SCHOOL OF ENGINEERING

THE EFFECT OF SUPERFINISHING ON GEAR

TOOTH PROFILE
Sponsors: US Army Research Development &
Standardisation Group UK London
Contract Number N68171-96-C-9043
FINAL REPORT
R W Snidle H P Evans M P Alanou

Report No 2284 June 1997

Division of Mechanical Engineering

and Energy Studies

Engineering
Approved for public release;
Distribution Unlimited

19970728 140 COLEG Y BRIFYSGOL

CMRDYDD
YSGOL BEIRIANNEG
THE EFFECT OF SUPERFINISHING ON GEAR
TOOTH PROFILE
Sponsors: US Army Research Development &
Standardisation Group UK London
Contract Number N68171-96-C-9043
FINAL REPORT
R W Snidle H P Evans M P Alanou

Report No 2284 June 1997

rac
^^aa.

Approved for public release;

Kstributkm Unlimited
Research Project "The effect of superfinishing on gear tooth profile"
Sponsors: US Army Research Development & Standardisation Group UK London
Contract Number N68171-96-C-9043

FINAL REPORT

R W Snidle H P Evans M P Alanou

School of Engineering
University of Wales Cardiff
Cardiff CF2 3TA, UK

SUMMARY

The report describes the results of a project carried out to determine the effect of
superfinishing of gears on the profile and surface finish of the teeth. A batch of fourteen
NASA 3.5 inches reference diameter spur test gears were prepared in the usual way by
grinding. The gears were inspected for profile and lead quality and surface profiles taken.
The gears were then superfinished by the "Abral" process. Following superfinishing the gears
were again inspected and surface profiles taken. It was found that typically the surface finish
improved from about 0.4|j.m roughness average (Ra) to better than O.lum Ra. Results of gear
metrology inspection showed that the quality of the gears in terms of profile and lead was not
affected by this process. It was concluded that approximately 2.5um had been removed from
the tooth surfaces as a result of superfinishing.

For further information please contact:

Dr R W Snidle
Division of Mechanical Engineering
University of Wales Cardiff
PO Box 925
Cardiff CF2 3TA
UK

Tel: (01222) 874273 Fax: (01222) 874317 E-mail: SnidleR@cardiff.ac.uk

Research Project "The effect of superfinishing on gear tooth profile"
Sponsors: US Army Research Development & Standardisation Group UK London
Contract Number N68171-96-C-9043

FINAL REPORT

R W Snidle H P Evans M P Alanou

School of Engineering
University of Wales Cardiff
Cardiff CF2 3TA, UK

1. INTRODUCTION

The objectives of this project were summarised in the STATEMENT OF WORK included in the
contract document as follows:

OBJECTIVES: The overall aim of the proposed research is to improve the

durability of gears used in helicopter transmissions. The two primary
questions to be addressed are as follows:

a. Will the superfinishing process adversely affect gear tooth shape ?

b. What is the relationship between gear tooth surface roughness and gear
life, especially for superfinished gears?

The project carried out at University of Wales School of Engineering was mainly concerned
with objective (a); the second objective (b) is to be completed at NASA-Lewis Research
Center where fatigue testing of the superfinished gears supplied by the University is now
taking place (June 1997).

In order to accomplish task (a) arrangements were made for a batch of 14 standard NASA test
gears (28 teeth, 8DP, 6.35 mm facewidth) to be delivered to University of Wales. The gears
had been finished by grinding in the usual way.. On arrival the gears were inspected to
determine the initial accuracy and surface finish. They were then superfinished and re-
inspected to determine the effect of superfinishing on accuracy and surface finish. Detailed
results of the project are given as follows.

2. INITIAL INSPECTION

2.1 Gear metrology

Four gears were randomly selected for detailed inspection from the batch of 14 supplied.
These were already stamped with serial numbers as follows:

AMS6260 #11
#15
#20
#23
The four gears were sent to the UK National Gear Metrology Laboratory at Newcastle
University. The following parameters were measured on each gear:

lead and profile errors on four teeth, left and right flanks, spaced at 90 degree intervals;
adjacent and cumulative pitch errors on all teeth, left and right flanks;
radial runout of the tooth space;
mean circular tooth thickness.

A reference tooth ("tooth 1") on each gear was marked so that re-examination could be carried
out on the same teeth following superfinishing. Four teeth (Teeth 1, 8, 15, 22) were used in
the gear metrology tests. This initial metrology showed that the gears were generally to DIN
grade 5 or better on profile and lead. A copy of the metrology report on the gears as received
(dated August 1996) is shown in Appendix 1.

2.2 Surface finish

In order to show the detailed effects of superfinishing it was decided to take "re-located"
profiles from the gear teeth before and after finishing. This was achieved by use of a special
stepper motor-driven profilometer with which it was possible to take a profile or series of
profiles at a precisely known location on a gear tooth. The principle of relocation was based
on detection of the edges of the gear tooth by running the profilometer stylus in the axial
direction of the gear to detect the side of the tooth and radially to detect the tooth tip. Three
profiles were taken from both sides of two teeth (teeth 1 and 15) on each gear (i.e. a total of
12 profiles from each gear). Two of the three profiles on each gear flank were located 1mm
from each side edge and the third profile was on the centre line as illustrated in Figure 1.
Profile data was taken up to and slightly beyond the tip of the teeth as a direct means of
verifying the accuracy of relocation in every case. Figure 2(a) shows a typical profile obtained
in this way. It should be noted that the profiles are measured relative to a nominal circular-arc
datum and the long wavelength undulations do not indicate any deviation of the profile from
the desired involute but simply the deviation of the gear tooth profile from a nominal circular
arc. All profiles were processed using a standard phase-corrected digital filter with a cut off
of 0.08 mm. The length of the raw profile which appears in the filtered data is shown in
Figure 2 (b) and the same length of profile after filtering is shown in Figure 2 (c). All
Roughness Average (Ra) and ten-point height parameters (Rz) values quoted in this report are
calculated from profiles filtered with the above cut off.

The centre profile (y=3.175 mm) from each flank of the two teeth examined on all four of the
gears as supplied are shown in Appendix 2 for reference. The remaining profiles taken at
lmm from each edge of the flanks (y=lmm and y=5.35 mm) are not shown for reasons of
space, but are available if required.

3. INSPECTION AFTER FIRST PHASE OF SUPERFINISHING

3.1 Gear metrology

Following initial inspection the gears were superfinished using the Abral process at Westland
Engineering of Yeovil, England. In this process the gears are immersed in bed of small zinc
chips, water and aluminium oxide powder. The container (a rubber-lined open tank) is
vibrated for a period of several hours and the grade of the oxide powder is increased in
fineness in several stages. In the first attempt at finishing the gears were clamped together and
mounted along with several other gears of different types that were being handled at the time
by Westland Engineering. Although the NASA gears appeared at first sight to be suitably
superfinished it was subsequently found on detailed inspection that a further stage of treatment
was needed in order to achieve the finish (Ra<0.1[im) that was expected on the basis of
previous work. The gears were, however, checked at this un-planned "intermediate" stage
and this proved to give a good quantitative measure of the rate of surface removal in the
process.

Gear metrology was again performed at Newcastle where it was found that there was no
significant change in the profile of the teeth. It was concluded from the metrology work that
an average of approximately lum of stock had been removed from the tooth flanks. The
inspectors also commented that the initial grinding marks were visible on some of the teeth.
The full report (dated December 1996) corresponding to this "intermediate" stage of finishing
is given in appendix 3.

3.2 Surface finish

The above comments by the metrology inspectors were confirmed at Cardiff by relocated
surface roughness profiles. Figure 3, for example shows relocated profiles from two teeth
diametrically opposed on gear #11 (i.e. teeth 1 and 15). Comparison of profiles before and
after finishing of tooth 1 (Figures 3(a) and 3(b)) show a significant degree of surface
improvement, but recognisable deep valley features are still present. These features are
indicated with small arrows in both profiles as shown. From this comparison we can see that
about 2um of metal has been removed from the surface. On the opposite tooth (tooth 15),
however, there is less evidence of polishing and comparison of Figures 3(c) and 3(d), which
are profiles from this tooth, suggests that about lu.m or less has been removed. This uneven
and incomplete finishing of the teeth was judged to be unsatisfactory and it was decided to
carry out a second stage of finishing by repeating the process.

In order to promote an even finishing during the repeat run the gears were clamped together on
their own separate mandrel which could circulate freely in the vibrating finishing tank. The
mandrel had "dumb-bell" ends to prevent contact between the gears and the sides and bottom
of the tank. A run of the finishing process was devoted to the gears and they were the only
parts in the tank. A photograph of the gears clamped on their mandrel is shown in Figure 4.
The gears were processed for the standard run time as before. After this second stage of
processing the gears were found to have a superb mirror finish and visual inspection showed
no signs of the initial grinding marks.

