Eng.&Tech.Vol.26,No.

8,2008 An Approach For Forming Spur Gear

Tooth Profile

An Approach For Forming Spur Gear Tooth Profile

Dr. Safaa H. Abdulrahman* Dr. Adnan D. Mohammed**
Received on: 14/3/2007
Accepted on: 6/9/2007

Abstract
Due to high working speed requirement in industry of rotating components, gear
design development become quite noticeable and rapid in the vicinity of engineering
parameters which become to have a large effect on its performance. In this work the spur
gear of straight tooth is chosen because of its wide usage in industry, also an equation
for joining the involute profile and fillet curve is generated. Variation effect on the shape
of tooth profile forming is studied. A suggested method for generating tooth profile is
obtained and a computer program is written for drawing the involutes and trochoid
curves. The results obtained from the new method are the true continuous involute and
trochoid curves in comparison with those obtained from Mechanical Desk software
which are approximated curves fitted results.

Keyword:tooth,gear,trochiod,involute
‫ﺍﻟﺨﻼﺼﺔ‬
‫ﻨﺘﻴﺠﺔ ﻟﺩﺨﻭل ﻋﻨﺼﺭ ﺍﻟﺴﺭﻋﺔ ﻓﻲ ﻤﺘﻁﻠﺒﺎﺕ ﺍﻟﺼﻨﺎﻋﺔ ﻟﻤﺭﻜﺒﺎﺕ ﺍﻟﻌﻨﺎﺼﺭ ﺍﻟﺩﻭﺍﺭﺓ ﻓﻲ ﺍﻟﻤﻜﺎﺌﻥ ﻓﺄﻥ ﺘﻁـﻭﺭ‬
‫ﺘﺼﻤﻴﻡ ﺍﻟﺘﺭﻭﺱ ﻗﺩ ﺒﺭﺯ ﺒﺸﻜل ﻤﻠﺤﻭﻅ ﻭﻤﺘﺴﺎﺭﻉ ﻓﻲ ﻤﺠﺎل ﺍﻟﻤﻌﺎﻤﻼﺕ ﺍﻟﻬﻨﺩﺴﻴﺔ ﻭﺍﻟﺘﻲ ﺃﺼﺒﺢ ﻟﻬﺎ ﺍﻟﺘـﺄﺜﻴﺭ‬
‫ ﻓﻘﺩ ﺘﻡ ﺍﺨﺘﻴﺎﺭ ﺍﻟﺘﺭﻭﺱ ﺍﻟﻌﺩﻟﺔ )ﺫﺍﺕ ﺍﻟﺴﻁﻭﺡ ﺍﻟﻤﺴﺘﻘﻴﻤﺔ( ﻓﻲ ﻫﺫﻩ ﺍﻟﺩﺭﺍﺴﺔ ﻭﺫﻟﻙ ﺒﺴﺒﺏ‬.‫ﺍﻟﻜﺒﻴﺭ ﻋﻠﻰ ﺃﺩﺍﺀﻫﺎ‬
‫ ﻜﺫﻟﻙ ﻓﻘﺩ ﺘﻡ ﺍﺸﺘﻘﺎﻕ ﻭﺘﻭﻟﻴﺩ ﻤﻌﺎﺩﻟﺔ ﻟﻠﺭﺒﻁ ﺒـﻴﻥ ﺸـﻜل ﺍﻻﻨﻔﻭﻟﻴـﻭﺕ‬.‫ﺍﻻﺴﺘﺨﺩﺍﻤﺎﺕ ﺍﻟﻭﺍﺴﻌﺔ ﻓﻲ ﺍﻟﺼﻨﺎﻋﺔ‬
‫ ﻜﻤﺎ ﺘﻡ ﺩﺭﺍﺴﺔ ﺘﺄﺜﻴﺭ ﺘﻐﻴﺭ ﺍﻟﻤﻌﺎﻤﻼﺕ ﺍﻟﻬﻨﺩﺴﻴﺔ ﻋﻠﻰ‬، (Fillet curve) ‫( ﻭﻤﻨﺤﻨﻲ ﺍﻟﻔﻠﺕ‬Involute profile)
