1.

3 Property（Basic rack, accuracy, strength）

[1] involuteΣiii(spur and helical gear design system)
English version Setup screen is shown in Fig.1.2～1.5．
・gear combination ：external × external，external × internal
・Basic rack ：normal, low, special
・tooth tip circle decision ：normal, equal clearance
・steel gear strength calculation spec is shown in Fig.1.5 as 3 types;
・JGMA 401-02:1974, 402-02:1975
・JGMA 6101-02:2007, 6102-02:2009
・ISO6336:2006
Plastic strength calculation spec is JIS B 1759(2013)．

Fig.1.1 involuteΣiii(spur and helical)

1.1 Abstract
involute Σ iii (spur and helical) has functions such as cylindrical gear
dimensions, strength (steel, resin), axial load, tooth surface modification, Fig.1.2 Basic rack
transmission error, tooth surface evaluation, FEM analysis, tooth profile
data, etc. for efficient and accurate design. Fig.1.1 shows the whole
screen.

1.2 Software structure

The structure of involute Σiii is shown in Table 1.1. ○ in the table
is included in the basic software, and ◎ is optional. Applicable gear: Fig.1.3 Dimension
involute spur and helical gear (external gear, internal gear)

Table 1.1 Software structure

No. Item Page Structure

1 Basic rack setup 1.3 ○

2 Dimension 1.4 ○ Fig.1.4 Accuracy
3 Inference 1.5 ○
4 Tooth creation drawing 1.6 ○
5 Meshing drawing 1.6 ○
6 Meshing rotation function 1.6 ○
7 Tooth profile rendering 1.7 ○
8 Gear accuracy 1.8 ○
Fig.1.5 Strength
9 Gear strength calculation (steel) 1.9 ○
10 Gear strength calculation (resin) 1.10 ○ 1.4 Dimension
11 Metal × resin gear strength 1.10 ○ Gear dimension calculates parts dimensions, contact ratio, sliding ratio,
12 Bearing load 1.11 ○ tooth thickness and so on. The gear with undercut determines the contact
13 Sliding ratio, Hertzian stress 1.12 ○ rate based on the TIF (True Involute Form) diameter. If tooth tip is
14 Tooth profile output（DXF, IGES） 1.17 ○ rounded, R is considered in contact ratio.
15 HELP menu 1.19 ○ (1)center distance and shift coefficient have the following 3 relationships．
16 Design data management 1.20 ○ <1> shift coefficient is given to pinion and gear to determine center
17 FEM Tooth Profile Analysis 1.13 ◎ distance.
Rotational transmission error <2> based on center distance, shift coefficient of each gear is
18 1.16 ◎
(Fourier analysis, Wow · flutter, CSV output) determined.
Tooth surface evaluation <3> center distance is set, regardless of shift coefficient.
19 (surface temp, film thickness, 1.12 ◎ (2)shift coefficient is set per following 4 types;
sliding velocity, PV value) <1>directly enter shift coefficient
20 Tooth modification (involute, lead, bias) 1.14 ◎ <2>based on split tooth thickness, shift coefficient is set
21 Contact pattern 1.15 ◎ <3>based on over pin dimension, shift coefficient is set
<4>based on arc tooth thickness, shift coefficient is set
Dimension setup screen is shown in Fig.1.6. Shift coefficient can be
set by tooth thickness. See Fig.1.7 for dimension result．

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 Fig.1.8 Inference-1（Bending strength）

Fig.1.6 Dimension setup

Fig.1.9 Inference-2（Shift coefficient）

1.6 Tooth profile (Involute) drawing

Meshing drawing is shown in Fig.1.10．As shown in support form,
zoom, distance measurement (Fig.1.11), R-measurement (Fig.1.12),
diameter, involute modification, line of action, tooth tip width, odd teeth
Y-measurement value display and rotation function are available.
Involute creation is shown in Fig.1.13.

Fig.1.7 Dimension result Fig.1.10 Meshing drawing & support form

1.5 Inference
For Inference-1, bending strength is used to set module and tooth
width. Based on the estimated module and tooth width, next step of the
design can be carried out. As there are multiple combinations of
module/tooth width/material to satisfy strength, inference can be used to
determine concept design.
For Inference-2, shift coefficient can be set based on sliding ratio and Fig. 1.11 distance measurement Fig.1.12 R measurement
contact ratio. Fig.1.9 shows max sliding ratio for pinion in red line, gear
in blue line, and contact ratio in green line. In Fig.1.9, the most suitable
shift coefficient is 0.3 based on sliding ratio and contact ratio. Reasons
for determining the shift coefficient are prevention of undercut, change of
center distance, adjustment of meshing pressure angle, etc. However, by
using this inference function, it is necessary to determine the shift
coefficient based on the relationship between sliding ratio and contact
ratio. When undercut is observed, sliding ratio will be large.
Fig.1.13 Involute creation（Pinion）& support form

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1.7 Tooth profile rendering
3D tooth profile meshing can be created as shown in Fig.1.14, and
contact line can be also observed. Control form allows the users to
change tooth profile direction and size.