4. INSPECTION AFTER SECOND STAGE OF SUPERFINISHING

4.1 Gear metrology

The gears were again checked at Newcastle University and were found to be DIN grade 5 or
better on both profile and lead as before. The report (dated March 1997, see Appendix 4)
concludes:

"The measurement results and a visual examination of the measurement traces shows that there
is very little difference between the initial flank geometry and the final flank geometry. The
superfinishing process has still not changed the basic flank form error but the grinding feed
marks have been removed on all the teeth. The normal circular tooth thickness measurements
show that after the results are corrected for the probe datum error, an average of
approximately 2.5jum of stock has been removed from each flank"

4.2 Surface finish

Following the second stage of superfinishing the four sample gears were again inspected.
Three profiles from both sides of two teeth on each of the four selected gears were taken.
Typical comparisons of the initial ground finish, the intermediate finish and the final
superfmished surface are shown in Figure 5. Again, the profile taken after the first stage of
finishing shows persistence of identifiable grinding marks. These have almost completely
disappeared from the profile taken after the second stage (Figure 5 (c)) although there are still
faint signs of some particularly deep marks. One such mark is indicated with an arrow on all
three profiles. Comparison of such features with the initial profile suggests that about 2-3 urn
has been removed from the surface. This estimate taken from surface profilometry agrees well
with the estimate obtained from the gear metrology measurements. Ra and Rz values for all
profiles from all the sample gears before finishing and after the second stage of superfinishing
are shown in Tables 1-8. It should be noted that the profiles were digitally filtered with a cut
off of 0.08 mm.

The centre profiles (y=3.175 mm) from each flank of the two teeth examined on all four of
the finally finished gears are shown in Appendix 5 for reference. The remaining profiles taken
at 1mm from each edge of the flanks (y=lmm and y=5.35 mm) are not shown for reasons of
space, but are available if required.

Typical three-dimensional surface plots from ground and superfinished surfaces are shown in
Figures 6 and 7, respectively. Note that the two surfaces are plotted to the same vertical scale
for comparison.

It should be noted that the profile data from the right flank of tooth 1 of gear #15 after
superfinishing were badly affected by vibration during data acquisition; the Ra and Rz values
for the three profiles affected should therefore be ignored. These profiles are not shown in
Appendix 5.
 Table 1. Roughness Average (Ra) results (jam), Gear AMS6260 #11

Tooth Flank Position Ra as ground Ra after superfinish

y = lmm 0.434 0.0558
left y=3.175mm 0.425 0.0529
1 y=5.35mm 0.417 0.0607
y=lmm 0.351 0.0805
right y=3.175mm 0.358 0.0962
y=5.35mm 0.346 0.0753
y=lmm 0.432 0.0884
left y=3.175mm 0.450 0.0707

15 y=5.35mm 0.433 0.0674

y=lmm 0.322 0.0458
right y=3.175mm 0.320 0.0674
y=5.35mm 0.350 0.0608

Table 2. Roughness Average (Ra) results (|im), Gear AMS6260 #15

Tooth Flank Position Ra as ground Ra after superfinish

y=lmm 0.484 0.0912
left y=3.175mm 0.513 0.1008
1 y=5.35mm 0.477 0.0926
y = lmm 0.358 0.1322*
right y=3.175 mm 0.366 0.1366*
y=5.35mm 0.348 0.1454*
y = lmm 0.476 0.0620
left y=3.175mm 0.471 0.0525
15 y=5.35mm 0.470 0.0658
y=lmm 0.333 0.0583
right y=3.175mm 0.335 0.0552
y=5.35mm 0.341 0.0676

* Vibration during acquisition of these three superfinished profiles

 Table 3. Roughness Average (Ra) results (um), Gear AMS6260 #20

Tooth Flank Position Ra as ground Ra after superfinish

y=lmm 0.415 0.0723
left y=3.175mm 0.458 0.0759
1 y=5.35mm 0.471 0.0972
y = lmm 0.372 0.0429
right y=3.175mm 0.364 0.0575
y=5.35mm 0.350 0.0600
y=lmm 0.394 0.0763
left y=3.175mm 0.415 0.0785
15 y=5.35mm 0.435 0.0735
y=lmm 0.351 0.0518
right y=3.175 mm 0.341 0.0590
y=5.35mm 0.335 0.0598

Table 4. Roughness Average (Ra) results (um), Gear AMS6260 #23

Tooth Flank Position Ra as ground Ra after superfinish

y=lmm 0.400 0.0711
left y=3.175mm 0.402 0.0629
1 y=5.35mm 0.418 0.0553
y=lmm 0.270 0.0683
right y=3.175 mm 0.275 0.0642
y=5.35mm 0.259 0.0659
y=lmm 0.343 0.0976
left y=3.175 mm 0.343 0.1062
15 y=5.35mm 0.355 0.0879
y=lmm 0.268 0.0623
right y=3.175mm 0.275 0.0730
y=5.35mm 0.267 0.0615
 Table 5. Ten-point parameter (Rz) results (jam), Gear AMS6260 #11

Tooth Flank Position Rz as ground Rz after superfinish

y = lmm 3.75 0.61
left y=3.175mm 3.64 0.55
1 y=5.35mm 5.50 0.73
y=lmm 3.03 1.07
right y=3.175mm 3.24 1.56
y=5.35mm 3.08 0.86
y=lmm 3.69 1.20
left y=3.175mm 4.01 0.88
15 y=5.35mm 3.63 0.63
y = lmm 2.72 0.50
right y=3.175mm 2.63 1.06
y=5.35mm 2.65 0.68

Table 6. Ten-point parameter (Rz) results (^im), Gear AMS6260 #15

Tooth Flank Position Rz as ground Rz after superfinish

y = lmm 3.84 1.36
left y=3.175mm 4.08 1.55
1 y=5.35mm 3.90 1.48
y = lmm 3.73 . 1.23*
right y=3.175mm 4.01 0.84*
y=5.35mm 3.88 1.30*
y = lmm 4.13 0.93
left y=3.175mm 4.30 0.71
15 y=5.35mm 3.93 1.20
y=lmm 3.77 0.77
right y=3.175mm 3.84 1.04
y=5.35mm 3.57 1.08

Vibration during acquisition of these three superfinished profiles

 Table 7. Ten-point parameter (Rz) results (um), Gear AMS6260 #20

Tooth Flank Position Rz as ground Rz after superfmish

y=lmm 3.78 1.14
left y=3.175mm 4.38 1.00

1 y=5.35mm 4.69 1.38

y = lmm 3.38 0.49
right y=3.175mm 4.03 0.64
y=5.35mm 3.35 0.68
y = lmm 3.54 1.35
left y=3.175mm 3.61 1.14

15 y=5.35mm 3.46 1.11

y = lmm 3.49 0.59
right y=3.175mm 3.34 0.63
y=5.35mm 3.72 0.59

Table 8. Ten-point parameter (Rz) results (um), Gear AMS6260 #23

Tooth Flank Position Rz as ground Rz after superfmish

y = lmm 3.44 1.00
left y=3.175 mm 3.34 0.95
1 y=5.35mm 3.92 0.82
y=lmm 3.05 0.84
right y=3.175mm 2.86 0.73
y=5.35mm 2.56 0.79
y=lmm 3.01 1.16
left y=3.175 mm 2.98 1.39
15 y=5.35mm 3.00 1.20
y=lmm 2.47 0.68
right y=3.175mm 2.66 0.86
y=5.35mm 2.80 0.67
5.. DISCUSSION AND CONCLUSIONS

As a result of careful gear metrology and surface profilometry it was found that the amount of
surface metal removed during the standard process as implemented by Westland Engineering
was relatively small and did not have any adverse effect on the gear tooth geometry or profile.
The test gears as supplied were found to comply to DIN grade 5 or better and they were still
within this grade after finishing. One cycle of the standard process was found to leave witness
traces of the initial grinding, and in order to achieve the best possible finish a second cycle of
the process was applied. After two cycles of finishing it was concluded on the basis of both
metrology and surface profile measurements that about 2.5(j.m of surface metal had been
removed from the gear flanks. This would appear to be about the minimum required to
remove all traces of the initial grinding marks for gears with an initial nominal finish of 0.4
urn Ra. The final surface finish of the gear flanks was in the range 0.05-0.1 |im Ra. In
conclusion, therefore, the answer to the question "Will the superfinishing process adversely
affect gear tooth shape?" is: no, the process as presently implemented gives minimum metal
removal and ensures the integrity of the tooth profile. This conclusion assumes, of course,
careful control of the process.

6. ACKNOWLEDGEMENTS

We are grateful to Mr Graham Wilkie and Mr Paul Fisher of Westland Engineering for their
careful finishing of the gears and to Mr Rob Frazer of Newcastle University Design Unit for
his equally careful gear metrology.

7. FURTHER INFORMATION

For further information please contact:

Dr R W Snidle
Division of Mechanical Engineering
University of Wales Cardiff
PO Box 925
Cardiff CF2 3TA
UK

Tel: (01222) 874273 Fax: (01222) 874317 E-mail: SnidleR@cardiff.ac.uk

Figure 1. Illustration of gear tooth showing x,y coordinates and location of the three profiles
(shown as broken lines) taken from both sides of two teeth from each gear. The y-coordinates
of the profiles shown are:
(a) y=l mm
(b) y=3.175 mm
(c) y=5.35 mm
Start and end x-coordinates of raw profiles are x=3.097 mm and x=-0.1 mm, respectively.
(The negative end coordinate ensures that tip of tooth is detected as a check on relocation of
profiles in x-direction.)
 100 pan.
NASA gear #11 (ground), tooth 1/left, x=-.lmm y= 3.175mm

100/tm
NASA gear #11 (ground), tooth 1/left, x=-.lmm y= 3.175mm

(c) RD861.FIL

^t^^ I
lfjiva.

