter Also see 5.8.1.2. The inside diameter of an internal gear, d, 4 = d~2y ~2ape © NOTE: The inside diameter should notbe smaller than the base circle diameter. 5.3.2 Root diameter Also see 5.8.1.3. ‘The root diameter of an internal gear, de, is: ~2y + 2bee (10) 5.3.3 Form diameter, dp The form diameter of an internal gear depends on the proportions of its generating gear. The analytical ‘method for determining this diameter is beyond the scope of this document. 5.3.4 Inside tip land The involute pressure angle atthe inside diameter of a spur internal gear, ¢y, i oo (4] 0 ‘The tooth thickness at the inside diameter of a spur internal gear, or inside tip land, n, is: y= [5 ~ inva + invgy] (12) 5.3.5 Fillet form ‘The form of the filet of an internal gear depends in part on the proportions of its generating gear. The ‘ANSV/AGMA 1006-A97 ‘exact form can be found by graphically reproducing the generating action. This form can often be closely eppraximated by a single circular arc. The analytical methods for finding the exact form and its approximation are beyond the scope of this document 5.4 Primary gear data for helical gears — number of teeth, 1; = normal tooth thickness, ,; = helix angle, y. 5.5 Derived gear data for external helical gears 6.5.1 Outside diameter Also see 5.8.1.1 ‘The standard pitch diameter of the gear, d, is: N a= ae (19) where Pyg_is normal diametral pitch; W__ ishelixangle atthe standard pitch diameter. Rack shift, y. nas I> are (14) where % iS normal tooth thickness at the standard pitch diameter. The outside diameter of the external gear, do, is: do = d+ 2y + 2apx (15) 5.5.2 Root diameter ‘The root diameter of the gear, de, dy = d + 2y ~2bpp (16) 5.5.3 Form diameter ‘The transverse pressure angle at the standard pitch diameter of a helical gear, ¢,, is: oar {238] om eres 1 ‘The form diameter of the gear, dr, is (see note at equation 6): Dy + deine, — 2b, dp STD-AGMA MOOb-A-ENGL 1997 MM Ob87575 OOOS326 17] a Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSI/AGMA 1006-A97 5.5.4 Normal top land ‘The transverse pressure angle at the outside diameter of a helical gear, ¢o, $00 = a= [| (20) ‘The transverse top land tooth thickness at the outside diameter, 40, is: ie 4d, zeigt ints - ino] (21) ‘The helix angle at the outside diameter of the gear, Yo. wo (22) “The normal tooth thickness at the outside diameter of a helical extemal gear, or normal top land, 9, i: ho =40 608 Yo (23) 5.5.5 Transverse fillet form ‘The form of the fillet in the transverse plane can be found by graphically reproducing the generating action of the transverse section of the helical basic rack. The analytical method is beyond the scope of this document. 5.6 Derived gear data for internal helical gears 5.6.1 Inside diameter, dy See 5.3.1, 5.6.2 Root diameter, de See5.3.2, 5.6.3 Form diameter, dr See5.3.3. Normal inside tip land ‘The transverse pressure angle at the inside diameter of a helical gear, dy, is: 4 eu o=[$] ~f24) ‘The transverse inside tip land at he inside diameter, wis [zig inv by] 08) ‘The helix angle at the inside diameter of the gear, wy, Ho [49] 05) 10 AMERICAN NATIONAL STANDARD ‘The normal tooth thickness at the inside diameter of the helical internal gear, or normal inside tip land, t,, is: f= hy COS Wy wl27) 5.6.5 Fillet form See 5.3.5. 5.7 Gear data derived from basic rack with tip relief modification ‘The generated gear tooth outline is changed by the ‘type of basic rack tip relief modification described in 4.3.1 and ilustrated in figure 2. Annex D gives the ‘method for calculating the location and size of the outline change caused by such a modified basic rack. 5.8 Gear data not derived from basic rack ‘There are some details of the gear tooth outline that are not always derived from the basic rack. These require their own separate specifications and are not to be considered as changes in the basic rack. 5.8.1 Diameter modifications 5.8.1.1 Outside diameter There are some design reasons for making the outside diameter of a gear slightly different from the value determined by the design tooth thickness and the basic rack. For example, a small increase in ‘outside diameter might significantly improve the ‘gear mesh contact ratio without causing interference at the root ofthe mating gear. Also, a small decrease ‘might be necessary to permit part assembly through a ‘restricted opening. Sometimes a substantial decrease is necessary in the case of pinions with small numbers of teeth and enlarged tooth thick- esses. In these pinions, the outside diameter determined by the basic rack would correspond to top lands that are too small, or even non-existent. This condition is discussed more fully in C.2. 