Fig.1.18 Strength calculation（material）

Fig.1.14 Tooth profile rendering

1.8 Gear accuracy

In Fig.1.15 & Fig.1.16, new JIS gear accuracy spec JIS B
1702-1:1998and JIS B 1702-2:1998 are shown for tolerances. Also, New
JIS and Old JIS can be switched as shown in Fig.1.4. Gear accuracy spec
are 5 types as shown below; Fig.1.19 Strength calculation（bending coefficient）
・JIS B 1702-1:1998, JIS B 1702-2:1998, JIS B 1702-3:2008
・JIS B 1702:1976
・JGMA 116-02:1983

Fig.1.15 JIS B 1702-1 Fig.1.16 JIS B 1702-2

1.9 Gear strength calculation(steel)

Gear strength calculation has several spec types as shown in Fig.1.5 Fig.1.20 Strength calculation（stress coefficient）
for ISO6336:2006 based JGMA6101-02:2007 and JGMA 6102-02:2009
spec and JGMA401-01:1974, 402-01:1975. Design unit can be switched
between SI and MKS unit. Strength calculation power setup menu is
shown in Fig.1.17. Material selection is shown in Fig.1.18 for material
and heat treatment. Bending coefficient setup menu is in Fig.1.19, stress
coefficient setup menu in Fig.1.20, strength results are shown in Fig.1.21.

Fig.1.21 Strength results

bending strength of plastic cylindrical gears", a method for determining

the allowable bending stress of gears is based on testing, and POM
allowable bending stress is set as 80.0[MPa] based on testing, and
materials other than POM can be determined based on spec. Root
bending stress and allowable root bending stress by considering each
coefficient (root profile coefficient, life coefficient, ambient temperature
coefficient etc) can be compared to determine the safety. Please see spec
for details.
Fig.1.17 Strength calculation（Power setup） Plastic gear strength calculation example is shown in Fig.1.22,
strength geometry is shown in Fig 1.23, bending stress is shown in Fig.
1.10 Gear strength calculation(resin) 1.24, spur gear equivalent value is shown in Fig.1.25, coefficient and
Plastic gear strength can be calculated by JIS B 1759(2013) or Lewis safety factor are shown in Fig.1.26.
as shown by Fig.1.5. According to JIS B 1759 "Method for evaluating

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 Fig.1.27 Bearing load

1.12 Gear surface evaluation

In surface evaluation, sliding ratio, Hertzian stress, film thickness,
contact temperature, sliding speed, sliding speed drawing (PV value) are
displayed. These are not used for tooth surface modification. Also, film
thickness, contact temperature (gear temperature + flash temperature) are
Fig.1.22 Gear geometry based on AGMA2001-C95, Annex A. Thus, for analysis by considering
surface medication amount and load sharing, [45]CT-FEM Opera ⅲ
should be used. Oil types in Fig.1.28 can be Mineral oil, synthetic oil and
ISO grade (customized setting is possible). In addition, the friction
coefficient can be selected from a fixed value, ISO, AGMA method. Fig.
1.29 to 1.34 show the sliding ratio, Hertz stress graph, etc., but the
horizontal scale can be switched between roll angle and line of action
length.
Probability of occurrence of wear can be calculated from the oil film
thickness in Fig.1.31, and the probability of scuffing from the contact
temperature can be calculated as shown in Fig.1.32.

Fig.1.23 Strength geometry

Fig.1.28 Surface evaluation（setup）

Fig.1.24 Root bending

Fig.1.29 sliding ratio Fig.1.30 Hertz stress

Fig.1.25 Equivalent spur gear

Fig 1.31 Film thickness Fig 1.32 Flash temperature

Fig.1.26 Coefficient
1.11 Bearing load
Gear load and bearing load are calculated. Types of loads are
tangential force, normal force and 20 loads on bearings are calculated as
shown in Fig.1.27. Fig.1.33 Sliding velocity Fig.1.34 Sliding velocity drawing

