Profile Shift of Involute Gears - Tec-Science

8/21/22, 10:39 PM Profile shift of involute gears - tec-science
In the case of a profile shift, the reference profile of the gear is shifted outwards during
the manufacturing process in order to positively influence the meshing.
1 Introduction
2 Profile shift
2.1 Influence of the profile shift on the shape of the tooth flank
2.2 Influence of a profile shift on the standard reference pitch circle
3 Profile shift coefficient
3.1 Increase of tooth thickness
3.2 Tip shortening
3.3 Center distance and operating pressure angle
3.4 Calculation of the profile shift coefficient to avoid undercutting
4 Summary
Introduction
In the article Undercut of gears it was shown that avoiding an undercut with a standard
gear (standard pressure angle of 20°) requires a minimum number of teeth of 17. If
gears are nevertheless to be manufactured below the limit number of teeth (e.g.
because a certain transmission ratio is to be achieved), the undercut must be avoided in
another way. For this purpose, a so-called profile shift can be used. Such a profile shift is
described in more detail in this article.
Profile shift
https://www.tec-science.com/mechanical-power-transmission/involute-gear/profile-shift/ 1/17
With a profile shift, the tool profile is shifted outwards by a certain amount during gear
cutting. The animation below shows the effects of a profile shift on the tooth form of a
gear with 8 teeth. It becomes clear that as the profile shift increases, the undercut
becomes smaller and can even be completely avoided.
0:00 / 0:28
Animation: Influence of the profile shift on the tooth shape
The figure below shows again the comparison of the tooth shapes with increasing
profile shift (from left to right). Even if the tooth shapes differ from each other, the teeth
can still mesh with each other. Profile shifted gears (also called corrected gears) can
therefore be easily paired with non-profile shifted gears (so-called standard gears) as
long as they are manufactured with the same tool and therefore have the same module.
Figure: Comparison of profile-shifted gears
0:00 / 0:16
Animation: Gears with profile shift in mesh
Undercuts can be avoided with a profile shift. For this purpose, the tool profile is shifted
outwards during gear manufacturing. Gears with different profile shifts can mesh with
each other without further ado!
Influence of the profile shift on the shape of the tooth flank
Even if this may not seem so at first glance, a profile shift has no influence on the shape
of the tooth flank itself. All profile shifted gears use the same involute for the tooth
shape compared to their corresponding standard gears. Only another part of the same
involute is used. This becomes clear when the tooth flanks of the gears with
different profile shifts are placed on top of each other.
Figure: Comparison of tooth flanks of profile-shifted gears
Note that the base circle for constructing the involute is determined solely by the flank
angle of the tool profile (= standard pressure angle) during gear cutting. And since the
angle of the cutting edges does not change with a profile shift, the base circle and thus
the involute do not change either.
0:00 / 0:04
Animation: Comparison of tooth flanks of profile-shifted gears
For profile-shifted gears, the same involute is used for the shape of the tooth flank. The
base circle therefore does not change with a profile shift, since the base circle is
determined solely by the flank angle of the cutting tool (standard pressure angle)!
As already explained in the article Construction and design of involute gears, the radius
of curvature of the involute increases with increasing length, i.e. the further away the
involute is from the base circle, the larger the radius of curvature is and the less strongly
it is therefore curved. The flank shape at this more distant area is rather “flat” than
“pointed”. The smaller curvature leads to a larger contact surface of the flanks, which
reduces the pressure accordingly (less Hertzian contact stress). This reduces the stress
on the flanks and thus increases the flank load-bearing capacity.
The flank load-bearing capacity can be increased by a profile shift!
Influence of a profile shift on the standard reference pitch circle
The reason why profile-shifted gears can engage with other profile-shifted gears is that
all gears have the same circular pitch on their manufacturing pitch circles. This will be
explained in more detail in this section.
First of all, it should be noted that the pitch point C between the rack-shaped cutting
tool and the gear does not change during gear cutting, even if the profile is shifted (see
article rack for further information on this). This is due to the fact that the pitch point is
defined as the intersection between the center line and the line of action. The line of
action in turn always results as a normal to the tool flank, which is tangent to the base
circle of the gear.
Figure: Independence of the position of the pitch point in the event of a profile shift
As the figure above shows, a profile shift has no effect on the flank angle of the tool or
on the base circle of the gear as mentioned in the previous section. Thus, even with a
profile shift, the line of action and thus the pitch point always remain unchanged.
The unchangeable position of the pitch point is already apparent from its meaning. The
pitch point describes the point in which the speeds of the rack-shaped tool profile and
the gear are identical (“sliding-free rolling”). A radial shift of the tool profile, however,
does not change the speed ratios and thus the position of the pitch point.
The pitch line of the tool and the (manufacturing) pitch circle of the gear run through the
pitch point. Regardless of the profile shift, the unchangeable pitch point therefore
always leads to the same manufacturing pitch circles on the gears. Finally, the pitch of
the teeth is referenced to these manufacturing pitch circles (circular pitch p0). This
means that the manufacturing pitch circle corresponds to the standard reference pitch
circle of the gear (see also the article on racks). A profile shift therefore has no effect on
the resulting reference pitch circle and the related circumferential pitch, so that profile-
shifted gears can mesh with non-profile-shifted gears!
The reference pitch circle (manufacturing pitch circle) of a gear does not change with a
profile shift, so that corrected gears can mesh with standard gears!
Profile shift coefficient