‫ ﻟﻘﺩ ﺘﻡ ﺍﻟﺘﻭﺼل ﺇﻟﻰ ﻁﺭﻴﻘﺔ ﻤﻘﺘﺭﺤﻪ ﻟﺘﻭﻟﻴﺩ ﺸﻜل ﺍﻟﺴﻥ ﻜﻤﺎ ﻜﺘﺏ ﺒﺭﻨﺎﻤﺞ ﺤﺎﺴﻭﺒﻲ ﻟﺭﺴﻡ‬.‫ﺸﻜل ﺘﻜﻭﻥ ﺍﻟﺴﻥ‬
‫ ﺘﻤﺕ ﺍﻟﻤﻘﺎﺭﻨﺔ ﺒﻴﻥ ﺍﻟﻁﺭﻴﻘﺔ ﺍﻟﻤﻘﺘﺭﺤﻪ ﻟﺘﻭﻟﻴﺩ ﺍﻟﺴﻥ‬. (Trochoid curve) ‫ﺍﻻﻨﻔﻭﻟﻴﻭﺕ ﻭﻤﻨﺤﻨﻲ ﺍﻟﺘﺭﻭﺠﻭﻴﺩ‬
‫ ﻭﺍﻟﺘﻲ ﺘﻤﺜل ﻨﺘﺎﺌﺞ ﻤﻨﺤﻨﻴﺎﺕ‬Mechanical Desk Software‫ﻤﻊ ﺍﻟﺒﺭﻨﺎﻤﺞ ﺍﻟﺘﺠﺎﺭﻱ ﺍﻟﻤﺴﺘﺨﺩﻡ ﻓﻲ ﺍﻟﻤﺼﺩﺭ‬
.‫ﺘﻘﺭﻴﺒﻴﺔ‬
1.Introduction investigated the gear tooth shape and its
Gear design is considered to be generating rack, based upon both
one of the most important and strength and noise consideration using
complicated fields of mechanical Finite Element Method (F.E.M). Peng
systems because of its wide usage and et al, 1998[6] their work on the stress
applications, so this makes their design concentration at the root fillet depends
be reviewed yearly. on the minimum radius of the fillet and
Norton,1998[2] developed the general configuration of this part.
first equation for the fillet shape for the Jweeg et al 1989 [7] developed the
spur or helical gears, in which involute tooth initial section and
considered it as arcs of circles, while in calculated the stress using F.E.M by
actual fact it is a trochoid as will be employing the 8-node Isoparametric
considered in this work. Peter elements.AL-Shaibany A.R 2002 [8]
Lynwander, 1983[3] introduced other studied the effect of geometrical and
form of equations for the involute and dynamical parameters on the design of
trochoid curves. Al-Dafai, 1995[4] used spur gear tooth and have shown the
FEM to study gear tooth stress then effect of choosing the pressure angle of
obtained the displacement and stiffness 25 degree and dynamic load and
values, Jweeg,M.J,Hussain,I.A[5] stresses on the gear performance using