100 fim
NASA gear #11 (ground),tooth l/left,x=-.lmmy= 3.175mm(filtered:Ra=0.425/tm/0.08mmcutoff)

Figure 2. Showing (a) typical raw surface profile from ground test gear as acquired;
(b) length of raw profile that appears in filtered data file; (c) profile after digital filtering (cut
off = 0.08 mm).
Figures above graphs (a) and (b) are the digitally stored ordinate numbers of the data. Filtered
data file contains ordinates 73-2628 from the raw data. Ordinate spacing=1.102|j.m; total
length of filtered profile=2.82mm. Note that tip of tooth is detected as a check on relocation,
and is shown on profile (a) as the sharp drop at the right hand end of the profile.
 100/im
NASA gear #11 (ground),tooth l/left,x=-.lmm y= 3.175rnm(filtered:Ra=0.425/tm/0.08mm cutoff)

(b) RD1004.FIL

1/nn
I t tf I
100/im
NASA gear #11 (polished),toothl/left,x=-.lmm,y=3.175mm(filtered:Ra=0.071/im/0.08mm cutoff)

Figure 3. (a) typical profile from ground gear before finishing; (b) re-located profile from
same tooth after first stage of superfinishing. Note persistence of identifiable deep valley
features as indicated on both profiles.
 100 /mi
NASA gear #11 (ground),tooth 15/left,x=-.lmm y=3.175mm(filtered:Ra=0.450^m/0.08mm cutoff)

(d) RD1007.FIL

I
l/*m
* t i ft
100/im
NASA gear #ll(polished),toothl5/left,x=-.lmm,y=3.175mm(filtered:Ra=0.229/im/0.08mm cutoff)

Figure 3 (continued), (c) typical profile from ground gear before finishing; (c) re-located
profile from same tooth after first stage of superfinishing. Note persistence of identifiable
deep valley features as indicated on both profiles. Note that the profiles shown in (c) and (d)
are from a tooth diametrically opposite the tooth shown in Figure 3 (a) and (b).
 ^f^iiU^ifriMtl) ti ill ii 11111 ill 1111111 iti n ITTI i iliiihiiliiih JiiihiiliiililJilihlililililililililtliliMijilihhhhj

*.-, !:./:;, >--&&a^ia*fiitBlSml

Figure 4. Photograph showing test gears clamped on mandrel used for superfinishing
 100 um
NASA gear #11 (ground), tooth 1/left, x=-.lmm y= 1mm (filtered: Ra=0.434^m/0.08mm cutoff)

(b) RD1003.FIL

*Y*f~<yf\*tl**<rf~*r*^^ '''VVv/*vVsr>*' '^*^*/^A/^,w'^fv>*rfv^,^v^^ I

Ifim
t

100 urn
NASA gear #11 (polished), tooth 1/left, x=-.lmm, y= 1mm (filtered:Ra=0.083/*m/0.08mm cutoff)

(c) RD1069.FIL

s |i<vts^^>i^/*v|w'^>^-Mv>v**-vvy* Aj A **yfr >*^dA'wft|

l/xm
T

100 ^im
NASA gear #11 (polished) tooth 1/left, x=-.lmm, y= 1mm (filtered: Ra=0.056^m/0.08mm cutoff)

Figure 5. Re-located profiles from (a) ground tooth surface; (b) same tooth surface after the
first stage of superfinishing; (c) same tooth after second (final) stage of superfinishing. Note
that initial finish is apparently removed but there is evidence of slight persistence of the
deepest grinding marks as indicated, this indicates that about 2.5 um has been removed from
the surface.
 100/xm
i 1 100 um

NASA gear #23 (ground) tooth 1/left, xdim=0.50 mm, ydim=0.99 mm

08-30-1996 file: 3D28.DAT No of profiles= 45; ordinates/profile= 452
YSCALE= .7633588

Figure 6. Typical three-dimensional surface plot from ground gear (before superfmishing).
 lOOfim
i 1 100 pm

NASA gear 11 (polished) tooth 14/right, xdim=0.50 mm, ydim=0.99 mm

03-20-1997 file: 3D56.DAT No of profiles= 45 ; ordinates/profile= 452
Surface is relocated: x=2.00 mm, y=1.00 mm
YSCALE= .7633588

Figure 7. Typical three-dimensional surface plot from superfinished gear.

 APPENDIX 1

INITIAL METROLOGY INSPECTION OF GEARS

AMS6260 #11
#15
#20
#23
 DESIGN UNIT GEAR TECHNOLOGY CENTRE
University of Newcastle upon Tyne
Department of Mechanical
Materials & Manufacturing Engineering
Stephenson Building
Newcastle upon Tyne NE1 7RU

PROJECT GM. 373/1

7th August 1996

SUPERFINISHING INVESTIGATION
INITIAL MEASUREMENT

For: Cardiff School of Engineering

University of Wales
Queens Buildings
The Parade
PO Box 917
Cardiff
CF2 1XH

Gear Reference: AMS 6260

Samples Checked: No. 11, 15, 20 & 23

Parameters Measured:
The following parameters were measured on each gear:

1. Lead and profile errors on 4 teeth, left and right flanks, spaced at 90 intervals.
2. Adjacent and cumulative pitch errors on ail teeth, left and right flanks.
3. Radial runout of the tooth space.
4. Mean circular tooth thickness.

Results:
Record sheets for each of the gears are included in this report. A full analysis will
be carried out after the gears have been superfinished.

Refer to Appendix A for assistance with interpreting the record sheets.

Director: 0. A. Hof mann Tel: (0191)222 6192
M.E.Norman J. Rosinski Direct Dial: (0191) 222
R. Ashby J. Haigh Fax: (0191)222 6194
E.J.Myers R. C. Frazer E.Mail:
 DESIGN UNIT University of Newcastle upon Tyne
Department of Mechanical,
Materials & Manufacturing Engineering
Stephenson Building
Newcastle upon Tyne NE1 7RU

GEAR MEASUREMENT SUMMARY SHEET

Client: L'we/a^ erf 6<>,/<2A DU Reference : dph [ s 1 5>

Gear Drawing : - /V/V) S & 2 &O

c
Gear Reference : g&z AJ // / 5 ZO < "2- S

Manufactured By:

Parameters Measured : Lead / Profile / Pitch / Runout / Tooth thickness / runout of reference bands.

Runout of Reference Bands : /\.CT chec k'$M

~J
uSttfx etched defsnfo ^rt tte* -fo,
P
Accuracy requirements:

Results:

PARAMETERS TOLERANCE MAX. ERROR COMMENTS

(Um) (urn)

LEAD -
PROFILE

ADJ. PITCH

CUM. PITCH

'RUNOUT

PITCH DIFF.

THICKNESS

General comments :

1. Gears have been measured in accordance with the code of practice DUCOP.03 for Involute
Gear Measurement.

I. TOTi AJW.5 / /5 <f Zl ( hii/i2 t<r\ ekeckid ra^

-5 .
Equipment: Machine: HCFL(^&1 =yw 63 2 Probe: A' /- 2

All measurements were earned out on traceably calibrated equipment in the UK National Gear Metrology
Laboratory ( NAM AS Accreditation number 0250 ).

Measured by n,
klCMflgW Date:
6 - atia >&
Director: D. A. Hofmann. BSc. CEng, MIMechE. MIEE
Senior Engineers: M. E. Norman, BSc, MSc, 8A,CEng, MIMechE Tel: (091)222 6192
R. Ashby, BSc, CEng, MIMechE Direct Dial: (091)222
E. J. Myers, SSc, CEng, MIMechE
Fax: (091)222 6194
 TOOTH 4

"TOTT-/ %
TOThf 12.

TDOTH IS

TO TH Aj u M ee 5

Calculated by Checked by Calculation Title

! ( DESIGN UNIT Universlty of Newcastle upon Tyne Project No. Date Item/Sheet No.
 DESIGN UNIT Lead + Profile Test
Designation: m'" 3.175 mm
6.35
CO
Part No.: AMS6250/7, z
S
o o
28 4 90
05 -
CO
C
REMARKS: REF 11-1ST a
" 2Q,Q'0" dh 83.539 mm
S|
O P O'O'O"
< V)

CM 3
co v) Quality R.eqdpp: 5 / Le: 5 Act.pr: 5 . /. [_e: 2 Regd.pr; 5 / Le: 5 Act. pr: 5 / Le: 2
a> zs
co o
3 Left Rank 2 1 tooth 1 2 Right Rank 3
If
Ol0)

WSBfi.PW-'.-.i^+i. rr^rr^^S^
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMS6250/./.
REMARKS: REF 11-1ST
z= m 3.1 75mm =- o'o'Q"
-2L R 88.900 mm | Date/lnsp.:p5 pg igg5/RnF
f fu * Fn,/8 fn fu * FDZ/8 Fr
Reqd.Qual. 5 E
5 5 5 5 5 5 5 5
Limit Value 5.0 6.0 20.0 12.0 c
5.0 6.0 20.0 12.0 14.0
Act Value CO
2.1 2.3 10.1 5.7 1.6 2.6 6.7 4.6 5.6
CO

Act Qual 2 1 3 3 2 3 2 3 3 2
TOOTH THICK: MOM.VAL. Min. Max.
E MAX.T.NO.: MEAS.VAL
4.987 0 0 4.871
.JZ
O J>
CD C
10 c
^ cd _ CO
um rjc
a
< OJ
J 1-1 n ft n n ^ ^ r-. r-i
U uu "

CM to
co <n
if
05
2
co o
SlS
Qc EJMIN.T.N0.: 14
t-J BMIN.T.NO.: 13
-.
.2-0)
CO 3

33 1
u u u
i-i "* i-Qn n n n n _ n 1
u >- u '
10 %
um -1
o
El MAX.T.NO.: 2

S MAX. '.NO.: 13

r
10 CO
LL.
urn
O O)
CX

BMIN.T.NO.: 25
Fp^
B MIN.7.NO.: 13

<>
10
(jm

BMAX.T.NO.: 24

BMAX.T.NO.: 10
Fr

10 ^nnnn-nflnnn-
UU
urn UUUULJL

IEIMIN.T.NO.: 24
 DESIGN UNIT
Lead + Profile Test
Designation: m
co
' 3.175 6.35
s^ Part No.: AMS6260/./. 28
o o
o> c
i 90_
CO REMARKS: REF 15-1ST * 20'0'0' dh 83.539 mm