5.8.1.2 Inside diameter ‘There are also design reasons for making the inside diameters of internal gears different from the basic rack defined values. Some are similar in nature to those that apply to outside diameters. A very important additional reason relates to the possibility of interference between the tooth tips of the mating pinion and the tooth tips of the internal gear. This interference would appear at the teeth adjacent to those in full engagement, either during assembly of the pinion into the internal gear or, in some cases, even when rotation is attempted in a fully assembled gear set. This condition is most likely when the pinion and gear are not sufficiently different in numbers of teeth. An increase in the STD-AGMA 1ODb-A-ENGL 1997 MM 087575 OO0S327 O08 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD inside diameter is often enough to eliminate the interference. 5.8.1.3 Root diameter ‘A change in root diameter from the value defined by the design tooth thickness and the basic rack is, generally considered as a change in the basic rack ‘The one possible exception arises in some intemal gears. In this exception, at the root (major) diameter ‘calculated using the basic rack data, the width of the ‘space between the teeth is too small or nonexistent. ‘This condition can generally be corrected by a slight reduction in root diameter. The root clearance in the mesh will also be reduced, but generally not enough to require a change in the outside diameter of the mating pinion 5.8.2 Tip reliet The tip relief, or other involute profile modification, is often not defined by specifying modifications to the basic racks. Instead, a separate profile specifica tion is used. See ANS/AGMA 2000-A88, Gear Classification and Inspection Handbook. 5.8.3 Tip rounding ‘The round at the tip of the teeth is independent of the basic rack and requires a separate specification This s usually in the form of a maximum permitted tip radius. An overly generous radius, introduced into molded gears by the cavity manufacturing process, can significantly reduce the effective engagement in very fine pitch gears. Tooth outline features introduced by tip rounding on external gears are shown in figure § and described below: = The top land, 1p, is reduced to the “remaining top land’, top = The outside diameter, do, is replaced by the “effective outside diameter”, doe. in determining the extent of engagement with a mating gear; = The tooth thickness at the outermost part of the involute profile is increased to the “effective top land’, oe Equations for the calculation of these outline fea- tures are provided below. These relatively simple equations give approximate results sufficiently accurate for typical applications of tip rounding. 5.8.3.1 Remaining top land for spur gears. See 5.2.4 for y and do The remaining top land with tip rounding, to, is: ‘on™ to ~2rr tan[0.5(90" ~ do] (28) ANSVAGMA 1006-A97 where rr istip radius. Figure 5 - Tooth outline features introduced by tip rounding on external gears 5.8.3.2 Effective outside diameter for spur gears ‘The effective outside diameter for spur gears, dog, is: dog * do ~2rr (1 -sin G0) (29) 5.8.3.3 Effective top land for spur gears The effective top land for spur gears, tor, is: ‘08 ton + 2rr 208 $0 (30) 5.8.3.4 Remaining top land for helical gears See 5.5.4 for G0, Wo. and 10. The normal pressure angle at the outside diameter of a helical external gear, qo, is: ho = tan“ [tan d40 cos Yo] (81) ‘The remaining normal top land with tip rounding, ‘on. Is for ® to ~2rr tanl0.5(90° 5.8.3.5 Effective outside gears ‘The effective outside diameter for helical gears, dor, is: dog © do - 2rz (1 ~ sin dro) 5.8.3.6 Effective normal top land forhi ‘The effective normal top land for helical gears, 0c. is: Moe ® toon + 2r7 608 x0 (84) " STD-AGMA LOOG-A-ENGL 1997 MM Ob87575 0005328 THY mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-A97 AMERICAN NATIONAL STANDARD (This page is intentionally blank) 2 STD-AGMA LODb-A-ENGL 1997 MM 0687575 0005329 980 om Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD ‘ANSVAGMA 1006-AS7 ‘Annex A (informative) Basic rack description and application {The foreword, footnotes, and annexes, if any, are provided for informational purposes only and should not be construed as a part of ANSVAGMA 1006-A97, Tooth Proportions for Plastic Gears.) AA General description ‘The concept of the basic rack is a useful aid in defining gear tooth proportions. It consists of a dimensioned outline ot arack tooth form, an example of whichis shown in figure A.1. Itis closely related to, but not identical to, the generating rack that might be used to shape the intended external gear tooth form. Like the generating rack, it defines this gear tooth outline by the shape enclosed by successive posi- tions of the rack outline as it is rolled about a generating pitch circle on the external gear (see figure A.2). The identification of the addendum and dedendum on the basic rack, asin figure A.1, relates the basic rack directly to the generated gear. This relationship is shown in figure A3. if a rack gear were to be machined by the rack-shaped tool, its outline would be identicalto the basic rack, as shown in figure A.4. A2 Applic ‘A properly designed basic rack is typically used to @) define a complete system of compatible gearing, Over @ wide range of design conditions, all gears conforming to this basic rack will un together in the desired fashion. This will be true for external and rack gears and, with some modifications, also for internal gears. A3 Features AA typical basic rack is shown in figure A1. As with ‘most basic racks, including the Standard Basic Rack {or Plastic Gears defined in clause 4, it consists of a ‘combination of connected straight-line and circular arc segments. Individual features are labelled in the figure and listed in A3.1 and A3.2 below. Where needed, explanatory comments are supplied Dimensional features are accompanied by symbols. Most of these symbols contain the characters “BR in the subsoripts to distinguish them trom symbols used for similar, but not always identical, features on the generated gears. This subscriptis omitted on the symbol used for the profile angle. |— Profle angle ‘Addendum (eae) “on? Whole depth teen) ne (gn) | dedendum Dedendum (Orpa) ” NUoaaess Crearance (an) Tooth C) thickness ete SPace width | (cn) od Girevarpiten (aa) Figure A.1 - Example of basic rack 18 STD-AGNHA LOOL-A-ENGL L957 MM 0b87575 0005330 bT2 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-A97 AMERICAN NATIONAL STANDARD Basic rack circular pitch se) Standard pitch circle of gear Gear circular pitch (p) Figure A.2 ~ Defining action of the basic rack “Topping tool 'Non-topping too! (gear blank outside (also generates outside diameter) ‘diameter unchanged) Rack-shaped x ‘generating too! Dedendum (67) ‘Addendum (ar) Basic rack ‘Addendum (aga) Dedendum (bs) ‘Addendum a) Dedendum (6) Figure A.3 - Basic rack in relationship to generated gear and rack-shaped generating tool 14 STD-AGMA LOOb-A-ENGL L957 Ml 087575 0005331 539 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD Rack tool (non-topping) Basic rack Rack gear ‘ANSVAGMA 1006-AS7 —— a ‘Addendum (ar) Dedendum (be) pate ‘Addendum (a) Dedendum (b) Figure A.4 - Basic rack in relationship to rack gear and rack tool A3.1 Primary features ‘These features are the minimum needed to ‘completely define this typical basic rack: ~ _Pitchline. This ine is parallel to the tips of the rack teeth, Several features are located relative to the pitch line. ‘The tooth thickness and space width dimensions are measured along this line. The pitch line is generally located where the tooth thickness is exactly equal to the space width Profile angle, ¢. This term is now preferred ‘over the traditional and still widely used term of “pressure angle” when applied to the slope of the flank of basic racks and other types of involute gear generating geometries. The term “pressure angle” is now to be used only for its other applica- tions, such as in “operating pressure angle”. See ANSI/AGMA 1012-F90. = Circular pitch, ppg. The use of the “circular” designation for this straight-line dimension derives from its connection to the matching dis- tance along the generating pitch circle of the gear. The circular pitch is related to the commonly specified diametral pitch by the following ‘equation: (AA) = Tooth thickness, ise; Addendum, asi = Whole depth, ear: = Fillet