Gear Inspection

Reference Manual

GM Gear Inspection
ISO Addendum
January, 2008

Table of Contents

Introduction

Definitions of Primary
Gear Tooth Elements

Analytical Gear Inspection

Radial Composite Testing

18

Gear Troubleshooting
Guide

23

Introduction
Gear quality is specified on the engineering
drawing in terms of two types of inspection
methods.
Analytical gear inspection
CNC equipment checks the following
characteristics:
Helix
Profile (or involute)
Pitch (or index)
Radial Composite (Functional) testing
This type of measurement requires a master
gear to roll in double flank contact with a
workpiece.
This manual is designed to explain the
results of these types of inspection
methods, and present possible solutions to
manufacturing problems as noted on the
results.

Page 1

Definitions of Primary Gear Tooth

Elements
Flank
The flanks of gear teeth are defined as right
or left. With reference face I facing you,
tooth tip up, the right flank is on the right,
and the left flank is on the left.
Crest (Tip)
Left Flank

Right Flank

Reference Face "I"

Internal Gear

Crest (Tip)
Left Flank

Right Flank

Reference Face "I"

External Gear

Page 2

Definitions of Primary Gear Tooth

Elements (Cont.)
Root and Tip Diameters
The diameter at the tip of the gear tooth is
the TIP DIAMETER, formerly called the
major diameter for external gears. The
ROOT DIAMETER was formerly called the
minor diameter.

Reference
(Pitch )

Tip (Minor )

Root (Major )

Internal Gear
Reference
(Pitch )

Tip (Major )

Root (Minor )

External Gear

Page 3

Definitions of Primary Gear Tooth

Elements (Cont.)
Helix
Helix is the angle of the gear teeth relative
to the axis of rotation.
Hand
Helical gears have either a right or left hand
helix. When looking at the end of a tooth
closest to you, a right hand helix will clock to
the right, while a left hand part will clock to
the left as you look farther down the tooth
away from you.

Right Hand Helix

Left Hand Helix

Page 4

Definitions of Primary Gear Tooth

Elements (Cont.)
ATTENTION! The ISO system is based on
HELIX deviations, NOT lead deviations.
This is opposite from the GM 1989
inspection standard. However, this is the
same convention as the GM DIN based
prints.
Profile (Involute)
The profile is the involute shape of the gear
tooth from the root to the tip.
Pitch
Pitch is the distance along the reference
circle from one tooth to the next tooth.

Page 5

Analytical Gear Inspection

Helix Slope Deviation (f )
HELIX slope deviation is the amount of
deviation from a nominal helix over the
evaluation range.

(L )
evaluation range

face width

(b)

fH

Helix slope deviation

Page 6

Analytical Gear Inspection (Cont.)

ATTENTION! The ISO system is based on
HELIX deviations, NOT lead deviations.
This is opposite from the GM 1989
inspection standard. However, this is the
same convention as the GM DIN based
prints.
For a right hand helix, if the measured helix
is more right, the measured value is
positive.
If the measured helix is more left, the
measured value is negative.

(-)

Left
Flank

(+)

Right
Flank

Right
Hand
Helix
Right
Hand
Helix
Page 7

(-)

(+)

Analytical Gear Inspection (Cont.)

For a left hand helix, if the measured helix is
more right, the measured value is negative.
If the measured helix is more left, the
measured value is positive.

(+)

(-)

(+)

Left
Flank

(-)

Right
Flank

LeftHand
HandHelix
Helix
Left

Page 8

Analytical Gear Inspection (Cont.)

Interpreting Helix Slope Deviation
The analyzed value of the helix slope
deviation (fH) represents the difference of
the slope as plus or minus from the nominal
zero slope line for the specified helix.
For example, given a right hand helix, a plus
(positive number) slope deviation on the
helix chart from an analytical gear checker
indicates that the helix is higher, or further to
the right, than nominal. A minus (negative
number) slope deviation indicates a helix
that is lower or more left than nominal.
Note that the slope deviation value is not a
variation in the actual helix angle, but a
linear deviation in millimeters across the
analyzed zone of the face width.
Mean Helix Slope Deviation (f )
Mean helix slope deviation is the average of
the helix slope values from the measured
teeth. Four teeth are typically measured.
Helix Slope Variation (f v)
Helix slope variation is the range of the
individual helix slope values, that is, the
maximum value minus the minimum value.

Page 9

Analytical Gear Inspection (Cont.)

Helix Crowning (C )
Helix crowning is the distance from the best
fit curve to the slope deviation line. This was
formerly called lead crown.

(L )
evaluation range

face width

(b)

Helix crowning
Helix
Crowning
Mean Helix Crowning (C )
Mean helix crowning is the average of the
crown values of the measured teeth.
Page 10

Analytical Gear Inspection (Cont.)

Helix Form Deviation (f )
Helix form deviation is the divergence from
a best fit curve along the helix. This was
formerly called lead irregularity.