C3 o O'O'O1
< to

CVJ (0
CD <n
Quality Regdpr; 5 / Le: 5 Act.pr: 5 / Le; 2 Reqd.Pn:5 / 5 Act. 4 / ]
05 3 Le: Pr: Le:
CO O
2 Right Rank 3
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AM.S6250/./.
REMARKS: REF 15-1ST
m
_2S_ ~ 3.175mm p- n'o'n" R 88. 900 mm | Date/lnsp.qe. 08.1996/RCF
f fu * FV8 f fu # Foz/8 Fr
Reqd. Qual. E
5 5 5 5 5 5 5 5 5
Limit Value c
5.0 6.0 20.0 12.0 5.0 6.0 20.0 12.0 14.0
Act Value CO

1.8 2.2 4.4 3.7 1.9 1.5 6.7 4.2 8.8

03

Act Qual. 2 1 1 2 2 1 2 2 4 5
TOOTH THICK: NOM.VAL. Min. Max.
CO 3 MAX.T.NO.: 28 4.987 0
MEAS.VAL
0 4.662
oo
CJ c
10 c
pm g t"1 -~ -
o ' ^
LJ i-i 1-1 utxn"= =-=-

ir

17
t-lBMIN.T.NO.: EIMIN.T.NO.:

22

<> -= U " [J I
10
pm
~6~
E MAX.T.NO.: 12

0 MAX.T.NO.: 11

JQL
10 3
um t

BMIN.T.NO.: 24

El MIN.T.NO.: 17

Jet

10
pm

E MAX.T.NO.: 8

0 MAX.T.NO.: 21
Fr

10 nnnfinrinnnnnn
pm "^TTLTTJ U u
uu
~6~

BMIN.T.NO.: 6

um^m-msscJ'issjryf.ni'jm^;':^
 DESIGN UNIT
Lead + Profile Test
Designation: n mm
" 3.175 6.35
CO
Part No.: AMS6260/./.
S-=
O O
28 Jj 90_
co REMARKS: REF 20-1ST a
" 20'0'Q" dh 83.539 mm

o< to O'O'O'

ss Quality Regdpr; 5 / Le: 5 Act.pr: 5 / Le: 5 Regd. Pr: 5 / Le: 5 Act. Pr: 3 / Le: 1
CO O
3 Left Rank 2 1
tooth 1 2 Right Rank 3 4
Qc
o,2

o
Bottom Qh 3
15
Left Rank 2
8
1
1 Tooth Nol
tooth 1 2 Right Rank-3
15 22
CJ
o cc.
pa
< 8 : 1
>
a O !(.32
o
J
o
1.25
OS
mm
W
O
s "O
es ca
<
w
a 1000
<
z 10 |o
o
M
OJ
< m
ZCO
urn
i-
Top

LU Limit Value I
CO
Limit Value
Kl -~ :
gQ/7

i co _2J_ _LL JJL 3?l4 0/7 -LI ?? -LI nil

O ''PQ/4.5 JLL 3.0 2,7< 5 0/4.5
a -LL -LI JLi 1 ail
H0+-6 -1.7 -1.2 0.0 -,9l 1 +-6
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMS6260/.7.
REMARKS: REF 20-1ST
z- gg |m= 3.175mm = O'O'O" R
88.900 mm Date/lnsp.:Q6.08.1996/RCF
fn f x F,/8 fn f * Fnz/8 Fr
Reqd. Quai 5 E
5 5 5 5 5 5 5 3.
Limit Value 5.0 6.0 20.0 12.0 5.0 c
6.0 20.0 12 14.0
Act Value 2.7
in
3.8 8.5 4.1 1.1 2.0 4.5 2.E
Act Qual. 5.6
4 4 3 2 1 1 1 1 3 3
B MAX.T.NO.: 12 TOOTH THICK: NOM.VAL.
4.987
Min.
0
Max.
0
MEAS.VAL
4.863
J&_
10 c
pm |f

if

BMIN.T.NO.: 11
p-J
BMIN.T.NO.: 10

- n ^ r-i n
tnr=Tr
10 %
pm -1
O
BMAX.T.NO.: 4

0 MAX.T.NO.:

10
Mm i
O 3

BMIN.T.NO.: 19
Fp-J
BMIN.T.NO.: 5

__ c

io
pm
O

BMAX.T.NO.: 20

BMAX.T.NO.: 9
Fr

10 ,nnnnnnnnn ''"UUUUUL:
|jm
O

BMIN.T.NO.: 21
 DESIGN UNIT
Lead + Profile Test
Designation: n mm mm
" 3.175 6.35
Part No.: AMS6260/./.
S-=
o u 28 j^ 90.
a> c
C3 REMARKS: REF 23-1ST ao'o'o"
" dh 83.539 mm
II
O

O'O'O'
< <n
b
-1
C\J BJ
CO V)
cn D
Quality Regdpr; 5 / Le: 5 Act.pr; 5 / Le: 3 Regd. Pr: 5 / Le: 5 Act. Pr: 3 / Le: 3
co o
4 3 Left Rank 2 1 tooth 1 2 Right Rank 3
SiS 4
Qc Tip
Oj2
^ E 2 : 1
S3
. O
>" to
S CD
CO 3 5
55 mm
0} 30.12

o+
1000 Q.
94.3

o| io |o
um
o
Root
to
cn Limit Value
cn
F
0/7 4.7
ca
o fa 0/5 4.5
Ha+-4,5

3 Left Rank 1 tooth 1 2 Right Rank-3

o
Bottom 02 15 1 Tooth Nol 15 a !
C_J
o cc.
<
J 8 : 1
.32
>H O JL32
o
J 1.25
o mm
OS
fcd o
S "O
cd
<
w
a'
CJ 1000
<
O
ol 10 o
M
pm 6.03\
t JB.03

Top

LU Limit Value
Limit Value
*^. F
T 8 0/7 _LL 0/7
co LL _LL 2A. 22. J2_ -LL ?fil2
f
o 'BQ/4.5 -LL 12. 1.6'2 0/4.5
X!
a. f
.LL 22. JLL -LL ? il3
H?+-6 - A -.31 1 +-6
LL.
-LL Hi.
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMSfi?fiO/ / REMARKS: REF 23-1ST
z 2SL m 3.175 mm
P O'O'O" R d= 88.900 mm Date/lnsp.Q7 QB igg6/RCF
fo fu* Fn7/8 fn f * Fpz/8 Fr
Reqd.Qual. E
5 5 5 5 5 5 5 5
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0
C
12.0 14.0 W
Act Value 03
2.2 3.1 11.8 6.4 2.6 2.0 10.4 6.0 4.8
Act Qual. 2 3 4 3 4 1 3 3 2 3
TOOTH THICK: NOM.VAL. Min. Max.
to 3 MAX.T.NO. 1 4.987 0 0
MEAS.VAL
4.884
X
oo
O) c
10 C
<o _
urn to
I I l-l i-i n r- H i

tr

El MIN.T.NO.: 17
fp-t
3 MIN.T.NO.: 21

H, n n ,-, n n n _ n
cr=T] ~
10 1
um -1
O
3 MAX.T.NO.: 28

3 MAX.T.NO.: 9

_fi_
10 j
um
O

MIN.T.NO.: 25

MIN.T.NO.: 13

10
um

L3MAX.T.N0.: 25

L3MAX.T.N0.: 13
Fr

10 nnnllnnnnnnnn^nn .,
pm

BMIN.T.NO.: 9
 APPENDIX A

rivv-i.'.-.- '
 INTERPRETATION OF GEAR MEASUREMENT RESULT SHEETS.

GENERAL

The gear measurement results in this report are from CNC measuring machines in the UK
National Gear Metrology Laboratory, which is run by Design Unit. The measuring machines
used are traceably calibrated to National Standards using a range of master gears and gear
artefacts which have been calibrated at the European National Laboratory, PTB, in Germany.
Gears have been measured in accordance with procedures layed down in DUCOP.03, a code
of practice for Involute Gear Measurement, which is issued by Design Unit and BGA (British
Gear Association).

It is the policy of the laboratory to measure :

a. lead and profile errors on 4 teeth equally spaced at 90 degree intervals. Both left
and right flanks are measured.

b. adjacent and cumulative pitch errors on all teeth on left and right flanks.

c. radial runout of the tooth space.

d. tooth thickness.

e. radial runout of the reference bands on the gear measuring machine.

Measured errors are interpreted strictly in accordance with the specified standards. It is the
policy of the laboratory to evaluate errors in accordance with DIN 3962 if the accuracy
requirements are not fully specified.

The following sections show how to interpret the result sheets and define the parameters which
are measured and evaluated.
THE DEFINITION OF LEFT & RIGHT FLANKS.

A definition of left and nght flanks in accordance with ISO 1328 (Technical Reports) is given in
Figure.1. Note that it is important to know which way up the gear was mounted on the
measunng machine for the correct interpretation of the measurement records

A1 Definition of left and right flanks on an

external gear and tooth numbering

cast

%JkJha*
A2 . Definition' of left and right flanks on an
internal gear and tooth numbering

Figure 1. The definition of left and right flanks.

PROFILE ERRORS.