The profile shift V for gears is usually indicated by a profile shift coefficient x in relation
to the module m. With positive coefficients (x>0) the tool profile is shifted outwards and
with negative factors (x<0) it is shifted inwards (applies to external gears).
V = x⋅m (1)
Figure: Profile shift coefficient
For example, a profile shift coefficient of x=+0.25 means that the tool profile is shifted
outwards by 0.25 times the module m. In general, both the root circle radius (dedendum
circle) and the tip circle radius (addendum circle) increase by the amount of the profile
shift.
The calculation of the root diameter dd,0 and the tip diameter da,0 for standard gears has
already been explained in the article Construction and design of involute gears. These
diameters result from the module m and the number of teeth z, whereby a clearance c
is also taken into account for the root diameter:
da,0 = m ⋅ (z + 2) applies only to standard gears (2)
dd,0 = m ⋅ (z − 2)– 2 ⋅ c applies only to standard gears (3)
In case with a profile shift, however, the tip circle radii and the root circle radii are
increased by the amount of the (positive) profile shift V with corrected gears. For the
corresponding diameters applies:
da = da,0 + 2 ⋅ V = m ⋅ (z + 2) + 2 ⋅ V = m ⋅ (z + 2) + 2 ⋅ m ⋅ x (4)
da = m ⋅ (z + 2x + 2) applies in general (without tip shortening) (5)
dd = dd,0 + 2 ⋅ V = m ⋅ (z − 2)– 2 ⋅ c + 2 ⋅ V = m ⋅ (z − 2)– 2 ⋅ c + 2 ⋅ m ⋅ x (6)
dd = m ⋅ (z + 2x − 2) − 2c applies in general (7)
Increase of tooth thickness
A profile shift also has an effect on the circular tooth thickness and the tooth space
width. As the tooth thickness s0 increases on the pitch circle, the tooth space e0
decreases accordingly. In the following, the tooth thickness s0 on the reference pitch
circle is determined as a function of the profile shift coefficient x.
Figure: Effects of the profile shift on the tooth
The figure below shows the increase in the distance of the tool flanks on the pitch line
(width Δs of the triangle marked blue) when the tool profile is shifted outwards by the
profile shift V=x⋅m. This distance of the tool flanks on the pitch line corresponds to the
tooth thickness s0 on the manufacturing pitch circle of the gear (= reference pitch circle).
Figure: Enlargement of the tooth thickness on the pitch circle
In comparison to a standard gear, whose tooth thickness corresponds to half the