radius, roe 32 Secondary features ‘These dimensional features can be derived from ‘some combination of primary features: = Dedendum, bar. Po = hon ~a6n (A2) = Working depth, hse se = 2ane ~(A3) - Clearance, cpp. on = bor ~a6n (a4) = Form dedendum, bpp. This is the distance from the pitch line to the point of fillet radius tangency to the straight-sided flank. beer = bar ~ "pp (1 - sino) (AS) 15 STD-AGHA LODL-A-ENGL 19597 MM Ob87575 0005332 475 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSV/AGMA 1006-A97 Space width, sge. This is the distance along the pitch line in the space between adjacent teeth, Sar = Par ‘oR (A8) = Maximum or “full-round"filetradius, ran. In some basic racks, such as the Standard Basic Rack for Plastic Gears defined in clause 4, the fi let radius has its maximum possible size. This makes the twofletradilin each basic rack deden- ‘dum area combine into one continuous, of “full round”, circular arc. = Sag 0080 — pp sing par = 2(1 ~ sing) “An ‘AA Transfer of outline features Each portion of the basic rack defines some portion of the generated gear tooth outline, as shown figure A.5. The straight-sided flank of the basic rack defines the involute profiles ofthe external gear. The straight top and bottom lands on the basic rack define the corresponding lands on the gear's outside and root circles. Finally, the fillet radius defines the trochoid-shapedfillet on the gear profile. Ifthe basic rack fillet is a “full round’ filet, then the distances D-E and d-e become zero. AS Application to generating tooling Although the basic rack is defined in terms of its Telationship to the generated gear, many of its features are directly or indirectly transferable to the generating tool. AMERICAN NATIONAL STANDARD A5.1 Rack-shaped tooling ‘The hob or other rack-shaped tooling receives the features corresponding to the inverse or “other- side” of the basic rack outline. See figure A3. The dedendum of the basic rack becomes the addendum of the tool. In topping hobs, the addendum of the basic rack becomes the dedendum of the tool. (in rnon-topping hobs, the tool dedendum is larger than Indicated by the basic rack.) The basic rack space- width becomes the tool tooth-thickness. Finally, the basic rack fillet radius becomes the tooltip radius. ‘A52 Gear-shaped tooling ‘The shaper cutter receives the features very similar to those that would be generated in the cutter by the inverse of the basicrack outline. See figure A. Ina topping tool, the whole depth would match that of the basic rack. (In a non-topping tool, it would be greater.) The tooth-thickness and addendum of the cutter would depend on other cutter design consider- ations, but the relationship between the two wouldbe determined by the relationship between the space- ‘width and dedendum of the basic rack. One feature of the basic rack, its filet radius, is not necessarily transferred to the shaper cutter. While the tool tip radius might be made the same as the basic rack filet radius in some cases, the tool tip radius must be made smaller when the basic rack has a full-round radius Outline Feature ‘on Basic Rack ‘on Gear Profile ‘Top land ‘A-B (Straight) a-b (Circular aro-convex) Flank B-C (Straight) bec (nvolute) Fillet radius C-D (Circular arc) ¢-d (Trochoid) Bottom land D-E (Straight) d-e (Circular arc-convex) Figure A.5 - Relationship between outline features of basic rack and gear profile 16 STD-AGMA LOQb-A-ENGL L597 MM 0667575 OO0S333 301 a Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD ‘Topping too} Gear generating tool Basic rack Generated gear ‘ANSVAGMA 1006-97 ‘Addendum (a7) Addendum (apa) Dedendum (bar) Dedendum (4) Figure A.6 - Basic rack in relationship to generated gear and gear generating tool A6 Application to mold tooling The basic rack is also applied in determining the shape of the mold cavity. First, it must be expanded to allow for shrinkage of the molded gear. Where shrinkage is anticipated to be uniform in all drec- tions, all the basic rack dimensions, but not the angles, are enlarged by the proper ratio. The correct cavity shapes then defined by the generating action of this enlarged basic rack. Some aspects of the cavity making process may require slight modifica- tions to this basic rack generated shape, especially in the filet and tip round areas, ‘A7 Application to defining gear proportions ‘The basic rack is