Profile errors are measured to define the diference between a true involute form and the actual
measured profile. Although the involute is a curve, the difference between the true involute
form and the measured form is given as a deviation from a straight line. See figure.2.
Profile errors are usually measured at mid face width unless specified otherwise.The profile
error curve is evaluated between lines, one of which is the start of active profile and the second
is specifed as 8% of the total active length of the profile.
The measured results are compared to the DIN standard and the accuracy grade of the gear is
determined. The largest error measured determins the accuracy grade of the gear.
Ail errors are measured in the transverse plane.

Errors are analysed in accordance with DIN 3962, which specifes 3 parameters :

f,fa profile form errors

profile slope error
F total profile error

Figure 2. Profile error parameters.

 LEAD ERRORS.

Lead or tooth alignment errors are measured at the pitch circle diameter of the gear assuming
that the gear is mating with its basic rack. Lead errors are evaluated over 90% of the facewidth
unless stated on the drawing.
Deviations from the true helix of the gear are plotted as errors from a straight line.
All lead errors are measured in the transverse plane.

The parameters which are evaluated in accordance with DIN 3962 are :

ffjj lead form error.

*H(3 lead error slope,
F total lead error.

An example of these parameters are given in figure.3.

Figure 3. Lead error parameters.

wmmemsmmsim*:-
PITCH ERRORS.

Pitch or spacing errors are measured on all teeth, both left and right flanks. Errors are
measured at mid face width and at the lead measuring diameter unless specified otherwise.

Adjacent pitch errors (errors between adjacent pairs of teeth ) are plotted on the record sheet
and the largest error is printed out and compared to the DIN Standard.

Cumulative pitch errors are calculated by summing the adjacent pitch errors andcalculating the
total range of errors. Again the value of the error is compared to the DIN Standard.

Radial runout of the tooth space is calculated by computing the radial position that a ball would
sit in the tooth space. The total variation inradial position is the radial runout error.

Examples of the parameter calculated is given in Figure 4.

The parameters evaluated are :

adjacent pitch error

Fp cumulative pitch error
Fr radial runout of the toothgap
 PITCH + RUNOUT TEST
Part No.:
REMARKS: X
z =-
_24_ m J0_ mm P- O'O'O' H mm Date/lnsp.gg.10.1994/
240.000
fo 'u* FDZ/8 fn fu * Fr
Reqd. Qual E !
8 8 8 a.
8 8 8 8 8 8 c !
Limit Value 20 25 45
71 20 25 71 45 56 CO :

Act Value 03
30 37 68 36 18 21 66 31 77 J3 :
Act Qual. 10 10 ;
8 8 8 8 a 7 9
TDOTW TMIOC NOM.YM..
II MAX.T.NO. iB.70a
Mtn.
0
I.VAL !
18.497 !
<>
40 C
iS
urn u_ ,nn n u,ni-y-"LiLi nu.nn.,n
O 2

f BMIN.T.NO.: 16
|E3MIN.T.N0.: 18
*

o xnr n__ nn.,nn,nnn rr n n. L-ff

40 e

CD
uu u u" y
um

EMAX.T.NO.: 4
El MAX.T.NO.:

40
um Z
O a
cc

BMIN.T.NO.: 18
Fp^
BMIN.T.NO.: 9

o
40
um r,p
^tQi
El MAX.T.NO.: 19
EMAX.T.NO.: 16
Fr
Jl
W In Fr
40
jjm TJ
uJliiii lllmflfln n.

Fl&u/ze 4 r EkA^PcS C/= P/~<^-1 gESOLT^-

EIMIN.T.NO.: 4
 APPENDIX 2

INITIAL SURFACE PROFILES OF GEARS

AMS6260 #11
#15
#20
#23
 1
1/im

ii 100 jim
NASA gear #11 (ground), tooth 1/left, x=-.lmm y= 3.175mm (filtered:Ra=0.425/im/0.08mm cutof

100/xm
NASA gear #11 (ground) tooth 1, right, x=-.lmm y= 3.175mm (filtered: Ra=0.358itm/0.08mm cut

100/xm
NASA gear #11 (ground),tooth 15/left,x=-.lmm y=3.175mm(filtered:Ra=0.450/xm/0.08mm cutoff)

100/xm
NASA gear #11 (ground), tooth 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.320/xm/0.08mm c
 100/im
NASA gear #15 (ground) tooth 1/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.513itm/0.08mm cuto:

100 fim
NASA gear #15 (ground) tooth 1/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.366/xm/0.08mm cut

100/xm
NASA gear #15 (ground) tooth 15/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.471tim/0.08mm cut

100/xm
NASA gear #15 (ground) tooth 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.335/xm/0.08mm ci
 100 ^m
NASA gear #20 (ground) tooth 1/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.45fym/0.08mm cuto:

100 pm
NASA gear #20 (ground) tooth 1/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.364/xm/0.08mm cut

100 ^m
NASA gear #20 (ground) tooth 15/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.415/im/0.08mm cut

100 /im
NASA gear #20 (ground) tooth 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.341/im/0.08mm ci
 100 ^m
NASA gear #23 (ground) tooth 1/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.402/zm/0.08mm cuto:

100 ^m
NASA gear #23 (ground) tooth 1/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.275/im/0.08mm cut

100 urn
NASA gear #23 (ground) tooth 15/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.343/zm/0.08mm cut

100/tm
NASA gear #23 (ground) tooth 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.275jim/0.08mm ci
 APPENDIX 3

INTERMEDIATE METROLOGY INSPECTION OF GEARS

AMS6260 #11
#15
#20
#23
 DESIGN UNIT GEAR TECHNOLOGY CENTRE
University of Newcastle upon Tyne
Department of Mechanical
Materials & Manufacturing Engineering
Stephenson Building
Newcastle upon Tyne NE1 7RU

4 December 1996

Project GM 373/2

Superfinishing Investigation
Final Measurement Results

Client: Cardiff School of Engineering,

University of Wales,
Queens Buildings,
The Parade,
P.O. Box 97,
CARDIFF
CF2 1XH

Gear Reference: AMS 6260

Samples Checked: N. 11,15, 20 and 23 (see GM 373/1 for the initial measurement results).

Parameters Measured:

The following parameters were measured on each gear:

1. Lead and profile errors on 4 teeth, left and right flanks, spaced at 90 intervals.

2. Adjacent and cumulative pitch errors on all teeth, left and right flanks.

3. Radial runout of the tooth space.

4. Mean circular tooth thickness.

Results:

The measurement record sheets for each gear after superfinishing are included at the
end of this report. Please refer to report GM 373/1 of 7th August 1996 for the original
result sheets.

An examination of the record sheets show that there is very little difference in measured
errors between initial and final results. The differences in total error parameters (Fa and
Fp) and mean error slope (fHa and fHp) are predominantly caused by slight differences in
mounting error during measurement. Therefore, for this analysis, the average form error

Director: D. A. Hofmann Tel: (0191)222 6192

M. E. Norman J. Rosinski Direct Dial: (0191)222
R. Ashby J. Haigh Fax: (01911222 6194
E. J. Myers R. C. Frazer E.Mail:
 parameters for left and right flank ffcl (profile form error) and f^ (lead form error) have been
used for comparison together with the average normal circular tooth thickness
measured(Sn). A summary of the results is given in table 1.

Discussion of Results:

The measurement results in table 1 and a visual examination of the measurement traces
shows that there is very little difference between the initial flank geometry and the final
flank geometry. The superfinishing process has not changed the basic flank form. (This
is supported by a visual examination of the gears which show that on most of the tooth
flanks, the grinding feed marks are still visible).

The normal circular tooth thickness measurements show that after the results are
corrected for the probe datum error, an average of approximately 1 pm of stock has been
removed from each flank.

A visual examination of the gears shows that stock removal is uneven: some teeth are
highly polished but on others the grinding marks and ground 'dull' finish still predominates
the flanks. In this test, we must conclude that process was not correctly controlled.

Sample Flank Initial Results Final Results

ffa * sn ffa ff s
11 LF 2.8pm 1.4pm 4.871mm 2.9pm 1.8pm 4.868mm
RF 1.9pm 1.4pm 1.8pm 1.8pm

15 LF 3.5pm 0.9pm 4.883mm 3.6pm 1.2pm 4.881mm

RF 2.8pm 0.7pm 3.0pm 0.7pm

20 LF 2.0pm 2.7pm 4.863mm 1.7pm 2.8pm 4.860mm

RF 1.9pm 1.4pm 2.1pm 1.6pm

23 LF 2.5pm 1.6pm 4.884mm 2.5pm 1.9pm 4.880mm

RF 1.9pm 2.1pm 1.8pm 2.3pm

Table 1: Summary of Results

Note: The difference in probe diameter, calibration size is 1.2pm (i.e. the probe
calibrated +1.2pm during the final measurements). This will reduce the nominal
measured tooth thickness in the final results by 1.2pm compared to the initial
results.
 DESIGN UNIT GEAR TECHNOLOGY CENTRE
University of Newcastle upon Tyne
Department of Mechanical
Materials & Manufacturing Engineering
Stephenson Building
Newcastle upon Tyne NE1 7RU
GEAR MEASUREMENT SUMMARY SHEET

!
Client: MWOHLA oj- CO&Ica DU Reference : 6rAA 3 7 3 / Z

Gear Drawing : AMS h2-6=>0

Gear Reference: ^^ *^ ,/ # ,5, Z<3 d? -2.3

Manufactured By:

Parameters Measured : Lead / Profile / Pitch / Runout / Tooth thickness / runout of reference bands.