*Electromagnatic Dept.UOT.Baghda-Iraq
**Mechanical Dept.UOT. Baghdad-Iraq

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Tooth Profile

FEM. As a conclusion from the ⎛ π ⎞

previous works mentioned earlier, the diametral pitch ⎜ ⎟. It is
fillet was considered as an arc in a ⎝ TH + TP ⎠
circle joined the involute by a suitable capable of cutting a whole family of
curve fitting routine. In the present gears with the same pressure angle and
work an equation for the fillet curve is diametral pitch. Such tools are standard
developed considering the latter as a as, for instance, a 20o pressure angle
trochoid. Also a computer program is and (8) pitch (diametral pitch) hob, and
developed for the matching (meshing) are easily obtainable. Gears that are cut
of the involute curve with trochoid. using this hob are capable to match
Construction of Involute Gear Tooth (mesh) each other.
The involute of a circle is a curve that The distance (B+Rrt) on the hob tooth
can be generated by unwrapping a taut is equal to the dedendum of the
string from a cylinder that always generated gear tooth, Rrt is the hob tip
tangents to the base circle and the radius with its center at point O, and B
centre of involute curvature is always at is the vertical distance from point O and
the point of tangency as shown in the pitch lines as shown in Fig. (3).
Fig.(1), and to plot the involute, simply TP the hob tooth space, is equal to the
pressure angle φ values are assumed. A tooth thickness of generated gear at
tangent to the involute is always normal gear pitch diameter.
to the string, which is the instantaneous The work piece moves an angle
radius of curvature of the involute curve (TP+TH)/rp, where rp is the gear pitch
[2], [9]. The involute tooth profile can radius. (TP+TH) is the circular pitch of
be generated using the following manufacturing gear.
relations [10], [11] as shown in Fig. The involute coordinates.
(1a). It was shown that the involute
rp = 0.5 * m * Z ---------- can be predicted if the base circle radius
(1) and the angle (θ) of involute are known,
ra = rp + m + Cf *m ---------- so the radius of involute curve can be
(2) found at any pressure angle φ by
rf = rp – m * (1.25-Cf) ---------- following equation [10]
(3) θ = tan (φ) – (φ) -----
The involute is generated at the position (6)
of the base circle whose radius is given To find the coordinates with respect to
by the equation: the centre of tooth, the tooth thickness
rb = rp * cos (φ) = m * Z * cos (φ) * at any radius must be known. Let's start
0.5(4) at the pitch diameter with pressure
and the root circle radius angle φ1, a pitch radius rp1, and a
rf = m * (Z-2.5) * 0.5 ---------- circular tooth thickness CTT1. The
(5) involute angle can be written asθ1 = tan
Gear Tooth Generation (φ1) – (φ1) ------------ (7)
Generating mean that the tool is and from Fig.(4), it can be seen that the
cutting conjugate form, such a straight angle A is:
sided tooth is sometimes referred to as a 0.5 CTT1
rack. As the tool transverse and the A = θ1 + ---------------
work rotates, an involute is generated rp1
on the gear tooth flank and a [trochoid] (8)
in the root fillet, as shown in Fig. (2). To find the circular tooth thickness at
Fig. (3) is a closer look at a hob tooth. any other radius rp2, use
This is a hob of pressure angle φ and

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Tooth Profile

0.5∗CTT1 Fig.(5) shows the trochoid generated by

B=A-(θ2) =θ1 + −(θ2) ------ point O at its starting point and after the
rp1 hob has moved a distance rp. β and the
(9) gear has rotated through an angle β the
coordinate are:
⎛ rb ⎞ Xo = RO * sin (T-β)=RO* (sin(T) * cos
φ2 = cos−1 ⎜⎜ ⎟⎟ (β) + cos (T) * sin (β))-----------------
⎝ R2 ⎠ (17)
θ 2 = tan(φ2 ) − (φ2 ) Yo = RO * cos (T-β)=RO* (cos (T) * cos
(β) + sin (T) * sin (β)-----------------
⎛ 0.5∗CTT1 ⎞
CTT2 = 2⎜⎜ + (θ1 ) + (θ2 )⎟⎟ ------ (18)
⎝ rp1 ⎠ rp − B
cos T =
(10) R O
So to find X and Y coordinates of the Where: and
involute at any radius R2, use following
equations: rp ⋅ β
sin T =
X = R2 * sin (B) ---------------- R O
(11) Therefore:
Y = R2 * cos (B) ----------------- XO = (rp.β) * cos (β) – (rp-B) * sin
(12) (β)(19)
The trochoid coordinates. YO = (rp-B) * cos (β) +(rp.β)* sin (β)
To find the trochoid (20)
coordinates on the desired X-Y system Fig.(6) shows how to calculate the
through the center of the tooth, they actual trochoid coordinates adding the
must be shifted through the angle (w) as hob tip radius rc to the trochoid
in Fig.(2) when the hob traverses a generated by point O.
distance (TH+TP) as in Fig.(3), the gear XT = XO + rc * cos (A) ---------------
rotates through an angle (TH+TP)/rp; (21)
therefore the angle (w+v) between the YT = YO – rc * sin (A) -----------------
center of the gear tooth and the center (22)
of tooth space is: A is the angle formed by a line normal
0.5 ∗ (TH + TP ) to the trochoid generated by point z and
w+v= ------ the YT axis which can be found as
rp
follows:
(1)
To find dXO/ dβ, dYO/ dβ from equation
Angle v can be calculated as follows:
(19, 20):
L dXO
v = ----------------- = −(rp∗β) ∗sin(β) + rp∗cos(β) − rp∗cos(β) + B∗cos(β)
rp dβ
(14) dYO
Where L = distance between center hob = rp∗sin(β) + B∗sin(β) + (rp∗β) ∗cos(β) + rp∗sin(β)
tooth and point O in Fig.(3) dβ
TH Rrt
L= − B∗ tan(φ) − ----------- dX O
2 cos(φ) and is
dY O
(15)
dX O − (rp ∗ β) ∗ sin (β ) + B ∗ cos (β) --
Then =
0 . 5 ∗ (TH + TP ) − L dYO B ∗ sin (β) + (rp ∗ β) ∗ cos (β)
w = ------------
rp (23)
(16) Finally, to obtain the trochoid
coordinates with respect to the system

