Worm Measurement

Program to measure Worms and evaluate and output

the results

User's Manual v3.5

 Worm Measurement Contents

1 Worm Measurement Contents

1 Worm Measurement Contents ........................................ 2
2 General Information ......................................................... 4
3 Performances and Features ............................................ 5
3.1 Integration in GEOPAK ............................................................ 5
3.2 CMM and GEARPAK................................................................. 5
3.3 User-Friendly Operation........................................................... 5

4 Setting Up ......................................................................... 6
5 Gear Type Selection......................................................... 7
6 Main Window Worm Measurement ................................. 8
7 Delete GEARPAK Data..................................................... 9
8 Nominal Geometries ...................................................... 10
8.1 Input of General Worm Data .................................................. 10
8.2 Automatic Calculation of Worm Data.................................... 10

9 Measurement Conditions .............................................. 12

9.1 Probe and Rotary Table ......................................................... 12
9.2 CNC Parameters ..................................................................... 13
9.3 Changing CNC Parameters .................................................... 14
9.4 Scan Worms ............................................................................ 15
9.5 Parameters of Scanning Measurement................................. 15
9.6 Input of the Measurement Conditions .................................. 16
9.7 Alignment Parameters............................................................ 19
9.8 Parameters of the Topographic Measurement..................... 20
9.9 Corrections.............................................................................. 20

10 Tolerances ...................................................................... 23
10.1 Tolerance System and Tolerance Classes ........................... 23
10.2 Tolerance Systems ................................................................. 24
10.2.1 DIN Tolerance System........................................................... 24
10.2.2 AGMA Tolerance System ...................................................... 24
10.3 Profile Tolerances................................................................... 24
10.4 Flank Line Tolerance .............................................................. 25

2 v3.5 12.04.13
Worm Measurement Contents

10.5 Tolerance for Pitch and Tooth Thickness ............................. 25

11 Report Output ................................................................. 27

11.1 Settings of the Numerical Report .......................................... 27
11.2 Settings of the Graphical Report ........................................... 28
11.3 Report Settings ....................................................................... 30
11.4 Measuring and Evaluation Ranges in Numbers ................... 31
11.5 Example and Variable Names of the Export File .................. 32
11.6 Filter for Scanning Measurement .......................................... 34

12 Measurement of a Worm................................................ 36
12.1 Dynamic Probe Selection ....................................................... 36
12.2 Static Probe Selection ............................................................ 36
12.3 Align Co-ordinate System of Worm....................................... 37
12.4 Example of Fixing a Position of a Part .................................. 37
12.5 Create a Measurement Course............................................... 39
12.6 Measurement of Toothed Gears ............................................ 39
12.7 Element Toothed Gear ............................................................ 40

12.04.13 v3.5 3
 General Information

2 General Information
Copyright (c) 2012 Mitutoyo
With GEARPAK, it is possible to measure and evaluate all types of involute
toothed gears. Those are
 Cylindrical gears
 Sectors
 Worms
 Bevel gears
 Hypoid gears
Neuss, April 2012
Mitutoyo Europe GmbH
Borsigstraße 8 - 10
D - 41469 Neuss
Phone: +0049 (21 37) 10 2 - 0
Fax: +0049 (21 37) 86 85
E-mail:info@Mitutoyo.eu
The program itself as well as this online help are copyrighted. It is not allowed to
copy or use them for other purposes. The rights are exclusively to the company
Mitutoyo Europe GmbH.

4 v3.5 12.04.13
Performances and Features

3 Performances and Features

3.1 Integration in GEOPAK
GEARPAK is a component of GEOPAK. GEARPAK is responsible for the toothed
gear specific tasks such as creating part programs, evaluation and creating a
report. The real measurement is done by GEOPAK.

3.2 CMM and GEARPAK

You can use GEARPAK, being a component of GEOPAK, with a co-ordinate
measurement machine (CMM). The combination of software and co-ordinate
measurement machine makes that the acquisition of an expensive tooth system
measuring device is superfluous because it can only be used for these purposes.

3.3 User-Friendly Operation

The GEARPAK input assistant (wizard) is guiding you through the input
dialogues. Only the dialogues and alternatives that are really needed for your
toothed gear will be shown. The other options will be deactivated. Thus,
GEARPAK increases the clarity of the data input.
By means of the input assistant, you may create a part program for a toothed
gear without problems and without much time used.

12.04.13 v3.5 5
 Setting Up

4 Setting Up
Use the GEARPAK defaults to adapt GEARPAK to your measurement tasks to
save input time and prevent input errors when entering parameters.
Use the GEARPAK settings mode for inputs of gear data with similar parameters,
like for example module, tooth number or tolerances.
 Click in the PartManager on "Settings /Defaults for programs".
 Click in the dialogue window "Settings" on the button "GEARPAK".
 Adjust in the dialogue window “Gear type selection” the appropriate
kind of gear type.
 GEARPAK is started in the "Settings" mode.
 Enter the required parameters in the GEARPAK input fields.
You find all parameters you have entered in the default mode upon the next start
of GEARPAK as a proposal in the relevant input fields.

You can define the defaults separately for each gear type (cylindrical gear,
worm).

Probe Coordination
In the GEARPAK settings wizard, you determine whether you want to use the
dynamic probe coordination of GEARPAK or the former static of INVOLUTE
(the probes 1 to 50 are determined).

This setting can only be realised in the settings wizard under

"Measurement Conditions / Probe and Rotary Table".

6 v3.5 12.04.13
Gear Type Selection

5 Gear Type Selection

This window is not shown unless you are working a part with no gear data in the
PartManager. This is the case when
 you have created a new part in the PartManager,
 you use a part with no gear symbol
Every gear type requires different inputs.
 Therefore choose the gear type you want to measure later.
 Presently, gear types shown as inactive are not supported or have
not been bought by the customer.
 Confirm your selection.
 The GEARPAK main window is displayed.
 Enter your gear data based on the gear type selected.

12.04.13 v3.5 7
 Main Window Worm Measurement

6 Main Window Worm Measurement

The object of entering the worm data is to capture the nominal worm geometry.
"GEARPAK-Worm" creates an automatic measuring cycle based on the worm
data.
The measurement itself is performed by GEOPAK.
The "GEARPAK-Worm" main window is the starting point for all worm
measurement input dialogues.
 First create a new part in PartManager.
 To start worm measurement in PartManager, you either

 mouse-click into the "Prepare Gear Measurement" symbol,

 or double-click on the button "GEARPAK" of the , part list or via
 the menu bar "CMM" on "GEARPAK / Prepare Gear Measurement".

Data should be entered with utmost care. Any mistake made when
entering worm parameters prevents a correct measuring cycle.

Settings mode
If you enter gear wheel data with same parameters as e.g. module, number of
teeth or tolerances, you can use the GEARPAK settings mode. Further
information you will find in the topic "Setting Up".
The various input dialogues are accessed via the buttons
 Nominal Gear Geometry
Clicking on this button causes the "Worm Parameter" window to
open. Here you enter the worm data taken from the data table of the
technical drawing.
 Measurement Conditions
Clicking on this button causes the "Probe and Rotary Table" window
to open. Here you determine how you want the part to be measured.
 Tolerance
Clicking on this button causes the "Tolerance System" window to
open. In the "Tolerance System" dialogue window and all following
dialogue windows, all required tolerances will be queried, or
calculated and proposed by "GEARPAK-Worm".
 Output
Clicking on this button causes the "Numerical Report" window to
open. In the following windows you determine how you want the
results of the nominal-to-actual comparison of worm measurement
to be output.

Data can be entered in any order in the four input dialogues.

Exception: Prior to defining the tolerances, you have to enter the gear
data.