Runout of Reference Bands :

Mcc.vrfV\a * A-p^A^/iAfi M-A^'^ I \,<>\.^l/\ QfoUzd Agttuls set Hm -hz\

Accuracy requirements:

Results:

PARAMETERS TOLERANCE MAX. ERROR COMMENTS

(pm) (Mm)

LEAD

PROFILE

ADJ. PITCH

CUM. PITCH

RUNOUT

PITCH DIFF.

THICKNESS

General comments :

1. Gears have been measured in accordance with the code of practice DUCOP.03 for Involute
Gear Measurement.
l.Me&ouSeMAT details, Cvr<L iM-vh^'J h &M Zl'h/ I

Equipment: Machine: 1-lo-fUr SM 2: <&& 2 Probe: t<-z

All measurements were carried out on traceably calibrated equipment in the UK National Gear
Metrology Laboratory (NAMAS Accreditation number 0250).

Measured by:
C6z\<yw Date 3 Dtc f)C

Director: D. A. Hofmann Tel: (0191)222 6192

M. E. Norman J. Rosinski Direct Dial: (0191)222
R. Ashby J. Haigh Fax: (0191) 222 6194
E. J. Myers R. C. Frazer E.Mail:
 DESIGN UNIT Lead + Profile Test
n
Designation: - 3.175 6.35
Part No.: AMS6260/./. 28 2 90_
o o
o> c n 200'0" dh 83.539 mm
co REMARKS: REF 11-2ND
i-

P O'O'O'
< <f> b
-? Act
CM <t!
CD <n Quality Reqdpr; 5 / Le: 5 -Pr: 5 / Le: 3 Reqd. pr: 5 / Le: 5 Act. pr: 5 / Le: 2
CT) =3
2 Right Rank 3

m
CO o 3 Left Rank 2 1 tooth 1

Tip
o
i 2 : 1
i
a> c O
> CO
= dJ
5
81 mm
<D 90.1?
~5~

0+ i-
1000 : 1 CL
4.33

CH 10 <5

urn
ID

Root
to
en Limit Value
en
F
0/7 4.9 3.1 2.6 2.0 3.21 4 0/7 1.5 1.9 1 7 5.5 2.7J5
CM
f
'0/6 5.0 2.7 1.9 2.9l 5 0/6 1.2 1.1 1.5 3.5 1.814
m
o W-4.5 2.6 2.2 1.6 1.71 4 +-4.5 -1.2
2
"to
Q

3 Left Rank 1 tooth 1 2 Right Rank 3

Pi
Bottom 22 15 1 Tooth Nol 8 15 224
O
H
C_)
O GC.
pa
<! 8 : 1
>< 0
.32! 1/ /
o
o
hJ 1.25
o mm
as
H
W
o
cd
<
ta
a 1000 I-1
o
w
H ru
<H m
CD
10 &
um 5.02 1 < ^ ^ 1-^ J 1
LU
Top

Limit Value Limit Value

F
P0/7 3 ? _LS_ 1 ql2 0/7 _2J_ ? ? _2_2_ J_L 2111
o f
'Q/4.5 _2J_ _LL U. 1 fll 3 0/4.5 ? 4 _L5_ 1 7 1 fll2
a f
+-6 411
LL. HW--6 -.31 1
 DESIGN UNIT Lead + Profile Test
Designation: _ ^ 3.175 mm 6.35
L
Part No.: AMS6260/./. 28 P 90 %
o o a
O) c REMARKS: REF 15-2ND n 200'0" dh S3.539 mm
cr>

I!
C3 o
O'O'O'
< in b
^ "o
c Act
c\J en
CD 05 Quality Regd.pr; 5 / Le: 5 Act.pr: 6 / Le: 2 Regd. pr; 5 / Le: 5 - Pr: 5 / Le: 1
CO o 3 Left Rank 2 1 tooth 1 2 Right Rank 3
Tip
2 : 1
> =1
O
> CO
~ 0)
CO 3 5
83 mm
0
O

i_
-t-
1000 : 1| 0.

M 10 O
urn
to

Root
CO
CD Limit Value Limit Value
CD
F
CM
0/7 21. _LL 6.5 4.4 3.8l 5 0/7 3.7 2.4 XL 3.9 3.013
f
faQ/6 1.6 1.9 6.1 4.7 3.6! 0/6 4.3 2.2 1.9 3.015
m
o W-4.5 1.7 -1.4 1.2 .61 3 +-4.5 1.5 -1.4 .112

CD
Q

3 Left Rank 2 1 tooth 1 2 Right Flank 3

Pi
O
Bottom * 15 8 1 Tooth Nol 8 15 22
H
2 o
O CX.
<! 8 : 1
HJ

ii i 1 !
><

O
o
hJ 1.25
o mm
pi
H
W
o
T3
Pi
cc
<3
W
O 1000 : |
<
o 10 O
M
H OJ
<U en
3 CD
um 6.c: ^
^
I.^ 1
:
l y y ^\
, 6.0
^ """
UJ
Top

Limit Value Limit Value

F
0/7 JL5_ 2JL 1 l 1 0/7 _L5_
o
n
f|
Q/4.5 1 ?l2 0/4.5 _UL Jll
f
a.
HH--6 :U_ ^9_ -Jll +-6 ^A. ill
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AM5526Q/. /. REMARKS: REF 11-2ND
28 m==
3.175mm = O'O'O" R d= 88.900 n Date/lnsp.:o3 .12.1996/RCF
f * Fpz/8 fu x Fpz/8 Fr
E
Reqd.Qual. 5 5 5 5 5 5 5 5 5 ZL
c
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12 14.0 co
Act Value 2.7 2.5 14.3 7.3 2.4 2.8 12.5 6 .E 6.2
<D

Act Qual. 4 3 4 4 2 3 4 4 3 5
TOOTH THICK: NOM.VAL. Min. Max. MEAS.VAL
CO
EMAX.T.NO.: 28 4.987 0 0 4.358
o o JL
o c

urn Q; n n n n n n ULJ n,_n

o u yuu
< CO

CM ca
co <n
ir
CO o

BMIN.T.NO.: 14

BMIN.T.NO.: 13
2.E
. CO
= a>
co =
81 TTTjrjTjrn
nnnnn^n^n
Trarr
10 %
um -1
O
El MAX.T.NO.: 2

S MAX.T.NO.: 6

J__
JL
10
o um ^
H
0 2>
O ix
pa
<3
J

>-*
a
o
F] MIN.T.NO.: 24
H
W BMIN.T.NO.: 8

<
W
o
< ^L
o 10
M
H |jm
<
5S

BMAX.T.NO.: 25

BMAX.T.NO.: 12
Fr
+
!* UJ
7 10 -^nnnnnnninifinnnnnn n n n fin
jjm
5
y a
u.
a tr

BMIN.T.NO.: 2
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMS6260/7. REMARKS: REF 15-2ND !
z=
28 m=
3. i 75 mm f5 = o'0'O" R d=
88.900 mm
Date/lnsp.:03.12.1996/RCF
fp fu * Fp Fpz/8 fp fu * FP FBZ/8 Fr
E
Reqd. Qual. 5 5 5 5 c 5 5 5 5 5 3-
c CO ,C
Limit Value CO 5.0 6.0 20.0 12.0 LL 5.0 6.0 20.0 12.C 14.0 CO
CD
Act. Value 1.9 2.8 10.4 6.1 1.1 1.1 3.5 2.1 10.2 3
CD
Act. Qual. _1 2 3 3 3 ir 1 1 1 1 4 2
CO
E MAX.T.N0.: 13 TOOTH THICK: NOM.VAL.
4.987
Mln.
0
Max.
0
- MEAS.VAL
4.881
I -^
o u <>
CX> C
10 -
~, <0
um Q:
ao
<r tn
-?
C\J to DC
CD 0)
CO o

If fp-
EJMIN.T.NO.: 5

BMIN.T.NO.: 4
si.
2 =
> to
S 0
CO 3

81 0 1 _mnflnn_n
-
_
uu"Uuuu- -u
..
U
n

10 <g
um -1
O
rz~
MAX.T.NO.: 27

S MAX.T.N0.: 19

1 1

10 I
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H (jm _-*

O ir
m
<l
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FlMIN.T.NO.: 9
Fp-
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S
EJMIN.T.NO.: 28
cd
<
w
o I 1

53
-i^ci
O
H 10
H urn _3
<U
53

1 1

El MAX.T.NO.: 12

ED MAX.T.NO.: 28
Fr
0
IS 111
10 uu u
yyyuuuuu^
1
!
ST
O
urn , uyy[j LJ
.a
a Ju
a:
i-

EJMIN.T.NO.: 12
 DESIGN UNIT Lead + Profile Test
Designation: ^ 3.175 6.35 mm
CO L
Part No.: AMS6260/./. z 28 90
o o
05 C REF 20-2ND n 20'0'0' db 83.539
co REMARKS:
I!
o
O'O'O'
b
-?
CD en
Quality Reqd.pr: 5 / Le: 5 Act.pr: 4 / Le: 5 Regd.pr; 5 / Le: 5 Act. pr: 4 / Le; 2
<J) =J
CO o 3 Left Hank 2 1 tooth 1 2 Right Flank 3

Tip
0,2
^E 2 : 1
i
c P
> to
~ CD
CO 3
mm
0

o+
1000 : 1| Q.

c\ 10 jo
en
ru
um
ic

Root
to
en Limit Value
CT)
'0/7 2. 4 _LL 2.0 2.3 2.3l 2 I 0/7 1.7 4.8 2.8 1.4 2.714
OJ
f
'0/5 2.7 1.2 1.6 1.7l 3 I 0/6 1.1 3.1 2.6 1.4 2.114
n
o W-4.5 1.5 2.6 2.0 2.014 I+-4.5 -2.5 -.5 -1.014

3 Left Flank 1 tooth 1 2 Right Flank 3

5H
Pi
o
Bottom * 15 1 Tooth Nol 8 15 22
H
LL.