used to define gear tooth propor- tions in all types of spur and helical gears. After the tooth thickness of the gear is established, the basic rack or, for internal gears, a derivative of the basic rack, is used in a generating fashion to define the ‘major features of the gear tooth. Further details are given in clause 5. A771 Spur external gears In this generating process, the basic rack, exactly as defined, is rolled on the extemal gear, with the generating pitch line on the rack contacting the generating pitch citcle on the extemal gear, as shown in figure A.7. The generating pitch circle on the gear is determined by the number of teeth and the circular pitch. Its identical to the standard pitch citcle. The generating pitch line is located on the rack where the space width along ths line is equal to the gear's specified circular tooth thickness. The generating pitch line does not always lie exactly on the standard pitch ine of the basic rack. When itis cise, the profile of the gear is sometimes called an “offset profile" ora “shitied profile” and the amount of offset is called the “rack ose” 7 STD-AGMA LOOb-A-ENGL 19597 MM 0687575 0005334 248 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSVAGMA 1006-A97 AMERICAN NATIONAL STANDARD }+— Basic rack circular pitch (pga) Basic rack tooth thickness ‘along generating pitch line Basic rack tooth thickness at standard pitch line (wr) Basic rack standard pitchline Basic rack Rack shift generating pitchline o Gear generating pitch circle thickness (i) Gear circular pitch (p) Figure A.7 - Rack shift offset in basic rack generating action The value ofthe rack offset affects not only the radial position of the offset profile but also its shape, as shown in figure A.8. The change in shape is most marked in gears of low number of teeth. In such gears, low values of basic rack offset, and especially negative values, can resuitin undercut tooth shapes (see B.1.6). High values can result in tooth outlines that come to a point (see B.2). Note also that the shape of the filet can change with basic rack offset, generally becoming sharper with increase offset. With very high numbers of teeth, these shape changes are minimal. Number of teeth ‘Tooth thickness Rack shift (for Py = 1) N= 1 y Figure A.8 - Tooth shapes generated by a single basic rack 18 STD-AGNA LOOb-A-ENGL 1997 MM OL87575 0005335 Lay mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD A72 Spur internal gears ‘Since a rack cannot be rolled inside of an internal gear, many of the features of the basic rack must be transferred to a pinion to perform the generating action. This pinion, essentially the same as the ‘gear-shaped tool described in A.5.2, rolls with contacting generating circles as shown in figure A.8. ‘These generating pitch circles are determined by the mesh ratio and the generating center distance which, in turn, are determined by the tooth thick- nesses of the pinion and internal geat. They will not necessarily coincide with the standard pitch circles. This indirect process will generate involute tooth forms and transfer many ofthe basic rack features to the intemal gear. The exact size and shape of the generated internal gear's root fillet willdepend on the sizes of the generating pitch circles and the choice of the tip radius on the generating pinion. When itis preferable to have the maximum fillet radius in the Inside (minor) diameter, dy Tool generating pitch circle Gear generating, x Internal pitch circle gear (non-topping) ANSVAGMA 1006-A97 root area of the internal gear, the tip radius of the generating pinion is made a full radius. A7.3 Spur rack gears ‘The tooth proportions of the spur rack gear are identical o those of the basic rack, as shown in figure AA A7.4 Helical gears ‘The same basic rack can be applied to helical gears by placing the rack in the “normal plane" instead of in the “transverse plane”. This can be visualized by reference to a three-dimensional helical rack gear, as shown in figure A.10. This concept can be extended to helical external gears by picturing the generating rack as such a helical rack, with its “helix angle” made the same as that of the specified helical gear, The cross-section of this helical rack in the plane perpencicular to the tooth surfaces would constitute the basic rack. For helical intemal gears, the concept of an intermediate generating pinion is