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Tooth Profile

through the gear tooth center, refer to Discussion

Fig.(2) the generated equation for the involute
X T + X ∗ cos( w ) profile and the fillet curve is used to
sin (w ) =
Y study the variation of tooth geometric
and on the shape of tooth profile. Its
observed clearly from figure (8-16),
YT − X ∗ sin ( w )
cos (w ) = how the involute and trochiod curve of
Y tooth profile changes from case 1 to
Then case 9. Case (4) is used for the
XT * cos (w) + X * cos2 (w) = YT * sin comparison between the profile resulted
(w) – X * sin2 (w) --------- from the present developed program
-------- (24) with that of the Mechanical Disk Top
X = YT * sin (w) – XT * cos (w)------ Software [1]. which shows that this
(25) approach gives exact true curve fit, also
And more accurate curve for trochiod, while
Y = YT * cos (w) + XT * sin (w) ------ from the software curve passes between
(26) the plotted point with interpolation
The value of (rc), the fillet radius of method to deduce the profile, also
curvature at fillet tooth (trochoid) is trochiod plotted by an arc at imaginary
given by:[10] centre point as in CAD QUST software
rc = Rrt +
(Addc − e − Rrt )2 (27 [13] as shown in fig (17-18).
rp s + (Addc − e − Rrt ) conclusion.
the constructed computer program
)
using the developed equation for
Where: Rrt = 0.3 * m-----------------
forming the involute and the trochiod of
(28)
spur gear tooth in comparison with
e = Cf * m ----------------- (29)
other works shown that present analysis
It is possible to add the trochoid and
gives a true profile especially at the
involute curves in complete program to
portion of trochoid, it also showed that
obtain spur gear tooth generation. This
the program developed form exact
program named (program 1) as showing
profile because it follows the real path
in Fig. (7).
of the cutter that cut's the real profile
Results.
during the manufacturing process. from
To explain the effects of varying tooth
that it can be conclude that construction
geometric parameters, nine cases of
of profile is more accurate than that
different pressure angles and correction
formed by arc of imaginary centre.
factors are selected as shown in table
References.
(1).
[1]: Mechanical Desk Top Software
Using the new written program on the
Ver.5, U.S. and international
above cases, results of spur gear
copyright laws, Autodesk, Inc.
profiles are generated and displayed in
ACIS of spatial Technology, inc.
Figures (8--16).The profiles shown are
2000
the true (non-approximated) curves of
[2]: Norton, Robert L. "Machine Design
involute and trochoid combinations
Handbook" Worcester
because they are based specifically on
polytechnic Institute, Worcester,
the true cutter motion . Also Fig(17)
Massachusetts, copyright by
shows tooth profile of case 4 with the
Prentice-Hill Inc. New Jersey,
Mechanical Desk Top Ver.5[1], and
1998
Fig(18) shows the drawn trochiod curve
[3]: Lynwander, peter "Gear Drive
of tooth profile for case 4 with
Systems" American Lohmann
Mechanical Desk Top Ver.5[1] .

