Profile contact ratio, Active profile diameter, Lowest and Highest

point of single tooth contact

In a pare of meshed and rotating gears, distance between the starting and
terminating point of contact of a tooth with the mating tooth on line of
action is called length of line of action
Ratio of the degree of rotation from starting to termination of contact of one
tooth to, the degree of rotation completed by next mating tooth at the same
time is called profile contact ratio. That is equal to, length of line of action
divided by base pitch. More than one teeth will share the load if contact ratio
is more than one. This factor is very important while calculating load
transmitting capacity of gears. Long addendum gears will have high contact
ratio when compared to short addendum gears. Long addendum gears may
have a contact ratio of more than two. High contact ratio will ensure smooth
power transmission and load sharing by more number of teeth, but pressure
angle has to be less than standard addendum gear.
Diameter at the point of termination / start of contact by the mating gear
tooth addendum is called active profile diameter. There will not be any
contact with mating teeth after this radius. Hence profile accuracy after this
radius is not important. But true involute form is a must from addendum to
active profile point.
When gears are meshed and rotating together, a pare of teeth will make and
terminate the contact. Even though the contact ratio is more than one, only
one tooth can be in contact with mating tooth for a short degree of rotation.
Lowest point on profile where single tooth contact exists is lowest point of
single tooth contact and highest point on profile where single tooth contact
exists is highest point of single tooth contact.
Usually gear stresses are calculated by applying the load at the highest
point of single tooth contact ( lowest point of single tooth contact for internal
gears). If gears are of lower accuracy, more than one pare of teeth may not
share the load even though the contact ratio is more than one. Hence tooth
stresses has to be calculated by applying load at highest point tooth of
contact (lowest point of contact for internal gears). That is at the tip of the
addendum.

External gears
Gear

rog

Radius at start of active profileRadius at highest point

of single tooth contact

Radius at lowest point

of single tooth contact

rhg

rag

rlg

Radius of base circle-

rbg
Co

Operating
Pressure angle

Base circle
Operating
Pitch circle

Line of action
Length- L

Operating center distance

Outer radius-

la

Operating
Pitch circle

Base circle

rlp Radius at lowest point

of single tooth contact

Radius of base circle-

Radius at highest point

of single tooth contact

rbp

Operating
Pressure angle
Radius at start
of active profile

Crp =

rap

Outer radius-

rop

Pinion

Ll a
Pb (Pbt)-For helical gears

rog2 - rbg2 +

rhp

rop2 - rbp2 - ( Sin o x Co ) = Ll a

rop2 - rbp2 - Lla

) +r

2
bp

= rap

rog2 - rbg2 - Lla

) +r

2
bg

= rag

rop2 - rbp2 - Pb

)2+ r

2
bp

= rlp

(
(

)2

rog2 - rbg2 - Pb + rbg2 = rlg

)2

rop2 - rbp2 - Lla + Pb + rbp2 = rhp

)2 + r

rog2 - rbg2 - Lla + Pb

bg

= rhg

Internal gearing
Line of action
Length- la

Operating
Pitch circle

Operating
Pitch circle

o - Operating pressure angle

Radius at lowest point

of single tooth contact

rlp

Active profile radius-

rai

Base circle
Base circle radius-

rbp

Base circle
Active profile radius-

rap

Inner radius-

(
(

(
(
(

rii2 - rbi2 = Ll a

rop2 - rbp2 - Ll a
r

2
op

- r

2
bp

)+r

= ra p

2
bp

+ ( Sin o x Co)

Ring gear

+ rbi2 = rai

2
op

- r

2
bp

- Pb

)+r

2
bp

= rl p

rop2 - rbp2 + ( Sin o x Co) - Pb

+ rbi2

= rli

2
op

- r

2
bp

- Ll a + Pb

)+r

2
bp

Operating center distance

Radius at highest point

of single tooth contact

Co

rli

Ll a
Pb (Pbt )- For helical gears

rop2 - rbp2 + (Sin o x Co ) -

Pinion

rbi

Radius at lowest point

of single tooth contact

Crp =

Outer radius-

rii

rhi

Base circle radius-

Radius at highest point

of single tooth contact

= rh p

rop2 - rbp2 + ( Sin o x Co) - Ll a + Pb

+ rbi2

= rhi

rop

rhp

Span measurement and measurement between pins/balls

Circular tooth thickness and space width of gear tooth can be controlled by
controlling, span measurements (base tangent length) or measurement
over/between pins/balls.
Usually tooth thickness of external spur / helical gears are established by
controlling the base tangent length (measured by gear tooth micrometer).
Tooth space width of internal spur/helical gears are established by
controlling measurement between pins/balls. Span measurement in helical
gears must be normal to the helix. In helical gears, measurement over Pins
will not give a accurate reading. Hence, instead of pins, Balls are to be used
for helical gears and balls are to be aligned with one of the gear faces while
taking measurements. Pins are to be used for measurement in spur gears.
For span measurement, number of teeth to be spanned has to be
established in such a way that the gear tooth micrometer flange will make
contact as tangent near the mid point on the gear profile. Similarly for
measurement over pins/balls, selected pin/ball has to make a contact near
the mid point of gear profile, and should not touch the root. If pin/ball
touching at the root, small relief has to provided on measuring pin/ball.
It is really not very important to make measurement at mid point of profile.
Measurement can be taken at any point on the profile, but contact point
(tangent point) must be on involute profile.
Span measurement is not possible in helical gears, if F Sin b x M n
Zx
+ 0.5 Non corrected spur gears
N=