circular pitch p0 (p0/2), with a corrected gear the tooth thickness increases by an amount
Δs. The figure above shows the following relationship between the profile shift
coefficient x and the resulting tooth thickness s0 on the pitch circle (with α0 as the
standard pressure angle):
p0
s0 = + Δs (8)
2
p0
s0 = + 2 ⋅ V ⋅ tan(α0 ) (9)
2
p0
s0 = + 2 ⋅ m ⋅ x ⋅ tan(α0 ) (10)
2
−−−−−−−−−−−−−−−−−−−−−−
The circular pitch p0 can also be expressed by the module m (see article Construction
and geometry of involute gears):
p0 = π ⋅ m (11)
−−−−−−−−
Finally, for the tooth thickness s0 on the reference pitch circle of a profile shifted gear
applies:
π ⋅m
s0 = + 2 ⋅ m ⋅ x ⋅ tan(α0 ) (12)
2
π
s0 = m ⋅ ( + 2 ⋅ x ⋅ tan(α0 )) with α0 = 20° (13)
2
By the same amount Δs as the tooth thickness increases, the tooth space width e0
decreases:
π
e0 = m ⋅ ( – 2 ⋅ x ⋅ tan(α0 )) (14)
2
Tip shortening
In the previous section it was shown that a (positive) profile shift increases the tooth
thickness on the reference pitch circle and thus increases tooth strength. At the same
time, however, the width of the tooth tip sa on the addendum circle is reduced.
Figure: Effects of the profile shift on the tooth
If the tip of the tooth is too small, however, there is a risk of teeth breaking out. In order
to prevent this, the tip diameter must then be shortened so that a certain thickness is
maintained. The tip diameter should be shortened in such a way that the tooth
thickness at the addendum circle is at least 0.2 times the module (such a tip shortening
shortening is not yet considered in the equation (5)!). Note that with a shortend tip
diameter the line of contact is reduced accordingly! The detailed calculations for
determining the line of contact are shown in the article Calculation Of Involute Gears.
Figure: Tip shortening
The thickness of the tip tooth at the addendum circle should be at least 20 % of the
module. To achieve this, a tip shortening may be necessary! This reduces the line of
contact!
The animation below shows the profile shift of a gear with 6 teeth to avoid an undercut.
In this case, the thickness of the tip tooth even decreases so much that the involutes
taper before the shifted tip diameter is reached. The increase of the tip circle radius by
the amount of the profile shift cannot therefore be maintained in this case – the tip
diameter is inevitably shortened.
0:00 / 0:04
Animation: Profile shift of a gear with 6 teeth to avoid undercut
In addition, the tip circle would have to be shortened again to at least 0.2 times the
module in order to increase the thickness of the tip tooth. However, such a large
reduction of the tip circle would also result in a correspondingly large reduction of the
line of action. Involute gears with fewer than 7 teeth should therefore be avoided by any
means.
Involute gears with less than 7 teeth should be avoided due to excessive tip shortening!
Center distance and operating pressure angle
In the previous section it was shown that with corrected gears (green gear in the figure
below) an extended part of the involute is used as tooth flank compared to standard
gears (shown in red). When meshing with another gear, this further curved part of the
involute is used for power transmission. Therefore, there is a clearance between the
tooth flanks when the center distance a is increased by the amount of the (positive)
profile shift V=x⋅m. The back flank bends away before it touches the flank of the other
gear, so to speak.
Figure: Backlash when increasing the center distance by the amount of the profile shift
For a backlash-free engaging, the gears must therefore be moved together a little bit.
This reduces the centre distance slightly, but it is still larger compared to the a standard
gear. At the same time, however, the clearance c between the tip of the tooth and the
tooth root of the other gear is reduced (see figure below). This may require a tip
shortening in order to maintain a certain clearance.
Figure: Decrease in clearance with backlash-free mating of a profile shifted gear
The center distance is therefore larger with a positive profile shift and smaller with a
negative profile shift compared to standard gears without a profile shift. This means
that the center distance can be adjusted by means of a profile shift. This is another
reason why a profile shift is frequently used.
Profile shifts are often used to adjust the centre distance!
In addition to the effects already mentioned, a profile shift also results in a change in the
operating pressure angle α. The operating pressure angle α is not to be confused with