Further information you will find in the topic "Creation of a Measurement Course".

8 v3.5 12.04.13
Delete GEARPAK Data

7 Delete GEARPAK Data

To delete gear data which are no longer required, proceed as follows:
 Mark a part in the PartManager that contains gear data.
 Parts containing gear data can be identified by the gear symbol.
 Start GEARPAK.
 Click in the menu bar on "File / Delete Data".
 Confirm the safety question with "Yes".
 Only the GEARPAK specific data (all entries and settings of
GEARPAK) is deleted. The part programs included in the part
concerned are not deleted.

12.04.13 v3.5 9
 Nominal Geometries

8 Nominal Geometries
8.1 Input of General Worm Data
To enter worm data, click on the "Nominal gear geometry" button in the main
window "GEARPAK-Worm". For the worm data refer to the data table of the
technical drawing.
In this dialogue you enter the basic parameters of your worm data.
 Length unit
 Worm type
 Number of teeth
 Axial module
 Pressure angle
Enter the normal pressure angle into the "Pressure Angle" input box.
 Addendum modification coefficient
 Lead angle direction
 Reference lead angle
 Tip and root diameter
 Reference Diameter
 Length of worm
The length of worm is the axial distance between the end faces of
the worm gear teeth.
 Usable Ranges

Make sure that you enter the addendum modification coefficient. Many
technical drawings specify addendum modification in place of addendum
modification coefficient.

The addendum modification coefficient x can be calculated as follows:

x = addendum modification / mn (normal module = mn)
Grinding wheel diameter
The grinding wheel diameter can only be entered when you want to measure a
worm with the flank form K (ZK-worm).
The left part of the dialogue shows a worm in schematic form. The representation
of this worm depends on the input of the number of teeth.
Further information you will find in the topic "automatic calculation of worm data".

8.2 Automatic Calculation of Worm Data

The entries of number of teeth, module, addendum modification coefficient,
reference lead angle and pressure angle have an influence on the input boxes 'tip
and root diameter', ' usable tip and root diameter' and 'reference diameter'. These
input boxes are calculated by GEARPAK and automatically entered.

10 v3.5 12.04.13
Nominal Geometries

As a rule, these automatically calculated values correspond to the

specification shown on the technical drawing. It may happen, however, that
the values calculated by GEARPAK deviate from the values on the gear data
table. In this case you should enter the values of the gear data table into the
respective input boxes.

A different situation: Technical drawing or data sheet do not specify the

usable range.
The usable range restrict the gear measurement evaluation range, since gear
measurement extends over the whole tooth.
Entering the value "0" into the usable root diameter input box causes the base
diameter to be used as usable root diameter.

Is the root diameter bigger than the base diameter, the root diameter is
used as default.

Entering the value "0" into the usable tip diameter input box causes the tip
diameter to be used as usable tip diameter.
Further information you will find in the topic "Input of the general worm data".

12.04.13 v3.5 11
 Measurement Conditions

9 Measurement Conditions
9.1 Probe and Rotary Table
Using this dialogue window you determine whether your are going to use a rotary
table and which probe you will work with. These parameters affect directly the
configuration of your CMM.
The "Probe and Rotary Table" dialogue window is accessed through the main
window "GEARPAK-Worm / Measurement Conditions".
There are four respectively six dialogue windows to input the measurement
conditions:
 Probe and rotary table
 CNC parameter
 Scanning measurement
 Measurement parameters
 Topography parameters
 Corrections

The dialogue window "Scanning measurement" and "Topography

parameters" are only displayed if you decide for this type of measurement or
evaluation.

Probe Information
If you use a rotary table, then you can measure with the "Single Probe".
If you don't use a rotary table, you can measure with the following probes:
 Indexable probe
 Star probe
Prepare topography measurement
For a topographical output of the measurement results,
 activate the option "Use rotary table" by clicking "Yes".
 The function "Scanning measurement" is represented as active.
 Activate the function "Scanning measurement".
 In the following dialogue window "Parameters of scanning
measurement", activate the function "Rotate rotary table during
measurement (only MRT)".

The dialogue window "Parameters of scanning measurement" is only

displayed if you have activated the function "Scanning measurement".

12 v3.5 12.04.13
Measurement Conditions

Define Start Probe

Entering a probe number for the start probe enables you to determine the probe
position from where to start worm measurement. You know already now whether
you align your worm along the X, Y, or Z CMM axes. Using the start probe you
determine the axis alignment in the workpiece position definition. For the Z CMM
axis and the X CMM axis use the probes 2 and 26, for the Y axis the probes 14
and 38.

Make sure that you have set the correct CMM axis under "Alignment" in
the "Measurement" dialogue window.

Stylus Diameter
Enter the nominal value of the stylus diameter into this input box. Together with
the root and tip diameter, the stylus diameter influences the measurement length.

The stylus diameter has to be dimensioned such to allow each

measurement point to be approached without clashing with the part to be
tested.
For the selection of the stylus diameter, keep to the rough formula:
D(probe) > 0.9 normal module.

Reduce Probe Movement

Enter a value into the "Z Position for Probe Change" input box only, when you
use an indexable probe. This helps you reduce probe movement, since new
probe positions can be approached directly, without having to bypass the gear.

The "Z Position Probe Change" has to be located as far above the gear
that collision with the probe tip and the worm are excluded. For the
standard alignment of the co-ordinate system, the Z value has to be
positive.

Angle A Positions of the Indexable Probe

Entering an angle into the input box "Angle A" you define all probes to be
calibrated using the same angle A. To use the entered "Angle A", it is necessary
that you first set "Dynamic Probe Selection" in "Default Settings".

9.2 CNC Parameters

If you want to avoid processing your gear measuring program in the GEOPAK
Editor, you can use GEARPAK to change the CNC parameters:
 Movement speed
 Measurement speed
 Safety distance
 Measurement length
 Positioning distance
 Deflection (Touch trigger)
 Deflection (Scanning)

12.04.13 v3.5 13
 Measurement Conditions

 High precision measurement

This is advisable when your standard measuring tasks require CNC parameters
different from those for gear measurement.
To open the "CNC Parameter" dialogue:
 Activate in the dialogue window "Probe and rotary table" the check
box "Set CNC parameter".

 Click on the "Continue" button.

 Make your changes as described under the topic "Change CNC
Parameters".

Entries you make in the "CNC parameter" dialogue will show up again as
suggestions in the "Scanning parameter" dialogue.

9.3 Changing CNC Parameters

In case you wish to change, during CNC run, the parameters e.g. measurement
speed or movement speed, choose "Machine / CNC Parameters" from the menu
bar.
In the following dialogue box, you can change all settings at the same time.
Releasing/locking text boxes

Click the CMM icon if you wish to enter values for the individual parameters.
The corresponding text boxes are active.

Click this icon if you wish to maintain individual parameters. The

corresponding text boxes are inactive. An accidental input is not possible.
Activating/deactivating CNC functions

Click this icon if you wish to activate/deactivate individual functions of the

CNC parameters.
Characteristic features
For the movement and the measurement speed, you have two specific values.
You can select between the

maximum value or the

default.
Hint
The default value for the measurement speed (probing speed) is the value
able to realise the maximum accuracy. If your part program is determined
to function on different CMMs with different properties, the default setting
is recommended.
Click this icon if you wish to deactivate the static "Retraction length". In this
case after a probe hit the probe retracts to the point where your CMM changed to
the measurement speed and started the probing. The text box of the retraction
length is deactivated.
In the status line of the GEOPAK main window (bottom left) you see, next to the
CMM icon a LED symbol, which shows the status of operation.
Green: CNC mode off

14 v3.5 12.04.13
Measurement Conditions

Yellow: CNC mode on

9.4 Scan Worms

In this operating mode, the measurement points of the worm measurement are
recorded continuously.
This means:
 No individual measurement points are measured and evaluated at a
specific measurement position.
 Measurement takes place from a start point to an end point.
 The probe stays in constant contact with the gear surface during the
complete measurement process.