needed, but in this case a helical pinion. Root (major) diameter, de Tooth thickness | at generating pitch circle “Relationship to basic rack shown in figure A.6. Figure A.9 ~ Internal gear generating 19 STD-AGMA LOOb-A-ENGL 1997 MM 087575 0005336 O10 a Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005ANSV/AGMA 1006-A97 AMERICAN NATIONAL STANDARD Transverse plane Transverse profile angle x CF Vv \ Le Se Normal plane Figure A.10 - Basic rack in a helical rack form Basic rack (in normal plane) 20 STD-AGMA LOQb-A-ENGL 1997 MM 0687575 O0OS337 57 mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD ANSVAGMA 1006-AS7 Annex B {intormative) Experimental basic racks for plastic gears [The foreword, footnotes, and annexes, if any, are provided for informational purposes only and should not be ‘construed as a part of ANSVAGMA 1006-A97, Tooth Proportions for Plastic Gears.) B.1 Applications for extended depths of engagement In the design of gear tooth proportions, there are ctten two competing requirements. On one hand, the combined tooth thicknesses must be small ‘enough so that there is no interference between teeth under the tightest conditions imposed by ‘manufacturing variations and operating tempera- tures. (A high operating temperature often results in ‘greater thermal expansion of the plastic gears than cf the housing which locates the gear centers. The ‘smaller expansion of the housing may be due to its tower material expansion property or duetoits lower temperature.) On the other hand, the smaller tooth thicknesses noted above mean smaller outside diameters (on extemal gears). This contributes to @ reduced engagement under the loosest assembly and oper- ating conditions. The resulting loss in contact ratio may be too much for successful gear action. This crtical condition is most likely to occur with the finer pitches and the smaller numbers of teeth. A design option to help overcome this problem, without requiring tighter tolerances, is to change to a basic rack which permits greater engagement. In etfect, this means greater outside diameters and corre- spondingly smaller root diameters in external gears. This option may not solve all such design problems, butt has proven to be useful in enough applications to suggest the need for standard basic racks with this feature. B2 Experimental basic racks ‘This annex describes a family of three basic racks, each generally similar to the AGMA PT, but with increasingly greater working depths. They are ‘shown in figure B.1 and the data are listed in table B.1. These basic racks are experimental in the sense that they are not part of the standard but the descriptions are available for those that wish to use them. if any of these basic racks finds general acceptance, it could be changed from experimental to standard in a future revision of this standard, B.2 Tooth thickness enlargement to avoid undercutting ‘The experimental basic racks of table B.1 each have different form dedendums than those of the basic racks of table 2. Therefore, the tooth thickness ‘eniargement to avoid undercut with any of these table B.1 basic racks willbe different than the value developed for any of those table 2 basic racks. See D16. Table B.1 - Experimental basic racks (based on unit pitch) Basic rack feature ‘AGMA XPT-2 ‘AGMA XPT-3 AGMA XPT-4 Profile angle, @ 20 deg. 20 deg 20 deg, Circular pitch, pee 3.14160 3.14160 3.14160 Tooth thickness, tar 1.57080 1.87080 1.87080 Addendum, ape 1.15000 1.25000 1.95000 Whole depth, ise 2.63000 2.83000 3.03000 Fillet radius, ran 0.35236 0.30038 0.24840 Dedendum, bgp 1.48000 1.58000 1.68000 Working depth, hse 2.90000 2.50000 2.70000 Clearance, cap 0.33000 0.33000 0.33000 Form dedendum, érap 1.24816 1.98236 1.51656 Space width, soe 1.57080 1.57080 1.57080 CAUTION: Do not mesh gears whose tooth proportions are derived from the AGMA PT Basic Rack with gears derived from any of these experimental basic racks. Also, donot mesh gears derived from two different experimental racks. The likely resuit will be interference between the tooth tip of ene gear and the root of another. 