the standard pressure angle α0, which ultimately determines the flank angle of the rack-
shaped cutting tool and of course does not change with a profile shift!
0:00 / 0:04
Animation: Change of the pressure angle and the line of contact with a profile shift
Figure: Change of the pressure angle and the line of contact with a profile shift
Detailed calculations for determining the operating pressure angle and the centre
distance are shown in the article Calculation of involute gears.
Calculation of the profile shift coefficient to avoid undercutting
In the article Undercut it was shown that below the minimum number of zmin=17 teeth
an undercut occurs which weakens the teeth. A profile shift now provides the possibility
to completely compensate such an undercut. This raises the question of how the profile
shift coefficient x must be chosen to avoid an undercut with a given number of teeth
z<zmin.
Figure: Profile shift coefficient to avoid an undercut
As also explained in detail in the article Undercut, in order to avoid an undercut, the
intersection point B between the base circle and the line of action must be located
outside the line of contact AE. In the limiting case where an undercut is to be avoided,
the beginning of the undercut coincides with the end of the line of action. Then the
reference profile (“tool profile”) exits the gear before it undercuts the tooth.
0:00 / 0:41
Animation: Profile shift to avoid undercut
As the animation above shows, the displacement of the tangent point B to the end of
the line of contact in point E is achieved by a positive profile shift. Note that the end of
contact is determined by the intersection of the line of action and the tip line of the
reference profile and can therefore be influenced by a profile shift, whereas the line of
action does not change if the profile is shifted!
0:00 / 0:13
Animation: Profile shift coefficient to avoid an undercut
In the limiting case, the tangent point B coincides with the end of engagement E, as it is
the case for the green gear. From the resulting geometrics, the profile shift coefficient x
can be determined for a given standard pressure angle α0.
Figure: Calculation of the profile shift coefficient to avoid undercut
The orange triangle in the figure above is now considered more closely. It is shown that
the opposite side of the standard pressure angle α0 corresponds to the difference
between the module m and the profile shift V=x⋅m. Therefore, the following relationship
applies to the distance CE between the pitch point C and the end of engagement E:
m−V m−m⋅x m ⋅ (1 − x)
sin(α0 ) = = = (15)
¯
¯¯¯¯
¯¯¯ ¯
¯¯¯¯
¯¯¯ ¯
¯¯¯¯
¯¯¯
CE CE CE
¯
¯¯¯¯
¯¯¯
m ⋅ (1 − x)
CE = (16)
sin(α0 )
−−−−−−−−−−−−−−−
Now the blue triangle is considered more closely. It is shown that the distance CE can
also be determined from the pitch circle radius r0 or the pitch circle diameter d0. The
pitch circle diameter results from the module m and the number of teeth z.
¯
¯¯¯¯
¯¯¯ d0 m⋅z
C E = r 0 ⋅ sin(α0 ) = ⋅ sin(α0 ) = ⋅ sin(α0 ) (17)
2 2
¯
¯¯¯¯
¯¯¯
m⋅z
CE = ⋅ sin(α0 ) (18)
2
−−−−−−−−−−−−−−−−−
The two equations (16) and (18) can now be equated and solved for the profile shift
coefficient x:
¯
¯¯¯¯
¯¯¯ ¯
¯¯¯¯
¯¯¯
CE = CE (19)
m ⋅ (1 − x) m⋅z
= ⋅ sin(α0 ) (20)
sin(α0 ) 2
2
sin (α0 )
x = 1−z ⋅ (21)
2
−−−−−−−−−−−−−−−−
Furthermore, the term sin²(α0)/2 in the equation above corresponds to the reciprocal of
the minimum number of teeth zmin, above which an undercut would occur without a
profile shift (for the derivation of the formula, see article Undercut). For a gear with a
standard pressure angle of α0=20°, the minimum number of teeth is theoretically
zmin=17. The profile shift coefficient x required to avoid an undercut can thus be
determined as follows:
z
x = 1− with z min = 17 (22)
z min
For a gear with z = 8 teeth, the profile shift coefficient is x=0.53. In practice, a slight
undercut can often be accepted without major negative effects. In these cases the
minimum number of teeth is assumed to be zmin=14.
Note that for a number of teeth greater than zmin, the profile shift coefficient x becomes
negative. This means that theoretically a negative profile shift can be made without
undercutting.
Summary
In summary, it can be stated that a (positive) profile shift is always applied if …
an undercut is be avoided,
the tooth strength must be increased,
the surface pressure at the flanks is to be decreased, or
the center distance must be adjusted.
With external gears, a positive profile shift leads to …
an increase of the root circle,
an increase of the tip circle,
an increase of the tooth root thickness (increased strength) and thus to
a reduction of the undercut,