Worms can only be scanned using a rotary table in combination with the
single probe (e.g. Renishaw™ SP25 probe system).

For scanning worms, activate the check box "Scanning measurement". By

clicking the button "Next", the input dialogue "Parameters of scanning
measurement" opens.
Scanning worms
To scan worms, the following prerequisite must be met:
 To ensure a continuous recording of measurement points for a high
precision worm measurement, it is mandatory that you use the
rotary table type MRT (Mitutoyo rotary table).
Proceed as follows:
 In the dialogue window "Probe and rotary table", activate the
function "Use rotary table".
 In the section "Probe data", activate the function "Scanning
measurement".
 In the dialogue window "Parameters of scanning measurement",
activate the function "Rotate rotary table during measurement (only
MRT)".

9.5 Parameters of Scanning Measurement

The input dialogue "Parameters of scanning measurement" can only be opened
when you are in the operating mode "Scanning measurement". Inputs you have
already made in the dialogue "CNC parameters" are shown as suggestions in this
dialogue.
Specifically for scanning of worms, you can set
 Scanning Speed or Measurement Speed
 Safety Distance
 Deflection
in this dialogue. You can enter different values for profile and flank line.

For the profile measurement, for example, a smaller safety distance is

required. The gear measurement starts at the root diameter. Here, the gaps
between the teeth are very small.

12.04.13 v3.5 15
 Measurement Conditions

Clamp axis
When working with probe systems (e.g. MPP5) which are supporting the function
"Clamp MPP axis", you should activate this function. The function "Clamp MPP
axis" can be separately activated for profile measurement and flank line
measurement respectively. With this you will achieve more accurate
measurement results.
 Activate the check box "Clamp MPP axis".
 The buttons are represented as active.
 Click the button "Clamp Z axis" if the Z axis shall be clamped during
measurement (e.g. for profile measurement).

You can clamp maximum two axes as at least one axis is required for
recording the measurement data.

Do not activate the function when using probe systems (e.g. SP25) that are not
supporting the function "Clamp MPP axis".

The function "Rotate rotary table during measurement (only MRT)" is

already activated as worms can only be scanned when using the MRT
rotary table.

9.6 Input of the Measurement Conditions

The "Measurement Parameters" dialogue window is accessed through the main
window "GEARPAK-Worm / Measurement Conditions / Probe and Rotary Table /
Next".
This is the window to define your measurement strategy.
Workpiece Alignment with MRT
When using the workpiece alignment with the function "Use alignment with MRT",
the measurement and evaluation range is exactly defined. Furthermore, this
alignment facilitates the determination of the workpiece position.
Conditions
For the "Alignment with MRT", the following prerequisites must be met:
 You are using a Mitutoyo rotary table (MRT) and a scanning probe
system.
 The function "Scanning mode" in the dialogue window "Probe and
rotary table" needs to be active.
 In addition, a probe needs to be defined which allows for scanning a
groove point.
 When using the "Alignment with MRT", the plane "Z=0" must be
positioned above the worm.

16 v3.5 12.04.13
Measurement Conditions

The workpiece co-ordinate system depends on the shaft direction of the

probe. The X-axis of the workpiece co-ordinate system must be aligned
opposite to the shaft direction of the probe.

For more information refer to "Alignment Parameters".

Dual Flank Scan
Measurement of the flank line is enhanced by dual flank scan. If you wish to
measure your worm in the "dual flank scan" mode (probe recommendation:
MPP), check the "Flank line" check box. This function is not available unless you
use the "Use alignment with MRT" function (see above "Conditions").

Measurement in dual flank contact

Note
During a measurement in scanning mode the radial runout and the
dimension over rolls can be calculated by dual flank scan only.
Deviations of the flank line are calculated from the measurement points of
the single flank scan.
The dual flank scan gives exact measurement values for radial runout and
dimension over rolls. The calculation of the measurement data during dual
flank scan is comparable to the manual calculation of radial runout or
dimension over rolls (insertion of a measurement piece in the gap).
During calculation of the radial runout and dimension over rolls from
measurement points of the single flank contact, differences to the manual
calculation may occur. Possible reasons are e.g. different measurement
forces, a difference between measurement point and contact point of the
measurement piece and the surface finish.
Single flank scan is carried out by default. The dual flank scan is an
enhancement to the single flank scan and can be selected optionally.

12.04.13 v3.5 17
 Measurement Conditions

Conditions for Dual Flank Scan

The diameter of the measurement piece of the dimension over rolls must be
identical to the diameter in the alignment parameters of the groove point. The
probe used for dual flank scan is also used for groove point measurement.
Presettings for Dual Flank Scan
The GEARPAK presettings can be extended by the input of the "Retraction
distance". The retraction distance is important to avoid collisions with the
workpiece. The probe moves out of the gap in radial direction by the given value.

Input of the retraction distance

This parameter is only available in the settings mode. GEARPAK-Worm
calculates an appropriate retraction distance. In a particular case it may be
necessary to determine the retraction distance individually, e.g. to consider
specific conditions of the workpiece.
It is not necessary to specify the retraction distance for each worm.
Workpiece Alignment without MRT
As a rule, the workpiece axis corresponds to the CMM Z-axis. The worm is in a
"standing" position on the measuring table. Long worms or worms attached to
long shafts are measured in a "lying" position. In this case, the workpiece axis
agrees either with the CMM X-axis or the CMM Z-axis. Choose the worm position
using the radio buttons.

Bear in mind that the workpiece alignment set here is closely linked with
the "Probe Number for First Probe" entered in the dialogue "Probe and
Rotary Table".

Number of Reference Space

If the worm is placed, as shown by way of example in the FIG. below, in the Y-
position on the measuring machine, then you define the position of the X-axis in
the middle thread gap. Here it is the fourth one.

Workpiece axis corresponds to the CMM Y-axis

18 v3.5 12.04.13
Measurement Conditions

1 First gap; 2 Fourth gap

 Count the reference gaps opposite to the CMM axis to which the
workpiece axis is parallely aligned.
 Therefore enter 4 in the "Number of reference space" input box.
 The help graphic highlights the entered gap number.
Gear Geometry
Under gear geometry you determine whether you intend to measure ...
 tooth flanks / pitch; this means that the worm is measured
completely, or
 flanks; this means that only the tooth flanks are measured. Pitch
measurement points are not measured. Evaluations requiring pitch
measurement points cannot be performed.
Flank Measurement
For flank measurement you decide whether you want to enter the measurement
points as
 pitch, or as
 number of measurement points.
The generated profile measurement points are located in the part program
between root diameter and tip diameter. The measurement points for the flank
line are located on the length of worm entered previously.

If you have chosen, for instance, the input mode "Pitch", the number of
measurement point will be calculated in the deactivated input box
"Measurement Points". The information provided enables you to estimate
the time required for worm measurement in the "Pitch" mode. In the
"Measurement Points" mode, the distance of the measurement points
between each other is calculated in the deactivated input box "Pitch".

Topography measurement
If you activate the function "Topography measurement" and you click the button
"Next", the dialogue window "Topography" opens.

The function "Topography measurement" is only activated if you have set a

rotary table (MRT).

For more information, refer to the topic "Probe and Rotary Table, section
"Prepare topography measurement".

9.7 Alignment Parameters

You can only open the "Alignment parameters" dialogue box when the function
"Use alignment with MRT" is enabled.
The parameters for the automatic alignment are entered in the "Alignment
parameters" dialogue box.

