GR Ins

Gear inspection
The dimensional inspection of gear is one of the most important

function in manufacturing gears. It is the measurement that
controls initial machine set up accuracy, the necessary
allowances for heat treatment variations, overall level of quality
and to pin point the production problems.
Gear measurements are to be very precise, hence gear teeth
inspection has to be carried out in an air conditioned atmosphere
to assure accurate measurement.
Usually small batch of gears are processed and inspected before
the heat treatment. Final inspection is made after the heat
treatment and necessary allowances is established to provide
proper corrections to the gears in green stage. Once the process
capability is established, process starting from raw material to
dispatch stage has to be freezed. Any change in the process
requires process capability study, otherwise the accuracy and
performance of gear may change.
Gear laboratory is responsible for checking each new gear
cutting or finishing machine set up before proceeding the
production. Spot inspection from responsible gear laboratory
personal is required after the tool change and twice in each eight
hour shift. If deviation found, it is the responsibility of the gear
laboratory to analyze the problem and to suggest the necessary
correction to the set up.
Errors in gears
It is impossible to produce gears with out any error, hence we
need to control and limit the error to a level which is acceptable
for that particular application.
Pitch error
Pitch error : Difference between the actual pitch (circular

distance) measured and the calculated theoretical pitch of a gear
teeth is
referred as pitch error. Adjacent pitch error is the
difference in pitches of adjacent teeth. Accumulated pitch error is
the maximum variation in pitches measured on all the teeth of a
gear. In other words, difference between the minimum and
maximum values of pitches measured on one full revolution of a
gear is referred as accumulated pitch error.
Profile error : Difference between the actual involute profile
curve, and the theoretical involute profile curve of a gear teeth is
referred as profile error. It can also be defined as, the difference
between the actual involute coordinates and the theoretical
involute coordinates of a gear tooth profile. Some times profiles
are modified (deviated from theoretical involute curve) to meet
the application requirement and this is not referred as profile
error.
Lead error : Deviation in alignment of the gear tooth with reference

to its axis of rotation is referred as lead error.
In spur gear, teeth must be parallel to the axis of rotation of gear.

Hence, lead error is referred as the deviation in parallelism of the
gear teeth with reference to the axis of rotation.
In helical gears, teeth are inclined at an angle to the axis of

rotation. Hence deviation in helix angle with reference to the
axis of rotation is referred as lead error.
Usually lead error is not measured as a deviation in tooth
alignment angle. It is measured as linear variation per unit face
width of the gear teeth.
Radial runout : Out of roundness of the pitch circle combined
with the eccentricity of the pitch circle is referred as radial
runout of a gear. Eccentricity of the pitch circle is always
measured with reference to the axis of rotation of gear. Radial
runout and combined effect of pitch and profile error (composite
error) can be plotted in a roll tester.
Usually inspection of general accuracy of gears is carried out on

roll testing machine. Roll testing of the gear is done by rotating
the gear in tight mesh with the precision master gear and
measuring the variation in center distance. To allow the
measurement of variation in center distance, either the the
master gear or the gear which is under roll testing, has to be
mounted on flexible center. Such composite checks can show an
indication of profile, pitch,tooth thick ness and runout errors.
Bench type roll testers are equipped with motor drives and
electronic measuring instruments.
Since other gear parameters can be checked by individual
gauging, roll testing is sufficient in low production to check pitch,
profile and runout errors.
There are some problems in inspection of gears in a roll tester.
Proper care is necessary while taking plot and analyzing it. Only
experienced person can segregate and analyze the plot taken in
roll testing.
It is desirable to test all gears on bench type roll tester in a high

production line. This can avoid the difficulties of isolating the
defective gears in assembly line and testing .
Roll tests are not much useful for checking gears in green
stage.individual error checking is necessary in green stage to
carryout the correction to the process
One of the most frequent cause for the noise of the gears in
operation is, nicks and burrs on gear tooth profile. Sound testing
machine can detect noise quickly and it can be eliminated by
removing the nicks and burrs on gear profile by hand with the help
of fine emery paper. Motorized roll testing can also be used to detect
nicks and burrs. Some times visual inspection is also necessary to
detect them.

GR Ins

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Gear inspection

The dimensional inspection of gear is one of the most important

Pitch error : Difference between the actual pitch (circular

Lead error : Deviation in alignment of the gear tooth with reference

In spur gear, teeth must be parallel to the axis of rotation of gear.

In helical gears, teeth are inclined at an angle to the axis of

Usually inspection of general accuracy of gears is carried out on

It is desirable to test all gears on bench type roll tester in a high

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