a decrease of the tip tooth thickness (tip shortening may be necessary),
an increase of the tooth thickness at the pitch circle and to
a decrease of the tooth space width at the pitch circle,
a decrease of the Hertzian contact stress on the flanks (increased flank load-bearing
capacity) and to
an increase of the centre distance when meshing with a standard gear.
Neither the base circle diameter nor the reference pitch circle diameter change with a
profile shift! In the case of a negative profile shift, the effects listed above are just the
opposite. Due to the many positive effects, a profile shift is generally recommended.

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8/21/22, 10:39 PM Profile shift of involute gears - tec-science

Animation: Influence of the profile shift on the tooth shape

Figure: Comparison of profile-shifted gears

Animation: Gears with profile shift in mesh

Influence of the profile shift on the shape of the tooth flank

Figure: Comparison of tooth flanks of profile-shifted gears

Animation: Comparison of tooth flanks of profile-shifted gears

The flank load-bearing capacity can be increased by a profile shift!

Influence of a profile shift on the standard reference pitch circle

Profile shift coefficient

Figure: Profile shift coefficient

da,0 = m ⋅ (z + 2) applies only to standard gears (2)

dd,0 = m ⋅ (z − 2)– 2 ⋅ c applies only to standard gears (3)

corresponding diameters applies:

da = m ⋅ (z + 2x + 2) applies in general (without tip shortening) (5)

dd = dd,0 + 2 ⋅ V = m ⋅ (z − 2)– 2 ⋅ c + 2 ⋅ V = m ⋅ (z − 2)– 2 ⋅ c + 2 ⋅ m ⋅ x (6)

dd = m ⋅ (z + 2x − 2) − 2c applies in general (7)

Increase of tooth thickness

Figure: Effects of the profile shift on the tooth

Figure: Enlargement of the tooth thickness on the pitch circle

In comparison to a standard gear, whose tooth thickness corresponds to half the

Figure: Effects of the profile shift on the tooth

Figure: Tip shortening

Animation: Profile shift of a gear with 6 teeth to avoid undercut

Center distance and operating pressure angle

Figure: Decrease in clearance with backlash-free mating of a profile shifted gear

Profile shifts are often used to adjust the centre distance!

Calculation of the profile shift coefficient to avoid undercutting

Figure: Profile shift coefficient to avoid an undercut

Animation: Profile shift to avoid undercut

Animation: Profile shift coefficient to avoid an undercut

Figure: Calculation of the profile shift coefficient to avoid undercut

In summary, it can be stated that a (positive) profile shift is always applied if …

the surface pressure at the flanks is to be decreased, or

the center distance must be adjusted.

With external gears, a positive profile shift leads to …

an increase of the root circle,

an increase of the tip circle,

an increase of the tooth root thickness (increased strength) and thus to

a reduction of the undercut,

an increase of the tooth thickness at the pitch circle and to

a decrease of the tooth space width at the pitch circle,

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