12.04.13 v3.5 19
 Measurement Conditions

The automatic alignment uses a "groove point" to determine the Z-position of the
gap. If the actual position of the gap differs from the nominal position, the
required rotary angle is calculated for a new positioning of the gap. After rotating
the rotary table, the position of the gap is again determined using a "groove
point". This procedure is repeated until the nominal position is reached.
The rotary angle is calculated from the current Z-position of the groove point and
the input parameters of the worm.
Start of facewidth
Enter the distance to the plane Z=0. With this value you determine where the
tooth width of the worm begins.
Probe for groove point
 Diameter
Use the diameter of the dimension over balls.
 Number
This probe requires a probe diameter with which a dual flank
positioning in the tooth gap is possible.
 Deflection
In order to avoid an error during the alignment of the MRT while
taking a point with dual flank contact, you can enter a separate
value for the "Deflection". This value is not in the CNC parameters.
With the function "Use high precision measurement" the CMM is
moved with low movement speed. Select this function if it is required
for "Use alignment with MRT".
Co-ordinate system
In the text box "Free number" enter a co-ordinate system number which can be
overwritten during worm measurement. This number may not be identical to the
co-ordinate system number you are using for the manual prealignment.

9.8 Parameters of the Topographic Measurement

In this dialogue window you define the number of profile and flank line sections
according to the instructions of the measurement specifications or the technical
drawing for the topography measurement.
Furthermore, you can define the sections for the topography measurement.
Restrictions:
To obtain meaningful measurement results, enter at least two sections.
If you enter for the profile measurement a "0" into the input field "Number of
sections", you will only get a topographical evaluation of the flank line.

The sections of the topography measurement should be within the

Evaluation range of the worms.

9.9 Corrections
The dialogue window "Corrections" is accessed through the main window
"GEARPAK-Worm / Measurement Conditions / Next / Dialogue window Probe
and Rotary Table / Next / Dialogue window Measurement Parameters / Next".

20 v3.5 12.04.13
Measurement Conditions

Entries in the "Corrections" window are necessary, when you realise, for instance
by measurement, that the worm to be inspected deviates from the nominal
values, or if collisions have occurred during measurement.
The correction values should be located within the range from -1 mm to +1 mm
and not be selected greater.
Corrections to the following worm parameters are possible:
 Root Diameter
If during measurement there is a collision as a result of major
deviations of the nominal root diameter relative the actual root
diameter, then you can correct the root diameter entered previously.
In this case you enter the positive value by which the root diameter
is to be increased.
 Tip Diameter
During measurement, problems may be caused, for instance, by
major deviations of the nominal tip diameters relative to the actual
tip diameter. (Then measurement points of the tooth tip are located
outside the workpiece, the worm is not found by the probe). Correct
the tip diameter by the value between nominal tip diameter and the
effective (measured) tip diameter.

The correction value of the root diameter relates to the diameter of the
worm, i.e. a 1.0 mm correction moves the measurement point by 0.5 mm
towards the tip circle.

 Position Correction Left Hand and Right Hand

If during measurement a collision occurs as a result of major
deviations of tooth thickness, or if the movement range is too large,
then you can correct the flank position. Entering positive values
causes the positions of the measurement points and those of the
intermediate positions to be generated closer to the worm's material
side. Entering negative values increases the distances.
 Perform the flank line measurement on a diameter
Flank line measurement and pitch measurement are performed on
the reference diameter. Measurement problems may occur under
certain conditions, i.e. if the reference diameter of the part is
positioned at or even below the root diameter. Due to the worm
geometry, the reference diameter of the part may likewise be
positioned above the tip diameter. In this case, your measurement
would take place outside the workpiece.
 Activate the button "Flank line measurement on diameter".
 Into the activated input field, enter a diameter that is bigger than the
root diameter and smaller than the tip diameter. If you enter a
diameter outside this range, the colour of the input field changes to
red.
 The diameter input is recorded together with your measurement
results

12.04.13 v3.5 21
 Measurement Conditions

In order for the changes of the position corrections to become effective,

you have to start Repeat mode. This causes your worm part program to be
updated automatically.

The measuring conditions input are now finished. A clear indication is the fact
that the button "Next" is no longer shown as active.
 Click on "Finish".
 Your inputs are saved and the "Corrections" dialogue window is
closed.

22 v3.5 12.04.13
Tolerances

10 Tolerances
10.1 Tolerance System and Tolerance Classes
The "Tolerance System" dialogue window is accessed through the main window
"GEARPAK-Worm / Tolerances".
The required quality of the part to be tested (tolerance mode, tolerance classes
and tolerance modification) is specified in the worm data or in the technical
drawing.
Tolerance Mode

First determine in the "Tolerance System" dialogue window which tolerance

mode you are going to use for the gear, since the "Tolerance Classes" input
boxes depend on the tolerance mode.

Available tolerance mode

 DIN 3974-1
 AGMA 2111-A98 for metric
 AGMA 2011-A98 for inch
Using the function "Calculate tolerances" you can the set tolerances calculated
by "GEARPAK-Worm". The calculated tolerance values are automatically entered
into the input boxes.
Tolerance Classes
 Determine the required quality in the input boxes.
 Take the required tolerance class from the technical drawing or from
the data sheet of the part to be tested.
Calculate Tolerances
When clicking in the dialogue window "Tolerance system" on the button
"Calculate tolerances", in the following dialogue windows all tolerances in the
input fields are calculated and shown.

In the following tolerance dialogue windows, a click on the buttons

"Calculate tolerances" will only effect a calculation of the tolerances of the
opened dialogue window.

Show Limit Values

The function "Near Tolerance Limit" enables you to graphically highlight
measurement values. These are measurement values located within the
tolerance limits.
 To show measurement values located just outside the tolerance
limits, enter a positive deviation in the "Near tolerance limit" input
box.
 To show measurement points located just within the tolerance limits,
enter a negative deviation in the "Near tolerance limit" input box.
These measurement points are marked in the report with a blue dot.
Click on the "Next" button to open the "Profile tolerance" dialogue window.

12.04.13 v3.5 23
 Tolerances

10.2 Tolerance Systems

10.2.1 DIN Tolerance System
The DIN tolerance system comprises 12 gearing qualities. Gearing quality 1 is
the most accurate quality, 12 the most inaccurate one.
The DIN tolerance system consists of three functional groups:
 G Uniformity of motion transmission
 L Smoothness and quietness of running and dynamic load bearing
capacity
 T Static load bearing capacity
Make sure that you enter in the single tolerance input fields from left to right only
the numerical value of the required gearing tolerance.

10.2.2 AGMA Tolerance System

The AGMA (American Gear Manufacturers Association) tolerance system
comprises:
 13 gearing qualities ranging from 3 to 15. The higher the entered
numerical value, the better is the quality of the gear,
 a tooth thickness parameter A to D. The parameter D stands for the
exact tooth thickness, A for an inaccurate tooth thickness,
 the tolerance unit M (millimetres) or I (inches).
 Enter the gearing quality into the first input field.
 Enter into the second input field the tooth thickness parameter, with
no blank, followed by the tolerance unit.

10.3 Profile Tolerances

The dialogue window "Profile Tolerance" is accessed through the main window
GEARPAK-Worm / Tolerances / Dialogue window Tolerance System / Next.
For the "Profile Tolerance" window, we recommend that you make the inputs in
the following order:
First determine the tolerance for:
 the profile form error
 the profile angle error and
 the total profile error,
or accept the tolerances already written in the input boxes. "GEARPAK-Worm"
calculates these tolerances automatically.