(L )
evaluation range

facewidth

(b)

ff

HelixForm
form deviation
Helix
Deviation

Page 11

Analytical Gear Inspection (Cont.)

Profile Slope Deviation (f )
Profile slope deviation is the amount of
deviation from a nominal involute profile
over the evaluation range.

fH

evaluation range

(L )

End of
evaluation

SAP

Profile slope
Slope deviation
Deviation

Page 12

Analytical Gear Inspection (Cont.)

Mean Profile Slope Deviation (f )
Mean profile slope deviation is the average
slope of the measured teeth.
Profile Slope Variation (f )
Profile slope variation is the range of the
individual profile slope values, that is, the
maximum value minus the minimum value.

Page 13

Analytical Gear Inspection (Cont.)

Profile Barreling (C )
Profile barreling is the distance from the
best fit curve to the slope deviation line. This
was previously called profile or involute
crown.

evaluation range

(L )

End of
evaluation

SAP

Profile
Barreling
Profile barreling
Mean Profile Barreling (C m)
Mean profile barreling is the average of
profile barreling values (C ).
Page 14

Analytical Gear Inspection (Cont.)

Profile Form Deviation (ff )
Profile form deviation is the divergence of
the measured profile from a best fit curve.

ff

evaluation range

(L )

End of
evaluation

SAP

Profile Form Deviation

Profile form deviation

Page 15

Analytical Gear Inspection (Cont.)

Single Pitch Deviation (fpt)
Single pitch deviation is the difference
between the measured pitch and the
theoretical pitch value.
1

Flank Nr.
1
2
3
Pitch Nr.

-3

-3

10

10

11

11

12

12

13

13

14

14

15

16

17

15

16

17

+2

+3

+5

18

18

18

+3

+1

+3

+2

+1

-1

-1

-2

-3

-4

fpt diagram

-1

-3

Cumulative Pitch Deviation (Fpk)

Cumulative pitch deviation is the continuous
summation of the single pitch deviations.
Total Cumulative Pitch Deviation (Fp)
Total cumulative pitch deviation is the
difference between the maximum and
minimum cumulative pitch deviations.
18

Flank Nr.
1
2
3
Pitch Nr.

10

10

Fp

Fpk diagram

Page 16

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

Analytical Gear Inspection (Cont.)

Runout (F )
There are several methods used to
determine radial runout.
From a pitch measurement, radial runout
can be calculated.
It is also possible to measure radial runout
directly using a ball of the appropriate
diameter and checking every space for
radial deviation.

ATTENTION: Runout determined by

analytical inspection is NOT a direct
substitute for Runout by Composite
Test.

Page 17

Radial Composite Testing

Radial Composite Testing
Radial composite deviations are determined
by placing a product (test) gear in radial
double flank contact with a master gear. As
the product gear is rotated through one
revolution, the change in center distance
between the two gears is measured.
From the measurement data, a number of
analyses can be made to assess the quality
of the gear.

center
distance
variation

Master
Gear

Production
Gear

Page 18

Radial Composite Deviations

(Cont.)
Runout by Composite Test
Runout, as it pertains to radial composite
deviations, is the difference between the
maximum and minimum values of a low
pass filtered center distance measurement.
This method of determining double flank
runout captures both deviations from
eccentricity and circularity (out of
roundness).

Page 19

Radial Composite Deviations

(Cont.)
Eccentricity (f )
Eccentricity is half the total amplitude of a
single sine wave fit to the filtered center
distance measurement.

Page 20

Radial Composite Deviations

(Cont.)
Circularity
Circularity is the difference between the
maximum and minimum values of the
filtered center distance measurement after
the eccentricity has been removed.

Page 21

Radial Composite Deviations

(Cont.)
Mean Tooth-to-Tooth Radial Composite
Deviation
Mean tooth-to-tooth redial composite
deviation is the average change in center
distance due only to tooth action of undamaged teeth.
Nick
A nick (damaged tooth) is a large isolated
tooth-to-tooth deviation in excess of the
underlying tooth action.
Additional Evaluations
The following measurements may also be
available on many double flank testers.
These measurements can be used for
process control but are only approximations.
As such, these should not be used for
finished part acceptance.
Dimension Over Balls (D.O.B.)
Dimension Between Balls (D.B.B.)
FTT (Functional Tooth Thickness)
Sectional Runout
Helix Variation
Helix Average
Left/Right Flank Helix Slope
Taper
Taper Average

Page 22

Troubleshooting
Reading the charts
The shape and pattern reveal information
about the process that suggests potential
causes.

Page 23

Two high and low

points signifies
out of round or
egg shaped gear

Abrupt step means

index error
between first and
last tooth such as
with shaping
process or
measuring error

Tooth to tooth
abrupt peak means
problem with
single tooth or a
few adjacent teeth.