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Tooth Profile

Corporation, Hill side, New [9]: Hamilton H. Mabie, Charles F.

Jersey, 1983. Reinholtz, "Mechanisms and
[4]: Al-Dafai, Hatam K.K. "Finite Dynamics of Machinery", 4th
Element Study of Gear tooth Edition, J. Wiley, New York,
stresses with presence of a 1991.
keyway", Baghdad University , [10]: Maitra, G.M, "Gear Design
M.Sc thesis, 1995. Handbook", design Department
[5]: Jweeg,M.J , Hussain,I.A "Finite Rourkela Steel Plant, Rourkela.
Element Study of Gear Tooth Copyright by TATA, McGraw-
Stresses with presense of a Hill Publishing Company Ltd,
keyway" ,Baghdad University India, 1985.
M.Sc thesis,1995. [11]: Gustav, Niemann "Machine
[6]: Peng, X.Q., Liu Geng,Wu Liyan, Element" McGraw-Hill
G.R. Lin , K.Y. Lam, " A publishing Company, India, 1960.
Stochastic Finite Element Method [12]: Colbourne, J.R "The Geometry of
for Fatigue Reliability analysis of Involute Gears", Library of
gear teeth subjected to bending" Congress cataloging in
Computational Mechanics Publication , copyright by
21,253-261, spring-verlegl, 1998. Springer verlage, New York , Inc.
[7]: Jweeg, M.J, Balsam H. Abdshebib 1987.
and Nabil, M. Motash, [13]: CAD Quest Pro. "Involute Gears"
"Investigation of Involute-gear Engineer Tips and Tricks page,
tooth critical section", Journal of WWW.cadquest.com /tips/htm
Military Engineering College, 2000.
No.5, 1989.
[8]: AL-Shaidany,A.R,"The effect of
Geometrical and Dynamical
Parameters on gear design",
Military Engineering
College,2002.

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Tooth Profile

List of Symbols:

Symbol Definitions Units

Ad Addendum mm
Addc Addendum of cutter mm
Cf Correction factor
CTT1 Circular tooth thickness mm
CTT2 Arbitrary circular tooth thickness mm
Ded Dedendum mm
db Base circle mm
df Root diameter mm
m module mm
ra Addendum radius mm
rb base circle radius mm
re Curvature radius of tooth fillet mm
rf Root circle radius mm
R Radius of any point mm
Rrt Fillet radius of cutter tooth (hob tip radius) mm
rp Pitch radius mm
TH Hob tooth thickness mm
tp Hob tooth space mm
v Angle between yT and centre of tooth space degree
w Angle between yT and centre of tooth space degree
X X-coordinate of involute curve points mm
XT XT- coordinate of trochoid curve points mm
YT YT- coordinate of trochoid curve points mm
XX X- coordinate of trochoid curve points mm
Y Y- coordinate of trochoid curve points mm
yy Y- coordinate of trochoid curve points mm
YT YT- coordinate of trochoid curve points mm
Z Number of teeth

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Greek Symbols
φ Pressure angle degree
θ Involute value (Inv)

Table (1) The parameters for selected cases of gear tooth design:

Fig. (1) Involute curve formation

Fig. (1a) radii of circles

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Fig. (2) Root fillet Trochoid and involute curve

Fig. (3) hob geometry

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Fig.(4) Tooth thickness calculation

Fig.(5) Trochoid generated by point O

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Fig. (6)Trochoid coordinates

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Profile

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Fig.(7) Flowchart of spur gear tooth generation drawing program (program 1)

Fig.8 Fig.9

Fig.10 Fig.11

Fig.12
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Fig.13 Fig.14

Fig.15 Fig.16

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Fig.17 Tooth profile of case 4

From Mechanical Desk Top pakage Ver .5

Fig.18Trochiod curve of tooth profile for case 4

From Mechanical Desk Top pakage Ver .5

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