24 v3.5 12.04.13
Tolerances

Should you make changes to the tolerances proposed (calculated) by

GEARPAK-Worm, you must in no case operate the "Calculate Tolerances"
button afterwards. Otherwise the values calculated by GEARPAK-Worm
are reinserted into the input boxes. The changes you made will then be
lost.

Click "Next" to come to the "Flank Line Tolerance" window.

10.4 Flank Line Tolerance

The "Flank Line Tolerance" dialogue window is accessed through the main
window GEARPAK-Worm / Tolerances / Tolerance System Dialogue window /
Next / Profile Tolerance Dialogue window / Next.
The permissible deviations are shown in the input boxes. These values were
automatically calculated by "GEARPAK-Worm". They are based on the standards
you have previously specified in the "Tolerance System" dialogue window. These
deviations comprise:
 Form flank line
 Lead error
 Periodical lead error
 Lead angle error
 Total flank line
The deviations are absolute values describing permissible tolerance ranges.
Example
The tolerance for flank line total deviation is the range between the minimum
value of flank line total deviation and the maximum value of flank line total
deviation.

With a click on the button "Calculate tolerances", the acceptable deviations

are recalculated and written into the input fields.

Click on "Next" to get the dialogue window "Pitch, tooth thickness, rolling test".

Should you make changes to the tolerances proposed (calculated) by

"GEARPAK-Worm", you must in no case operate the "Calculate
Tolerances" button afterwards. Otherwise the values calculated by
"GEARPAK-Worm" are reinserted into the input boxes. The changes you
made will then be lost.

10.5 Tolerance for Pitch and Tooth Thickness

The "Pitch, tooth thickness, rolling test" dialogue window is accessed through the
main window GEARPAK-Worm / Tolerances / Dialogue window Tolerance
System / Next / Dialogue window Profile Tolerance / Next / Dialogue window
Flank Line Tolerance / Next.

12.04.13 v3.5 25
 Tolerances

Mode Pitch Evaluation

You choose
 Axis (the testing of working gears as used, e.g., in gearboxes
requires evaluation of the worm axis), or
 Tooth (if the deviations of the alignment element of the worm axis
('worm' 'worm gear') should not be part of the evaluation).
The input boxes under the heading "Mode pitch evaluation", show the permissible
deviations.
You choose
 Adjacent pitch
 Maximum pitch-to-pitch
 Total pitch
Calculate Tolerances

Start the calculation of the tolerances with a click on the button "Calculate
tolerances".

The deviations are absolute values which have been calculated by "GEARPAK-
Worm". The deviations describe permissible tolerance ranges. The tolerance
range for pitch single deviation, for example, is the range between the negative
pitch single deviation and the positive pitch single deviation.

Should you make changes to the tolerances proposed (calculated) by

"GEARPAK-Worm", you must in no case operate the "Calculate
Tolerances" button afterwards. Otherwise the values calculated by
"GEARPAK-Worm" are reinserted into the input boxes. The changes you
made will then be lost.

Tooth Thickness Evaluation Mode

Depending on the selected mode (tooth thickness or dimension over balls) you
enter the required parameters.
For the "dimension over balls" size you enter
 the upper "dimension over balls" size,
 the lower "dimension over balls" size, and
 the used "ball diameter".

Pay attention that in the "Tooth Thickness" mode the deviations of the
tooth thickness must be entered. For the dimension over balls, the
nominal size of the test size with the deviations must be indicated.

The tolerances have now been entered. A clear indication is the fact that the
button "Next" is no longer shown as active.
Click on "Finish". Your inputs are saved and the "Pitch, tooth thickness, rolling
test" dialogue window is closed.

26 v3.5 12.04.13
Report Output

11 Report Output
11.1 Settings of the Numerical Report
If you have clicked on the "Output" button in the main window of GEARPAK the
"Numerical Report" dialogue window will be displayed. Here you define by means
of the check box whether your results are to be read out as a numerical and/or
graphical protocol.
Storage in files
The gear measurement results are saved in files. By means of the radio buttons
"Numerical report first" and "Graphical report first" you define the order in which
to save the results in the result files. Clicking the "On separate pages" radio
button causes the numerical and graphical protocol to be saved in two files.
Contents of the numerical protocol
Using the check box you define the volume of the numerical protocol.

We recommend not to protocol the output of the complete flank

measurement. If you select the "Complete flanks", all measurement points
will be output in the protocol. At a large number of measuring points that
leads too much long tables, which extent over many pages.

Exporting data to GEOPAK

The "Export data" function allows to create a set of variables and to write them
into a file. This file can be used with the GEOPAK part program command "Load
variables from file".
The results of the tolerance comparisons of the exported gear deviations can be
shown in GEOPAK and in the ProtocolManager.
These data can also be used with a statistical program, e.g. MeasurLink.
 Check the "Export data" check box.
 The check boxes of the "Export data" function are activated and can
be used.
 If the nominal values and / or measured values are to be part of the
export file, check the "Nominal values" and / or "Measured values"
check boxes.
 When activating the function "Load variables" the part program
command "Load variables from file" is written into the part program
created by GEARPAK. The nominal values and measured values
are automatically loaded in GEOPAK after gear evaluation.
Decimals and length unit
You can determine the number of decimals for the nominal values and the
measured values. According to the settings in the gear parameters the values are
saved in the length unit mm or inch.
Note
It is recommended to set at least three decimals for the length unit "mm"
and five decimals for "inch".

12.04.13 v3.5 27
 Report Output

File name and directory of data export file

When using the standard settings the data export file is saved to the TEMP
directory of the MSCOSMOS installation.
To change the file name or the directory name use the "File name" text box or
click the "Save as" button.
Possible errors
In some circumstances the creation of a data export file can fail. The error
message "The file for the GEARPAK data export cannot be created" is displayed
on the screen.
 Non-existing directory for the data export file.
 Directory and / or file name is too long. The maximum number of
characters is 255.
 An existing data export file is read-only. Save the export data file
with a different name or undo the write protection.
 Not enough access rights on the file system for the current user.
 The preparations for gear measurement are done on a different
computer than the evaluation.
Layout of the data export file
The GEARPAK data export file (result file) imported by GEOPAK is an ASCII file.
This data export file contains variables with the format "Variable
name=measurement result". You will find an example of a file section and the
definition of the variable name in the topic "Variable name and example of a data
export file".
Define page break
GEARPAK protocols are generated in HTML-format. As HTML is not a page
orientated format, you can define the position of the page break for your
GEARPAK protocols. With this setting you can avoid that a second page with
only one line of your protocol is printed out.
 Enter a value in the "Adjust page break (in %)" text box.
 Execute a test print.
 If required, change the input.
Via "Next", you come to the "Graphical Report" dialogue box. When the graphic
protocol is no constituent part of the results, you get to the "Report Settings"
dialogue box".

11.2 Settings of the Graphical Report

The "Graphical Report" dialogue window will be displayed via the main window of
GEARPAK "Output / Numerical Report dialogue window / Next".
Structure of the Graphic Report
Using the check box you determine how you want to structure your report. Your
report includes the evaluations which are really required. This helps reduce the
printing time.
Large Diagram Representation
By activating the functions "Large profile and flank diagrams", the left and the
right profile and flank line diagram are each enlarged accordingly for the output
on one page.

28 v3.5 12.04.13
Report Output

You can only output large profile and flank diagrams if you have selected the
diagram orientation "vertical".

Topography Diagrams
By activating the function "Topography Diagrams", the graphical results are
output in a 3D-view. The topography diagrams are only output vertically.

The function "Topography diagrams" is only represented as active when

topographical measurement results are available.