O cc.
m
<
_V_
]
1 1
a
o
1-5 1.25
o mm
H
W
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CO
erf
< 0)'
w 1
1000 : 1

LI

1
<:
o t> 10
H
H
<3
z to
|jm 6.C3
^ l i
LU
Top

Limit Value Limit Value

F
0/7 5 4 _2J_ _L5_ ? 7 3 II 4 0/7 3 4 ? q _L2_ ?3l2
f
'Q/4.5 4 E _2J_ 2.fll5 0/4.5 _L3_ 1R'2
f
Hf-6 _dJL -.71 1 +-6 _ 711
 DESIGN UNIT Lead + Profile Test
Designation: n
n 3.175 mm 6.35 mm

Part No.: AMS6260/./. * 28 L 90 %

o o
co REMARKS: REF 23-2ND n 20"0'0" dn 83.539 mm
O'O'O'
O
< m b
-? Regd.pr; 5 / Le: 5 Act. pr: 3 / Le: 2
CM CO
CO (0
Quality Regd.pr; 5 / Le: 5 Act.pP: 5 / Le: 2
CJ> 3
co o 3 Left Flank 2 tooth 2 Right Flank 3
S|E
Q c Tip
o,
2 : 1
gi O
>* CO
= CU
5
33 mm
o
o
0+ -h
1000 : 1

^ 10 O

um
1"^

Root

en Limit Value Limit Value

en
*0/7 4J_ 2.5 2.3 1.9 2.9l 4 0/7 1.3 2.2 1 7 1.812
OJ
f
'0/6 4.5 2.! 2.4 2.5l 5 0/6 1.3 2.2 1.6 1.813
o Haf-4.5 -1.3 1.9 1.2 1.01 3 +-4.5 .411

CO
Q
3 Left Flank 1 tooth 1 2 Right Flank 3

o
Bottom * 15 1 Tooth Nol 8 15 22
H
o
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<! 8 : 1
J
>^ O
U
o
t-J 1.25
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H 6
W o
s
CO
Pi
< 0)'
w
o 1000 : 1
<3
z C> 10
o
M
H ru |jm
< m
Z to

2:
UJ
Top

Limit Value Limit Value

F
0/7 _Li ? 3 ? 0 ? nl 1 0/7 _2i 2 ? R ?fll2
f|
PQ/4.5 _L5_ _2J_ 1 ql 2 0/4.5 2A- 2. 2JL 2J- ?3<2
f
HIM-6 -fi -jli +-6 .711
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMS6260/./. REMARKS: REF 20-2ND
m=
28 3.175mm " 00'0" R d=
88.900 mm
Date/lnsp.:Q3.ig.igg6/RCF
fu * Fpz/8 fu * Fr
E
Reqd. Qual. n.
5 5 5 5 5 5 5 5 5 c
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12. C 14.0 CO
Act. Value 2.5 2.6 9.4 5.2 1.4 2.1 6.6 3./ 5
CD
3

Act. Qual. 4 3 3 3 1 1 2 2 3 2
CO
S MAX.T.NO.: 25
TOOTH THICK: NOM.VAL.
4.987
Min.
0
Max.
0
MEAS.VAL
4.86
PJZ _i
O
O) c
10 c
~
urn to
" _-_ r~i n - n

CM (0
CO CO
ir
> 5
CO o

SI? 0MIN.T.NO.: 13

BMIN.T.NO.: 10

> <0

~7. ^-.nnrir-.nrir-in.
uu U u uuu'
10 %
um -1
o
El MAX.T.NO.: 4

0 MAX.T.NO.: 5

JL
c
erf 10
o urn LL
H
O 2
o ir
PQ
<!
hJ
><
o
o
id MIN. T. NO. 20
o
erf
H
W QMIN.T.NO. 5
S
Pi
O
w
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< JL
O 10 Z
M
H urn a>
3
Z -0-

0 MAX.T.NO.:" 24

0MAX.T.NO.: 10

Fr

10 nnnnnnnnnnnnnnnnnnnn.
(jm

0MIN.T.NO.: 25
 DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMRfiPfiO/./. REMARKS: REF 23-2ND
z = 2fl_ m=
3.175 mm
mm
O'O'O" R 88.900 1 Date/lnsp.Q3 12 1996/RCF
f fu* Fpz/8 fn fu * Fpz/8 Fr
E :
Reqd.Qual, 3. :

5 5 5 5 5 5 5 5 5
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12.0 14.0 CO
CD
Act Value 2.1 10.9 6.1
2.3 3.2 12.7 6.9 2.1 5.6 3

Act Qual. 2 3 4 4 2 1 4 3 3 2
TOOTH THICK: NOM.VAL. Min. Max. MEAS.VAL
CO 3 MAX.T.NO. 1 4.987 0 0 4.88
P.C
o o
O) c
10 c

a nn n TTTJ-
1T"g>
SI
CM CO cc
CO CO
CO o

Qc MIN.T.NQ.: 21
0|

Si. MIN. T. NO.: 20

2 =
.)ffl
to 3
51 u ^ LI^ ^Linuunri"nnnnnn-",n'-'^cr
10 f
|jm -1

JJMAX.T.NO.: 3

Tl MAX. T. NO.: 9

erf
o 10 I
H
O g
o CC
pa
<C

o
25
Fp-IB MIN.T.NO.
J
o
H
W B MIN.T.NO. 13
2
erf
<
w
o

z
o 10
M
H urn
<
Z

ZJMAX.T.N0.: 25

BMAX.T.NO.: 14
Fr

10 uuu
nnnfinnnnnnnn,
pm

BMIN.T.NO.: 9
 APPENDIX 4

FINAL METROLOGY INSPECTION OF GEARS

AMS6260 #11
#15
#20
#23
 DESIGN UNIT GEAR TECHNOLOGY CENTRE
University of Newcastle upon Tyne
Department of Mechanical
Materials & Manufacturing Engineering
Stephenson Building
Newcastle upon Tyne NE1 7RU

13 March 1997

Project GM 373/3

Superfinishing Investigation
Final Measurement Results

Client: Cardiff School of Engineering,

University of Wales,
Queens Buildings,
The Parade,
P:0. BOX 97,
CARDIFF
CF2 1XH

Gear Reference: AMS 6260

Samples Checked: N. 11, 15, 20 and 23 (see GM 373/1 and GM 373/2 for the previous
measurement results).

Note: The 4 sample gears have been superfinished for a second time because stock removal
after the first attempt was uneven.

Parameters Measured:

The following parameters were measured on each gear:

1. Lead and profile errors on 4 teeth, left and right flanks, spaced at 90 intervals.

2. Adjacent and cumulative pitch errors on all teeth, left and right flanks.

3. Radial runout of the tooth space.

4. Mean circular tooth thickness.

Results:

The measurement record sheets for each gear after superfinishing are included at the
end of this report. Please refer to report GM 373/1 of 7th August 1996 for the original
result sheets and GM 373/2 for the second set of result sheets.

An examination of the record sheets show that there is very little difference in measured

Director: D. A. Hof mann Tel: (0191)222 6192

M. E. Norman J. Rosinski Direct Dial: (0191)222
R. Ashby J. Haigh Fax: (0191)222 6194
E. J. Myers R. C. Frazer E.Mail:
 ^

errors between initial and final results. The differences in total error parameters (F and
Fp) and mean error slope (fHa and fHp) are predominantly caused by slight differences in
mounting error during measurement. Therefore, for this analysis, the average form error
parameters for left and right flank ffa (profile form error) and ffp (lead form error) have been
used for comparison together with the average normal circular tooth thickness
measured(Sn). A summary of the results is given in table 1.

Discussion of Results:

The measurement results in table 1 and a visual examination of the measurement traces
shows that there is very little difference between the initial flank geometry and the final
flank geometry. The superfinishing process has still not changed the basic flank form
error but the grinding feed marks have been removed on all the teeth.

The normal circular tooth thickness measurements show that after the results are
corrected for the probe datum error, an average of approximately 2.5pm of stock has
been removed from each flank.