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1.12a Sliding ratio and Hertz stress graph
As involute tooth form, meshing pitch circle will be rolling motion,
but others will involve slip motion. The example gear (mn=2, z1=15,
z2=24, α=20° normal spur gear) in Fig.1.35 (left column) has sliding ratio,
Hertzian stress, tooth surface contact temperature (gear temperature +
flash temperature) and oil film thickness graph. Large Hertz stress Fig.1.37 Gear test (specific R) Fig.1.38 Gear test (theoretical involute)
change is observed in early meshing cycle due to pinion root sliding ratio.
In this case, accuracy improvement would not help. In addition to contact 1.13 FEM (Tooth profile stress analysis)
ratio, sliding ratio and Hertz stress changes must be considered in design. After strength analysis, clicking [FEM] icon allows the users to carry
To smooth out Hertz stress changes, shift coefficient medication may out stress analysis. FEM analysis setup screen is shown in Fig.1.39. By
easily solve the challenge. It is important to consider sliding heat when providing longitudinal elastic modulus, Poisson's ratio, number of
designing resin gears. partitions and load point position and load (changeable), stress
When tooth modification (Smooth meshing) is carried out by using (σx ,σy ,shear stress τ，main stress σ1, σ2) can be analyzed. Gear strength
shift coefficient of xn1=0.24, xn2=-0.24 without changing center distance, reliability can be improved by evaluating both gear strength and actual
sliding ratio, Hertz stress and tooth surface contact temperature changes stress on teeth. Pinion max main stress σ1 distribution is shown in Fig.
are shown in Fig.1.36. As a result, scuffing probability is reduced from 1.40. Tooth profile displacement (contour display is possible) and
59.4% in Fig.1.35(c) to 17.9% in Fig.1.36(c), while wear probability is involute modification amount is shown in Fig.1.41.
reduced from 36% to 32%. Tooth profile modification is a useful method for improving driving
performance of gears, so even if the gears are accurate, the difference in
normal pitch occurs between the teeth of the drive and the driven gears
due to deflection of teeth at the time of meshing. Mismatch due to this
difference in normal pitch causes [vibration] and [sound]. Tooth profile
modification is one way to solve this. Since displacement of small elastic
modulus like resin material increases, it can be said that the tooth profile
(a) Sliding ratio modification effect is even greater. As shown in Fig.41, it is possible to
know the amount of deflection of teeth when determining tooth tip
modification by 2D-FEM, determination of 3D tooth surface
modification requires [45] CT - FEM Opera iii.

(b) Hertz stress

Fig.1.39 FEM setup（2D）

(c)Tooth surface contact temperature (flash temperature）

(d) Oil thickness

Fig.1.35 Normal gear Fig.1.36 Shift coefficient Fig.1.40 Max main stress σ1（Pinion）

1.12b ０class grade gear

Involute surface is as important as root shape. Involute testing result
(both flank meshing) is shown in Fig.1.37 by connecting root curve with
specific R. Also, theoretical trochoid curve involute test result is shown in
Fig.1.38. Considering the creation motion as the basis, the root shape is a
quasi-trochoid curve determined by (1) pressure angle, (2) basic rack root
height, (3) basic rack root R, (4) shift amount, (5) number of teeth.
involuteΣⅲ(spur and helical) can output theoretical involute curve.
Please see Appendix [D] for the effect of stress on the root shape. Fig.1.41 Tooth displacement & graph（Gear）

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 Fig.1.42 shows 3D-FEM analysis condition setting screen. Fig.1.43
shows pinion and gear stress distribution, and Fig.1.44 shows pinion and
gear displacement. Also, observation angle can be changed by vertical
rotation and horizontal rotation function with the scroll bar at the top of
the screen in Fig.1.43 and Fig.1.44, and the figure can be enlarged or
reduced with zoom function.
In this software, stress and displacement of the tooth is calculated
when a load acts on one tooth. However, stress, tooth displacement, axial Fig.1.46 Involute modification
angle error, tooth profile error, pitch error, and tooth surface modification
need to be considered when load is applied to multiple simultaneous
meshing teeth, please use [45]CT-FEM Opera ⅲ.

Fig.1.47 Lead modification

Fig.1.42 FEM setup（3D）

(a)Pinion (b)Gear
Fig.1.43 Max main stress σ1 Fig.1.48 Involute ＆ Lead modification & Topo graph

Modified tooth profile can be set with the tooth profile calculation data
in Fig.1.49. The tooth profile calculation conditions set here are valid for
the tooth form shown in Fig.1.10 to 1.14 and can be superimposed on the
tooth form rendering of Fig.1.14, so it can be displayed as shown in Fig.
1.50. Here, since tooth surface modification is given to Pinion, a yellow
(a)Pinion (b)Gear tooth surface appears within the red tooth surface in the figure (Gear is
Fig.1.44 Tooth displacement unmodified).