Diagram Position
Select whether in the graphical report, the position of the flank diagrams must be
displayed vertically or horizontally. The vertical alignment corresponds to the
traditional representation. The horizontal alignment corresponds to the report
layout of INVOLUTE.
Size of Plotting
For the measurement of gears with different deviations of profile or flank line it is
possible to set different scales. By different scales the representation of the
deviations of each diagram type is improved.
 In the "Size of plotting" group box click the respective drop-down list.
 Select the scale.

Settings of the size of plotting

With highly exact produced toothed gears, we recommend to adjust the scale of
the automatic scaling smaller. By this, the representation of the test pictures will
be more detailed.

The selection "Large diagrams" is not active unless you check the "Large
diagrams" check boxes in the "Show" group box.

Positions of Tolerance Line

The tolerance lines can be displayed symmetrically or touching. In case of a
symmetrical representation, the tolerance lines will be displayed with the same
distance from the center line. In practice, generally the "touching" setting will be
selected. This means, that the tolerance lines will be shifted in such a way that
the upper tolerance line is adjacent to the highest point of the test picture (meas.
points).

12.04.13 v3.5 29
 Report Output

Representation of the Usable Ranges / Evaluation Ranges

The Usable Range / Evaluation Range can be represented either as radius or as
rolling way. Which representation to choose depends on how your toothed gear is
to appear in the report.
Define Page Break
GEARPAK reports are generated in HTML format. As HTML is not a page
orientated format, you can define the position of the page break for your
GEARPAK reports. With this setting you can avoid that a second page with only
one line of your report is printed out.
 Enter a value in the input field "Adjust page break (in %)".
 Execute a test print.
 If required, change the input.
Graphical report of several teeth
The default setting when measuring with GEARPAK-Worm is four teeth of a
worm. According to your requirements you can specify how many teeth are
represented on one page.
Representation of the teeth on one page
 You have measured four teeth of a worm.
 Under "Flank diagrams", type 4 in the "Teeth per page" spin button.
 Profile and flank diagrams of four teeth are printed side by side.

Teeth per page spin button

Representation of the teeth on several pages
 You have measured four teeth of a worm.
 Under "Flank diagrams", type 2 in the "Teeth per page" spin button.
 Two flank diagrams, one for the right and one for the left flank are
printed enlarged, side by side.
 The remaining flank diagrams are printed on the second page.

Only if "vertical" is selected under "Diagram position", you can specify the
number of "Teeth per page".

Use "Next" to get to the "Report settings" dialogue window.

11.3 Report Settings

You come to the "Report Settings" dialogue box through the main window
"GEARPAK / Output / Dialogue Box Numerical Report / - and, if selected, -
Dialogue Box Graphical Report / Next".
Add Company's Logo
You can add a company's logo to the report output. At the beginning of the
report, this logo is entered into the report head and printed-out. In case you have
set the "On separate files" option in the "Numerical Report" dialogue box, the
logo can be viewed in the report head of the numerical and graphical report.
 Check the "Display logo" check box.

30 v3.5 12.04.13
Report Output

 Click on the "Open file" button.

 Select your logo file.
 The file name of the logo file is displayed to the left of the "File"
button.
The logo file is entered into your report with the ratio of 50 to140 pixels
(height/width). For self-generated logo files make sure that you do not change
this ratio; failure to do so may result in a distorted representation of the graphics.
The following file formats are supported:
 Compuserve Graphics Interchange (*.gif)
 JPEG -JIFF Compilant (*.jpg)
 Portable Network Graphics (*.png)
Markings in the Diagrams
For details as to how you enter the limits of the measuring, nominal and
evaluation ranges into the graphic report refer to the topic "Measuring and
Evaluation Ranges in Numbers".
Reports of single flanks
For a report of a single flank only (e.g. for asymmetric flanks) choose the relevant
option in the "Report flanks" group box. The GEARPAK measurement protocol
then only contains information about the selected flank even if both flanks have
been measured.
Filter Vibrations
For details about how to filter scan vibrations out of the measurement data and
thus from the evaluations, refer to the topic "Filter for Scanning Measurement".

11.4 Measuring and Evaluation Ranges in Numbers

The numerical values of the measurement and evaluation ranges can be entered
on the diagrams for the profile and flank line measurements.
Marking for profile diagrams
 Check the "Display values for measurement range" check box for
the profile diagrams.
 The report shows in the area of the gear base circle the diameter of
the first measuring point.
 In the tip circle area, the last measuring point is displayed.

The measuring range of profile measurement depends on the diameter of

the probe tip used. Should the probe tip diameter have been selected too
large, the first profile measuring point will shift towards the tip circle
diameter. It is then possible that the first measuring point is within the
evaluation range. Consequently, the entire evaluation range would not be
recorded. This should be avoided.

When checking the "Display values for evaluation range" check box of the profile
measurement the diameters of the evaluation range are shown in the diagram.
Marking for flank line diagrams
If you wish to have the numerical values of the measurement and evaluation
ranges of the flank line measurement entered on the diagram check the "Display
values for nominal range" and "Display values for evaluation range" check boxes.

12.04.13 v3.5 31
 Report Output

In the graphic representation of line measurement the black borderlines

describe the tooth width. In profile measurement they represent the first
and last measuring point.

Vertical flip for flank line diagrams

When using the standard settings of the flank line diagrams the tip is represented
on the top of the diagram and the tooth root is on the bottom.
When checking the "Vertical flip" check box the measurement points are shown
inverse. The tooth root is on the top and the tip is on the bottom. This
representation corresponds to a gear during a manufacturing process, e.g. in a
gear hobbing machine.

The "Vertical flip" check box can only be checked for vertical flank diagrams.

11.5 Example and Variable Names of the Export File

Example
x_Act=-0.28
x_Nom=-0.53
Fr_Act=0.00000/Sys.UF
Fr_Nom=0.03200/Sys.UF
DoB2_Min_Act=0.00000/Sys.UF
DoB2_Max_Nom=91.22100/Sys.UF
fp_L_Act=130.67217/Sys.UF
fp_L_Nom=0.01000/Sys.UF
fu_R_Act=134.13022/Sys.UF
fu_R_Nom=0.00000/Sys.UF
Beta_Min_R_Act=-0.0019
Beta_Min_R_Nom=0.00000
Variable names for the export to GEOPAK
Gear parameters
Variable Meaning
x_Act Addendum modification coefficient, actual value
x_Nom Addendum modification coefficient, nominal value

Lead angle parameters

Variable Meaning
Gamma_Min_R_Act Lead angle on right flank, minimum actual value
Gamma_Min_R_Nom Lead angle on right flank, minimum nominal value
Gamma_Min_L_Act Lead angle on left flank, minimum actual value
Gamma_Min_L_Nom Lead angle on left flank, minimum nominal value
Gamma_Max_R_Act Lead angle on right flank, maximum actual value
Gamma_Max_R_Nom Lead angle on right flank, maximum nominal value
Gamma_Max_L_Act Lead angle on left flank, maximum actual value
Gamma_Max_L_Nom Lead angle on left flank, maximum nominal value