Random variation
pattern means
multiple tooth
problems or
problems with
testing equipment

Straight line may

indicate a
measurement
problem

Page 24

How composite data is specified on the

print:

Size Measurements

Diameters
Tip (major)
Minimum chamfer
Reference (d)
SAP (start of active
profile)
Base
Root (minor)

Size over pins

or balls

Page 25

Gear Troubleshooting Guide

Gear
Element
Category

Characteristics

Runout
Total Composite
Tooth to Tooth
Nicks

Inspection
chart
appearance
Hobbed/checked off
center

Possible root
cause

Verify tooling
(radial runout)

Corrective
action

Check for involute

error

Verify Master

Profile error

Check for plus tip

Possible
contamination

Mesh interference

Page 26

Gear
Element
Category
Helix

Characteristics

Slope (Angle)
error
Variation
(wobble)
Form or
waviness

Inspection
chart
appearance
Input correction
needed on machine

Possible root
cause

Verify axial runout

of fixture
wear

Input correction

Corrective
action

Inspect cutter
Verify
workholding
rigidity

Chips on fixture or
workholding
misaligned (axial
runout)
Chips on cutter edge
Cutting force to high

Page 27

Gear
Element
Category
Involute
(profile)

Characteristics

Angle (slope)
error
Variation
(runout)
Form or
waviness

Inspection
chart
appearance
Possible root
cause

Hob rake angle error

Corrective
action

Check hob
sharpening

Check hob
mounting and
quality

Check workpiece
and fixture runout

Cutter mounting error

Check stock
removal amount

Radial runout of gear

Excessive finish stock

Worn tool

Page 28

Gear
Element
Category

Pitch
(index)

Characteristics

Pitch
(symbol fp)
Index (total
accumulated
pitch errorsymbol Fp)

Inspection
chart
appearance
Possible root
cause

Corrective
action

Inspect hob for

thread error

Verify
workholding

Thread error on hob

Clean chips off

broach

Runout of production
fixture or inspection
arbor

Wear or chips on
broach bar

Page 29

Gear
Element
Category
Tooth
thickness

Characteristics

Size over pins

or balls
Relative tooth
thickness

Inspection
chart
appearance
Possible root
cause

Tapered hob
Heat causing
machine growth
Hob swivel angle
error

Corrective
action

Check hob for

proper quality

Monitor cutting oil

temperature

Adjust hob swivel

angle for correct
size over pins
(DOB or DOP)

Page 30

Gear Inspection Symbols and

Terms
Note: These symbols may not be fully
implemented on all gear inspection systems.

Symbol
b

Term
facewidth

profile barreling

helix crowning

profile slope deviation

profile form deviation

mean profile slope deviation

profile slope variation

helix slope

helix form deviation

mean helix slope deviation

helix slope variation

Fp

total cumulative pitch deviation

Fpk

cumulative pitch deviation over a

sector of k pitches

F
F

single pitch deviation

total radial composite deviation

runout

eccentricity

Page 31

Gear Inspection Symbols and

Terms (Cont.)
f"

tooth-to-tooth radial composite

deviation

reference face

profile evaluation range

helix evaluation range

z
No
Symbol
No
Symbol
No
Symbol
No
Symbol

number of teeth
circularity by composite test
mean tooth-to-tooth radial
composite deviation
Nick (damaged tooth)
runout by composite test

Page 32

References
Please reference GM Document 24241147
for gear inspection standards and practices
The following ISO standards and technical
reports represent the basis of cylindrical
gear inspection for GM Powertrain:
ISO 1328-1:1995 Definitions and allowable
values of deviations relevant to
corresponding flanks of gear teeth.
ISO 1328-2:1997 Definitions and allowable
values of deviations relevant to radial
composite deviations and runout
information.
ISO TR 10064-1:1992 Inspection of
corresponding flanks of gear teeth.
ISO TR 10064-2:1996 Inspection related to
radial composite deviations, runout, tooth
thickness and backlash.
ISO 1122-1:1998 Vocabulary of gear terms.

Page 33

Index
Circularity......................................... 21
Cumulative Pitch Deviation......... 16
Eccentricity...................................... 20
Flank .............................................. 2, 22
Form .................................................. 15
Hand .................................................... 4
Helix................. 1, 4, 6, 9, 10, 11, 22, 27
Helix Crowning ............................... 10
Helix Slope......................................... 9
Involute ............................................... 5
Mean Helix Slope ............................. 9
Nick .................................................... 22
Pitch..................................... 1, 5, 16, 29
Profile ................ 1, 5, 12, 13, 14, 15, 26
Profile Barreling ............................. 14
Radial Composite 1, 3, 18, 19, 20, 21,
22
Radial Composite Testing ........... 18
Root ..................................................... 3
Runout ...................... 17, 19, 22, 26, 29
Runout (F )....................................... 17
Single Pitch Deviation .................. 16
Slope........................ 6, 9, 12, 13, 22, 27
Tip ........................................................ 3
Tooth-to-Tooth................................ 22
Total Cumulative Pitch Deviation
........................................................ 16
Variation ........................................... 13
Page 34

Notes

Page 35

Notes

Page 36