1.14 Gear modification（involute, lead, bias）

Fig.1.45 shows an example of giving tooth surface modification. In
order to obtain this tooth form, it is possible to give tooth profile
modification by numerical input as shown in Fig.1.46, or it can be done
by inputting a numerical value to patterned tooth form as shown on the
right side. Likewise, lead modification can also be set as shown in Fig.
1.47. Fig.1.49 Tooth calculation dimension
The tooth profile modification and lead modification represented in
Fig.1.48 can be copied on the opposite tooth surface for identical tooth
profile as shown in Fig.1.45. In addition, "involute", "lead",
"involute/lead" in the combo box at the top of the screen in Fig.1.48 can
be selected, and involute height direction can be assigned by line of
action or diameter. In addition, the magnification of tooth profile
modification can be set up to 1000 times.

Fig.1.50 Tooth rendering（tooth modification）

1.15 Contact pattern

It is possible to check the tooth contact by setting the tooth contact
condition in Fig.1.51 on the gear given the tooth surface modification
Fig.1.45 Tooth surface modification（Topo graph） (Fig.1.45). Here, the tooth contact is shown in Fig.1.52 and Fig.1.53

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when parallelism error and discrepancy error are 0 and the contact
maximum clearance is 2.0 μm.

Fig.1.56 TE result Fig.1.57 Wow flutter

TE analysis, Wow flutter, Fourier analysis results can be output to csv

file (361 pieces of data in this example) as shown in Fig.1.59 in the lower
Fig.1.51 Contact setup left corner of Fig .1.56 ~ 1.58
This software is a TE analysis test with no load. For TE analysis
corresponding to load and shaft angle error, please use [45]CT-FEM
Operaⅲ.

Fig.1.52 Contact pattern（Pinion）

Fig.1.58 Fourier analysis Fig.1.59 csv file example

1.17 Tooth profile output

The generated tooth profile can be output in the tooth profile file
format shown in Fig.1.60. In the case of 3D-IGES, it is possible to select
integrated type and separated type of tooth profile,
In the case of a separated type, it is split into a root fillet part, involute
Fig.1.53 Contact pattern（Gear）＆ magnified tooth surface, tooth tip R, and a tooth tip, and then output as shown in Fig.
1.61. In the coordinate correction setting shown in Fig.1.62, it is possible
1.16 Transmission error (TE) analysis to output tooth profile considering the module shrinkage rate, pressure
In TE analysis, it is possible to perform a rotation transmission error angle correction, helix angle correction, and discharge gap in
test under no load with a non-modified tooth profile or the tooth profile consideration of use for molds. As an example, Fig.1.63 shows a tooth
given in Fig.1.45. The TE setting is shown in Fig.1.54. In this case, 2D profile (2D) considering the module shrinkage factor of 20/1000. Also, it
analysis or 3D analysis can be selected, and axis runout and rotation is possible to output the tooth profile coordinate value as a text file as
speed can be set. As for pitch error, maximum value or pitch error of all shown in Fig.1.64.
teeth can be set as shown in Fig.1.55. TE analysis, wow flutter (rotation （arc or line）
irregularity) and Fourier analysis results are shown in Fig. 1.56 to 1.58.
In Fig. 1.57 [Sound] can be heard.

Fig.1.60 Tooth file format Fig.1.61 CAD sample

(a)Pinion (b)Gear
Fig.1.54 TE setup

(a) Max value setup (b) All teeth setup

Fig.1.55 Pitch error setup Fig.1.62 Coordinate correction setup Fig.1.63 CAD sample

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 Fig.1.67 Rendering
Fig.1.64 Text file (.txt)

1.18 Internal gear

Internal gear can be calculated like External gear by selecting
"External gear × Internal gear" in Fig.1.3. Fig.1.65 shows concept
dimensions, while Fig.1.66 shows detail dimensions. Fig.1.67 shows
tooth profile rendering while Fig.168 shows tooth contact pattern. In
addition, Pinion that meshes with Gear in Fig.1.68 is given the same
tooth surface modification as Fig.1.45. Strength calculation, TE analysis,
FEM analysis and tooth profile output are the same as "External gear x Fig.1.68 Contact pattern（Gear）
External gear".
1.19 HELP feature
[HELP] function can be used to understand the operation method. For
example, if the user wants to know about gear accuracy, by activating
the "Precision" form and press the [F1] key, the explanation about
accuracy is displayed as shown in Fig.1.69.

Fig.1.69 HELP function

Fig.1.65 Concept dimension（Internal gear）
1.20 Design data management（Saving / Loading）
The design data can be saved and loaded as shown in Fig.1.70. In
addition to the control number and the title, users can also retrieve the
data from the gear specification (module, number of teeth, pressure angle,
helix angle).

Fig.1.70 Data saving, loading

Fig.1.66 Detail dimension（internal gear）

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