Cos

-1

(d )
b

D + 2k

N=

Zn x n
N=
N=
Zn1 =

x Z
+ 0.5

Corrected spur gears

+ 0.5 Non corrected helical gears

Zn1 x n1
+ 0.5 corrected helical gears

n1 =

Z
Cos 1

1 = Tan

-1

(D + 2k) x Tan
D

Tan

-1

(Tan t1 x Cos 1)

t1= Cos -1

db
D + 2k

External teeth
b
Pitch circle
Base circle

Even no.of teeth

Odd no.of teeth

Measuring pin/ball

All angles are in radians

b =

b =

(t

q=

Mop =

D ++

ao
rb

For spur Gears

o
D + t+ rb x Cos b - Z
t

rb
Cos

For Helical Gears

Mop = 2 (q + ao )

( ( ) )
Cos

2xZ

x 2q

+ 2 ao

For even no. of teeth

For odd no. of teeth

Internal teeth
b

Pitch
circle
Base
circle

Mbp

Even teeth

Odd teeth

Measuring
pin/ball

b =

b =

s
D

q=

st
D

ao

+ t -

rb

ao

For spur Gears

rb x Cos b

rb

( ( ) )
Cos

For Helical Gears

Mbp = 2 ( q + ao) For even no. of teeth

Cos b

Mbp =

All angles are in radians

2xZ

x 2q

+ 2ao

For odd no. of teeth

Pitch circle

Base circle

Helical

Mn

gear

Mt
All angles are in radians

(N-1) 2
M=
Z

(N-1) 2

Mt =

2t
D

2 tt

+2

rb

+ 2 t rb

Mn =( Mt x Cos b )

Spur gears

Helical gears

Tip interference - Internal Gearing

Ring gear

A
A

Tip interference
Pinion

A
Center distance

In internal gearing, if difference in number of teeth between ring gear and

pinion is very small, Pinion teeth will interfere with ring gear teeth and this
is called tip interference. Hence proper care to be taken while deciding
number of teeth of ring gear and pinion to avoid Tip interference. This
problem can also be avoided by giving required profile correction to ring
gear / pinion.
Difference in number of teeth between ring gear and pinion is also a
deciding factor for assembling pinion and ring gear. Avoiding the tip
interference will only ensure the axial assy of pinion in to the ring gear and
may not ensure the radial assembly of pinion. If radial assembly is
required to be ensured, sufficient profile correction to be given to ring gear
/ pinion, or difference in number of teeth between ring gear and pinion to
be increased.
Tip interference may also pose a problem while generating ring gear teeth
on machines. It can be avoided by selecting proper gear cutting tool,
otherwise cutter will cut part of ring gear teeth near the tip of the
addendum.

Tip clearance - Internal gearing

A
Ring gear

Clt

A
Pinion

Co

g
Inner radius
Ring gear

rii

Outer radius
Pinion

Operating center distance

rop

= Cos - 1

Sin

1 =

p=

-1

Co 2 + rii2 - rop2
2 x Co x rii

Sin x Co
+ -p
rop

tp
Dp

+ - dop

dop = Tan dop - dop

dop = Cos -1

rbp

( )
rop

Clt = (1 - ) x rii
Clt must be positive to avoid tip interference

+ g

All angles are in radians

g=

s
Di

+ - dii

dii = Tan dii - dii

dii = Cos -1

rbi
rii

( )

Interference of base circle - Internal gearing

Pitch circle-Ring gear

Pitch circle-Pinion

Base circle
Pinion

Base circle-Ring gear

We encounter this problem In internal

gearing, if difference in number of
teeth between ring gear and pinion is
too large. Ring gear teeth inner edge
will try to dig in to the pinion profile
near base circle.

This problem can be avoided by providing

positive correction to pinion or by increasing
inside diameter of the ring gear.
This problem can also be avoided by
decreasing the difference in number of teeth
between ring gear and pinion.

( rop2 - rbp2 )

Lla

If above condition is met, base circle interference

problem will be avoided.

A= m

Under cut
Hob

Pitch circle
Base circle
Under cut

Pitch circle radius

Pitch circle radius -m

Material removed from involute profile near

the root diameter is called undercut. Usually
this will occur while hobbing small pinions,
when hob tries to generate profile below
the base circle. Hence profile generation
below the base circle is not possible, hob
will remove material from involute profile
near base circle. Under cut will increase the
bending stress because of reduction in
tooth thickness near root.
Magnitude of under cut depends on pressure angle, number of teeth,
and helix angle. Increase in pressure angle, number of teeth and helix
angle will reduce the under cut. Under cut can be avoided by providing
positive correction to pinions. Helical gears will have less under cut when
compared to a spur gear of same number of teeth and normal pressure
angle.
To avoid under cut this condition must be satisfied
Cos x db

Minimum number of teeth

to avoid under cut Std Add and Ded

Cos2 x Z x m (Z x m) - 2A
Pressure angle

Zminimum =

2xA
Sin2

xm

If addendum = module

Zminimum =

2
Sin2

For helical gears substitute with t

14.5
20

22.5
25

D
2

Min. No. of teeth

( spur gears)

32
18

14
12

-A