32 v3.5 12.04.13
Report Output

Variable Meaning
fgamma_L_Act Lead angle error on left flank, actual value
fgamma_L_Nom Lead angle error on left flank, nominal value
fgamma_R_Act Lead angle error on right flank, actual value
fgamma_R_Nom Lead angle error on right flank, nominal value
fpz_L_Act Lead error on left flank, actual value
fpz_L_Nom Lead error on left flank, nominal value
fpz_R_Act Lead error on right flank, actual value
fpz_R_Nom Lead error on right flank, nominal value
fpz_per_L_Act Periodical lead error on left flank, actual value
fpz_per_L_Nom Periodical lead error on left flank, nominal value
fpz_per_R_Act Periodical lead error on right flank, actual value
fpz_per_R_Nom Periodical lead error on right flank, nominal value
Tooth thickness mode parameters
Variable Meaning
DoB2_Min_Act Dimension over two balls, minimum actual value
DoB2_Min_Nom Dimension over two balls, minimum nominal value
DoB2_Max_Act Dimension over two balls, maximum actual value
DoB2_Max_Nom Dimension over two balls, maximum nominal value
Pitch parameters
Variable Meaning
Fr_Act Radial runout, actual value
Fr_Nom Radial runout, nominal value
Fp_Total_R_Act Cumulative pitch error on right flank, actual value
Fp_Total_R_Nom Cumulative pitch error on right flank, nominal value
Fp_Total_L_Act Cumulative pitch error on left flank, actual value
Fp_Total_L_Nom Cumulative pitch error on left flank, nominal value
fp_Single_R_Act Adjacent pitch error on right flank, actual value
fp_Single_R_Nom Adjacent pitch error on right flank, nominal value
fp_Single_L_Act Adjacent pitch error on left flank, actual value
fp_Single_L_Nom Adjacent pitch error on left flank, nominal value
fu_R_Act Difference between adjacent pitches on right flank, actual
value
fu_R_Nom Difference between adjacent pitches on right flank, nominal
value
fu_L_Act Difference between adjacent pitches on left flank, actual
value
fu_L_Nom Difference between adjacent pitches on left flank, nominal
value
Profile parameters
Variable Meaning
ffa_R_Act Profile form error on right flank, actual value
ffa_R_Nom Pprofile form error on right flank, nominal value
ffa_L_Act Profile form error on left flank, actual value
ffa_L_Nom Profile form error on left flank, nominal value
fHa_R_Act Profile angle error on right flank, actual value
fHa_R_Nom Profile angle error on right flank, nominal value
fHa_L_Act Profile angle error on left flank, actual value
fHa_L_Nom Profile angle error on left flank, nominal value

12.04.13 v3.5 33
 Report Output

Variable Meaning
fHa_R_Min_Act Profile angle error on right flank, minimum actual value
fHa_R_Min_Nom Profile angle error on right flank, minimum nominal value
fHa_L_Min_Act Profile angle error on left flank, minimum actual value
fHa_L_Min_Nom Profile angle error on left flank, minimum nominal value
fHa_R_Max_Act Profile angle error on right flank, maximum actual value
fHa_R_Max_Nom Profile angle error on right flank, maximum nominal value
fHa_L_Max_Act Profile angle error on left flank, maximum actual value
fHa_L_Max_Nom Profile angle error on left flank, maximum nominal value
Fa_R_Act Total profile error on right flank, actual value
Fa_R_Nom Total profile error on right flank, nominal value
Fa_L_Act Total profile error on left flank, actual value
Fa_L_Nom Total profile error on left flank, nominal value
Flank line parameters
Variable Meaning
ffb_R_Act Form flank line error on right flank, actual value
ffb_R_Nom Form flank line error on right flank, nominal value
ffb_L_Act Form flank line error on left flank, actual value
ffb_L_Nom Form flank line error on left flank, nominal value
Fb_R_Act Total flank line error on right flank, actual value
Fb_R_Nom Total flank line error on right flank, nominal value
Fb_L_Act Total flank line error on left flank, actual value
Fb_L_Nom Total flank line error on left flank, nominal value

11.6 Filter for Scanning Measurement

Vibrations which influence the accuracy of the measurement results occur during
the scanning of gear wheels. You can smooth these measurement peaks in your
measurement results using a filter. The filter can be used separately for the
profile and flank lines.
Activate Filter
 To use the filter, select the "Profile" check box and/or "Flank line"
check box in the "Report settings" dialogue box.
 The input fields "Cutoff wavelength" displays the calculated cutoff
wavelengths.
Using the cutoff wavelength, you specify how the filter affects the measured data.
 If you input a small cutoff wavelength, this means a small effect on
the measured data.
 If you input a large cutoff wavelength, this means a large filtering
effect and thus a large effect on the measured data.
If you have activated the "Scanning mode" function in the "Probe and rotary
table" dialogue box, it is possible to make entries for the "cutoff wavelength".
Calculating the cutoff wavelength
The proposed values for the cutoff wavelength are calculated depending on the
selected ball diameter, as the ball stylus has the same effect as a mechanical
filter.
Our experience shows the following:
 For a ball diameter up to 2 mm the following formula is useful:
cutoff wavelength = ball diameter * 0,250

34 v3.5 12.04.13
Report Output

 For a ball diameter larger than 2 mm the following formula is useful:

cutoff wavelength = ball diameter * 0,125 + 0,250
 A useful restriction of the cutoff wavelength is:
cutoff wavelength = ball diameter * 0,125 + 0,250
 Minimum proposed value:
0,05 mm (for a ball diameter <= 0,2 mm)
 Maximum proposed value:
1,5 mm (for a ball diameter >= 10,0 mm)
The suggested cutoff wavelength is calculated for the profile on the diameter that
is positioned next to the involute used. For the flank line, the cutoff wavelength is
calculated with the reference diameter.
Changing the suggested cutoff wavelengths requires a huge amount of
experience. If the cutoff wavelength is too big, the filter distorts the measurement
results. If the cutoff wavelength is too small, a portion of the scan vibration still
remains in the measurement results.
The selection of the cutoff wavelength depends on parameters, such as e.g.
 measuring system
 measuring speed
 workpiece surface
The calculated proposal for the cutoff wavelength cannot be the ideal value. If
necessary, determine the cutoff wavelength iteratively or from your experience
values.
Proposals for the input
The filter will only be used for the profile and flank line measurement and only for
the scanning measurement.
 Input the number of measuring points or increment according to the
required cutoff wavelength. The number of measuring points or the
pitch depends on the cutoff wavelength (see "Measurement"
dialogue box).
 The cutoff wavelength entered should be greater than or equal to
four times the pitch (at least five measuring points per cutoff
wavelength).
 The cutoff wavelength should be smaller than the measurement
length.
Topographical evaluation for worm gears
You will activate the setting "Diameter depend cutoff wavelength" for executing
topographical evaluations. The topographical flank line evaluation is performed in
different sections. In each one of these sections, a different diameter is used for
calculating the cutoff wavelength.

12.04.13 v3.5 35
 Measurement of a Worm

12 Measurement of a Worm
12.1 Dynamic Probe Selection
As for the coordination of the static probe, you determine according to rules
D probe < 0.9 normal module
the probe diameter for your gear measurement.
 The dynamic probe coordination controls by means of the used
probes in the toothed gear measurement program in the probe data
whether all probes have been calibrated.
 Missing probes will be displayed on your screen.
 The toothed gear measurement will be interrupted.
 Open under the "Probe" menu the "Probe data management".
 Mark the new probes listed and calibrate the probe with the
"Calibrate" function.
 Click on the "Gear" element and continue your toothed gear
measurement.

With the dynamic probe coordination, you only must calibrate as many
probes as really necessary.

12.2 Static Probe Selection

For a smooth and time-saving course of GEARPAK, we recommend to verify
whether in the drawing of the sample all necessary data are available, e.g. the
diameters of the usable ranges.
Define Probe Diameter
Next, you define the probe diameter that you use for your sample. You must take
into account:
 The probe diameter must only be as tall so that each meas. point
can be accessed with the sample without collision.
 The probe diameter must be selected as to rules.
D probe < 0.9 normal module
Definitions of the Probe Positions
You can measure toothed gear with a single probe, star probe or an indexable
probe (PH9 / PH10 / PH50). If you use a single or star probe, you must consider
that you will only dispose of a limited measurement range.
Star Probe
Probe no. Direction
1 -Z
2 -X
3 +Y
4 +X
5 -Y

36 v3.5 12.04.13
Measurement of a Worm

The statements in the table "Star Probe" refer on the workpiece co-
ordinate system.