2 STD-AGHA LOQb-A-ENGL 1597 MM 0687575 OO0S338 993 me Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005‘ANSVAGMA 1006-A97 AMERICAN NATIONAL STANDARD 1.35 AGMA XPT-4 AGMA XPT-3 >} 20 1.15 1.248 he 35296 AGMA XPT-2 ~ Experimental basic racks 22 STD-AGMA LOOb-A-ENGL 1997 MM Ob87575 0005339 B27 i Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005AMERICAN NATIONAL STANDARD ‘ANSVAGMA 1008-A97 Annex C (informative) Determination of tooth thickness and other design variable: {The foreword, footnotes, and annexes, it any, are provided for informational purposes only and should not be construed as a part of ANSIAGMA 1006-A97, Tooth Proportions for Plastic Gears.) This annex discusses some of the design consider- ations that go into the determination ofthe gear tooth thickness. For tooth forms generated by basic rack, the design tooth thickness and other primary gear data, together with the basic rack data, will define most of the other tooth proportions (see clause §). In certain cases, the defined outside diameter will require modification. The modification for the case of enlarged pinions is discussed in detail. NOTE: The tooth thickness and diameter data presented here are not parts ofthe standard. This in: formation is provided toillustrate how some pariscfthe total gear design process connect to the basic rack concept. This annex does not impose any standard rules or procedures for the design and manufacture of plastic gears €.1 Determination of tooth thickness There are many different, and often competing, factors to be considered in determining the tooth thicknesses of a set of mating gears. C.1.1 So-called standard tooth thickness and center distance ‘There Is a widespread, mistaken concept about a “standard tooth thickness”. Unlike the case with other kinds of mechanical components, ike screws and nuts, theres ne industry standard forthe precise dimensions of gears or the center distances at which they must operate. This is true for stock gears, as discussed in C.1.3, and even more so for custom molded plastic gears. The tem “standard tooth thickness", when it is used, refers to a thickness equal to one-half the circular pitch. The term “standard center distance’ refers to a distance equal toone-halfthe sum (for a set of external gears) ofthe two standard pitch diameters. However, a set of ‘gears made to precisely those tooth thicknesses and mounted at precisely that center distance would, most likely, not operate properly. Nevertheless, these “standard” dimensions are offen useful, but only as starting values in a design process that introduces various adjustments and modifications. €.1.2 Tooth thinning The precise specified tooth thicknesses for two mating gears to operate at a spacified center distance must take into account various manufacturing and operating considerations, such as: = runout and out-of-round of the individual gears; = imperfectly shaped or spaced gear teeth; = required minimum backlash; = _telative size changes due to thermal expan- sion during operation (in the form of more rapid heating and expansion of the gears relative to the housing ot to the greater expansion rate of the Plastic gears as compared to a metal housing when the assembly is subjected to a large temperature range); = with some plastics, other expansion due to environmental conditions, such as_moisture absorbtion; ~ _ manutacturing variations that produce tighter center distances. Itis common practice to make allowance for allthese ‘conditions by thinning, that is, reducing the starting values of tooth thickness, of one or both of the gears, while maintaining the starting nominal value of center distance. Less commonly, the allowance is provided by changing the nominal center distance €.1.3 Tooth thickness in stock gears When gears are sold as stock, off-the-shelf components, some degree of standardization is Tequired. Such gears are expected to operate Properly when mounted at the referenced center distance. Furthermore, interchangeabilty between gears from different sources is needed. Common practice is to use the “standard tooth thickness" as the starting values for tooth thickness, the “standard center distance” as the referenced center distance, and to thin the teeth of each gear to allow for some, but not necessarily all, of the conditions listed in C.1.2. The resultis that each tooth thickness is made close to, but somewhat smaller than, the “standard” values. Very often, custom molded plastic gears are ex- pected to perform in the same way as the stock gears STD-AGMA LOGb-A-ENGL L447 MM ObA7S7S OOOS340 S¥L mm Copyrighl by the American Ceor Manufolurers Association Sa Jun 25 1022308 2005