Indexable Probe (PH9 / PH10 / PH50)

Probe no. Angle A Angle B
1 0.0 0.0
2 90.0 +180.0
3 90.0 +172.5
4 90.0 +165.0
5 90.0 etc.
If you use an indexable probe, the angles B of the angles A must be defined in
steps of 7.5° (see above).

To completely record a toothed gear, you need fifty calibrated probe

positions. The calibration of the probes will be realised in GEOPAK with
the "Probe data management" function.

12.3 Align Co-ordinate System of Worm

One of most important issues in co-ordinate measuring technology is to
determine the co-ordinate system of the parts to be measured. This is, of course,
also true for measurements you perform on worms.

Thoroughly clean the worm you want to measure. Chips or residues of

coolant may distort the results of worm measurement.

GEOPAK is used to align the co-ordinate system. Bear in mind:

 The symmetry axis of the worm can be aligned along each CMM
axis.
 You have, for instance, defined in the "Measurement Parameters"
dialogue that the worm is to be aligned along the CMM Z axis. Then
the X and Z axes of the worm are aligned in a way to correspond to
the directions of the CMM's X and Z axes.
For details refer to "Example of Fixing the Position of the Part with an Indexable
Probe".

12.4 Example of Fixing a Position of a Part

The part program for defining the position of the worm can be created in the
Learn or Repeat modes of GEOPAK.

During part position definition you have to capture 2 measurement points in

a tooth space. For measurement of these two points you use the probe you
have entered in the "Probe and Rotary Table" dialogue under "Probe
Number for First Probe".

12.04.13 v3.5 37
 Measurement of a Worm

No matter whether you are in the Learn mode or in the GEOPAK Editor, the
following applies in any case:
Align Plane
 Choose the machine co-ordinate system as your co-ordinate
system.
 Use menu "Co-Or. Sys." to open the "Align co-ordinate system"
dialogue.
 Click on the symbol "Machine Co-Ordinates".
 Open the element "Cylinder".
 Check that the buttons "Mean", "Autom. Elem. Finished" and
"Measurement" are activated.
 Measure the cylinder at the bearing seats.

Make sure that you perform cylinder measurement from bottom to top so
that the normal vector of the cylinder has the same direction as the CMM Z
axis.

 Open the "Align Plane" function.

 Check that the buttons "Alignment element cylinder", "XY plane" and
"Origin in element" are activated.
Zero Point Definition
 Open the element "Plane".
 Check that the buttons "Mean", "Autom. elm. finish", "Measurement"
are activated.
 Measure one plane on the face of the worm.
 Open the "Point" dialogue.
 Activate the "Intersection Element" function.
 Confirm to open the "Intersection Element Point".
 Choose plane as your "First Element" and cylinder as your "Second
Element".
 Open the "Create origin" dialogue.
 Check that the buttons "Alignment Point", "X, Y and Z Co-Ordinate"
are activated. It is necessary that the intersection element point is
used for zero point definition.
Axis Alignment
 Perform a probe change to your start probe which you have already
defined in the "Probe and Rotary Table" dialogue.
 Measure one point each on the left and right flank in the thread
space (reference space).

Align the worm on your CMM in a way that the from you selected reference
space is located on half the worm width.

 Open the element "Point".

 Activate the button "Symmetry Element".

38 v3.5 12.04.13
Measurement of a Worm

 Use the two points you have measured last to form the symmetry
point.
 Open the "Create origin" dialogue.
 Check that the buttons "Alignment Element Point", "X Co-Ordinate"
are activated and the symmetry point is selected.
 Open the function "Alignment by Point".
 Check that the buttons "Alignment Element Point" and "Co-Ordinate
Plane - Axis XY Plane: X Axis" are activated.
 Save the work steps with the function "Save Co-Ordinate System".
 Leave the Learn mode or the GEOPAK Editor and save your part
program.

You have already defined the position of your part in Learn mode. If you
have made this part program in GEOPAK Editor, you have to run your part
program in the Repeat mode as well.

12.5 Create a Measurement Course

If have passed through all the input dialogues, the "Finish" button will be
displayed as being active.
 Click on "Finish".
 GEARPAK creates a parameter set, which is the basis for your gear
measurement program.
 GEARPAK will be finished.

For the moment, there is no GEOPAK part program ready for the
measurement of your gear. How to measure a gear and to create a part
program, will be described in detail of the topic "Measurement of Gears".

12.6 Measurement of Toothed Gears

Before measuring a toothed gear, you must have realised the following steps
before:
 You have entered all toothed gear parameters.
 You have terminated GEARPAK with the "Finish" button.
 GEARPAK has created a parameter set with that you can measure
your toothed gear.
Continue as follows:
 In the PartManager, you select the part that has been marked
during your GEARPAK inputs.
 This part is marked with the toothed gear icon.
 Start the GEOPAK learn mode.
 Click in the toolbar on the toothed gear icon or
 click in the "Element" menu on the "Gear" function.
 The "Element Gear" dialogue window will be opened.

12.04.13 v3.5 39
 Measurement of a Worm

In the "Element Toothed Gear" dialogue window, you can enter the designation
and the drawing no. of the toothed gear as well as a comment. These entries are
output together with the measurement results.
Furthermore, your report will be completed with the operator's name and the time
of measurement.
Here, you determine how your report must be output. You can select:
 Screen
 Printer
 File
For more information, see the topic "Element Gear".

12.7 Element Toothed Gear

With this function, you measure the element "Gear". The element "Gear"
consists of entries you have realised in the input dialogues of GEARPAK.
 In the GEOPAK learn mode, click either on the icon (see above) or
take the way via the menu bar "Element / Gear".
 The dialogue "Element Gear" will be displayed.
 In the text fields, you will see, as usual, the element names
respectively the storage number.
Entries for the Report Data
The inputs in the "Designation", "Drawing Number." and "Comment" fields are
output together with the toothed gear report. Your toothed gear report will be
automatically completed with the operator name and the time of measurement.
Report Output
In the "Report Output on" section, you determine how your toothed gear report
must be output.
The report output will be automatically realised.
If you select the screen for the report output, the default browser (e.g. Internet
Explorer) will be started after the toothed gear measurement, and the
measurement results will be displayed.
When selecting the report output with a "Printer", the system prints out the gear
report on your standard printer as long as you have not changed the default
printer.
When you select the report output "File", it is necessary to indicate a file name
and a directory.
 Click on the "Select File" icon.
 The "Select File" input window will be opened.
 Select a directory, in which your report file must be stored.
 Enter a name with that your report file must be stored.
 Click on the "Save" button.
 The "Select File" input window will be closed and the file name of
your report file will be displayed on the left besides the "Select File"
icon.

40 v3.5 12.04.13
Measurement of a Worm

Start Measurement
If the "Start Measurement" check box is activated, the part program will be
automatically created according to your inputs in GEARPAK and the
measurement will be started.

If the check box is not activated, after the automatic creation of the part
program, the measurement will not be started.

You can have a look at your part program in the GEOPAK Editor and realise the
measurement of the toothed gear later.
 If you have finished your inputs and selection, activate the OK
button.
 Your toothed gear will be measured.

If you have not activated the check box of the report output, no toothed
gear report will be output. This means that your toothed gear will only be
measured.
It is possible to output the report afterwards with the "CMM / GEARPAK /
Gear Evaluation" function in the PartManager.

12.04.13 v3.5 41