Sample Flank Initial Results Final Results

ffa f* sn ffa ff sn
11 LF 2.8pm 1.4pm 4.871mm 3.1pm 2.0pm 4.865mm
RF 1.9pm 1.4pm 1.9pm 2.3pm
15 LF 3.5pm 0.9pm 4.883mm 3.6pm 1.6pm 4.877mm
RF 2.8pm 0.7pm 3.0pm 1.3pm
20 LF 2.0pm 2.7pm 4.863mm 1.8pm 3.1pm 4.857mm
RF 1.9pm 1.4pm 1.7pm 2.3pm
23 LF 2.5pm 1.6pm 4.884mm 2.7pm 2.3pm 4.877mm
RF 1.9pm 2.1pm 1.8pm 2.5pm

Table 1: Summary of Results

Note: The difference in probe diameter, calibration size is 1.2pm (i.e. the probe
calibrated +1.2pm during the final measurements). This will reduce the nominal
measured tooth thickness in the final results by 1.2pm compared to the initial
results.
 3>
DESIGN UNIT

Designation:
Lead + Profile Test
m
CO n 3.175 mm 6.35 mm
Part No.: AM56260/. /.
s REMARKS:
28 L go"
CO REF. 11 3RD
n 20'0'0'
is
CS O'O'O"
^b 83.539 mm
< to
-^ "a
Si <3
co to Quality
a) 3 Reqd.pp; 5 / Le: 5 Act.Pp; 5 / Le: 3
co o Reqd.pp; 5 / Le: 5 Act. pr; 5 / [ P~A
4
2 Right Flank 3
 DESIGN UNIT PITCH + RUNOUT TEST T
Part No.: AMS6260/./. REMARKS: REF. 11 3RD
z = 28 m==
3.175 mm
O'O'O" R d= 88.900 mm Date/lnsp.:p7,03.1997/RCF
fn fu * Fpz/8 o f * FDZ/8 Fr
E
3.
Reqd.Qual. 5 5 5 5 5 5 5 5 5
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12.0 14.0
Act Value 2.4 2.6 15.7 7.8 2.5 2.7 13.9 7.0 7.7
Act Qual. 2 3 5 4 4 3 4 4 4
TOOTH THICK: NOM.VAL. Min. Max . MEAS.VA
CO
3 MAX.T.NO.: 3 4.987 0 0 4.865
o o J2_
o> c
2= (jm a;
o nnflnnn [jxT- yuuLiL. u u ^ ^ n n

-?
cvj eg cc
co to
05
2
co o

Qc El MIN.T.NO.: 14
o,
^E B MIN.T.N0.: 15
St
2.S
> (O
~ CO
co u
83 _SL_
a. UUUL!UU'
pnnnnn n n n.
-nrrTj-
10 %
\iTC\ -1

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3 MAX.T.NO.: 2

MAX.T.NO.: 8

c
PA 10
o urn U.
H

O s>
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<
>*
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QM'IN.T.NO.: 24
Fp^
H
W
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El MIN.T.NO.: 8
Pi
<
w
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1-4
<
Z
O 10
W
H ^m
<!
Z "5"

IJMAX.T.NO.: 24

+ u1AX.T.N0.: 15
Fr
1 + 0
8S UJ
10 ^nnnnnfl PPnnnnn^ nn
H T urn
0
fe O
% zc

El MIN.T.NO.: 1
 DESIGN UNIT Lead + Profile Test
Designation: . mn 3.175 6.35 mm
Part No.: AMS6260/7. 28 -p 90
o o
O) c REMARKS: REF. 15 3RD
co On 20"0'0' dp 83.539
O'O'O'
C3 o
< co b
-?
c\J ra
CD CO Quality Reqd.Pr: 5 / Le: 5 Act.Pr: 5 / Le: 2 Reqd. pr: 5 / Le: 5 Act. Pr: 4 / Le: 1
CD 3
co o 3 Left Flank 2 tooth 2 Right Flank 3
If Tip

i 2 : 1
2 =
>" CO
~ CD
CO 3

81 mm
a> 90.1 S0.i2
o

1000 : 1
0_ 34.3!

<^ 10 <$
m
on
um
in
o
Root
en Limit Value
en

m
Fa0/7 1.5 6.3 5.1 3.7l 5 0/7 4.3 2.1 2.0 4.6 3.31-
o f
5.2
fa0/6 1.4 2.C 5.9 3.6l 5 0/6 2.1 2.1 3.7 3.014
o W+-4.5 1.2 -1.1 .31 2 +-4.5 -1.5 -2.2 -1.114

CO
Q

3 Left Rank 2 4
o&
1 tooth 1 2 Right Flank 3

o
Bottom 15 8 1 Tooth Nol 8 15 22
H
2 O
O (X.
P3
: 1
>* O
CJ3
O
iJ 1.25
o mm
H
W
O
-a
Pi
<C
w
o 1000
<;
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O 10
M
H OJ
6.0:4k.
<J m urn S.03
Z to

LU
Top

m Limit Value Limit Value

W7
CO

2.1 1.2 2.7 2.6 2.2J2 0/7 1.3 1.1 1.0 1.9 I.3II
W4.5 1.9 1.9 1.8 1.6l2 0/4.5 1.4 1.2 1.1 1.5 1.311
a
Li.
fHf-6 -.4 -1.5 -1.3 -.91 1 +-6 .5 -.111
 -
DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AM56260/./. REMARKS: REF. 15 3RD
z= 28 m= 3.175 O'O'O" R d- 88.900 mm Date/lnsp.:p7,03 .1997/RCF
fD f * fo fu * Fpz/8 Fr
E
Reqd. Qual. n.
5 5 5 5 5 5 5 5 5
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12.0 14.0 in
Act. Value 1.6 2.3 4.4 3.4 1.6 1.6 5.5 3.E 8.0
Act. Qual. 2 1 1 1 2 1 2 2 4 2
0 MAX.T. 28
TOOTH THICK:

*
NOM.VAL.
4.987
Min.
0
Max.
0
MEAS.VAL
4.877
_SL
10
urn
o

QMIN.T.NO.: 15
lp-1 QMIN.T.NO.: 3

" r-i " "

10
urn
m
MAX.T.NO.: 27

[+1 MAX.T.NO.: 14

JL
10 5
urn 4-

O
ir

H MIN.T.NO. 26

B MIN.T.NO. 19

10
pm

5 MAX.T.NO.: 8

El MAX.T.NO.: 19
Fr

nnfinnnnnnllnn
10
TJin pjn^
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H MIN.T.NO.: 9
 ^

DESIGN UNIT Lead + Profile Test

Designation: . mn 3.175 6.35
CO Part No.: AMS6260/./. 28 "tp 90"
.sz
o o
CD c
CO- REMARKS: REF. 20 3RD n 20'0'0" db 83.539 mm
00'0"
CD
< en b
-? Reqd. Pr: 5 / Le: 5 Act. Pr: 5 / Le: 3
IN CO
CD en
Quality Reqd.Pr: 5 / Le: 5 Act.Pr: 5 / Le: 6
en D
co o 3 Left Flank 2 1 tooth 1 2 Right Flank 3
z
Q c Tip
2 : 1
si 0
> CO
~ CD
CO =J

83 CD 90.12
0

1000 : 1|
+
0-

c>| lo <?
in
OJ
um
IT)
o
Root
CD Limit Value
cn
FoO/7 2.9 3.0 1.9 1.9 2.4l 2 0/7 2.6 5.B 1.2 2.915
o f
fa0/6 3.2 1.2 1.4 1.5 l.fll 4 0/6 1.1 3.1 1.6 1.1 1.7l4
o
f
Haf-4 . 5 1.6 3.1 1.7 1.3 1.91 5 +-4.5 -2.3 -3.7 -.2 -1.715

2 Right Rank 3 4
3
15
Left Flank 2 1 tooth
1 Tooth Nol
1
15 22
 PITCH + RUNOUT TEST 2
DESIGN UNIT
Part No.: AMS6260/./. REMARKS: REF. 20 3RD
z= 28 m= 3.175mm = O'O'O" R d= 900 mm Date/lnsp.:Q7.03.1997/RCF
fn f * fn f * Fpz/8 Fr
E
Reqd.Qual. 5 5 5 5 5 5 5 5 ' a.
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12.0 14.0
CD
Act Value 3.0 3.3 13.9 6.9 2.0 1.3 11.7 5.7 9.6 3
Act Qual. 4 3 4 4 2 1 4 3 3
XI TOOTH THICK: NOM.VAL. Min. Max. MEAS.VAL
MAX.T.NO.: 26 4.987 0 0 4.857

10 c
(jm rz r-, n r-l p-i in n n n n n
uuumj-uu'ju

ir

JMIN.T.N0.: 11

EMIN.T.NO.: 15

^_ n n InI n n n n n n .
TrrjtTj
10 %
um -1

MAX.T.NO.: 4

1 MAX.T.NO.: 5

JL
10 I
pm
if

EI MIN.T.NO.: 19

El MIN.T.NO.: 5

_S_
10
pm

5 MAX.T.NO.: 24

El MAX.T.NO.: 12
Fr
+
ffc
*J
LU
<t 10 DM Innnn.
g T pm
O
0 -Q

a: or
t-

0MIN.T.NO.: 26
 DESIGN UNIT Lead + Profile Test
Designation: mn 3.175 mm 6.35 mm

'-I.C
Part No.: AMS6260/./. z 28 Lp 90 %
o o
en c REMARKS: REF. 23 3RD On 20'0'0' db 83.539 mm

M
o
P
Pb
O'O'O'

-1
IM CO Quality Reqd.Pr: 5 / Le: 5 Act.pr: 5 / Le: 3 Reqd. Pr: 5 / Le: 5 Act. Pn: 3 / Le: 3
CD <n
O) =J
cr> o 3 Left Flank 2 tooth 1 2 Right Flank 3
2iE
Qc Tip
Si
p 2 : 1
1
-2 = O
> to
= cu
co =: 5
81 mm
CD 90.12
o
o+
1000 : 1
84.8:

o 10 <3

o
urn
in
o
Root
en Limit Value Limit Value
en
FcO/7 5.3 1.9 2.1 2.7 3.0! 5 0/7 1.3 2.1 2.4 1.5 1.812
m
o f
fa0/6 4.7 2.3 2.9 2.7! 5 0/6 1.2 2.2 2.3 i.8l;
o W-4.5 -1.7 1.1 1.8 .61 3 +-4.5 -.211

CO
a
3 Left Flank 2 1 tooth 1 2 Right Flank 3
>>
erf Bottom F& 15 8 1 Tooth Nol 8 15 22
O

2 C_>
O CC.
8 : 1
.32 f 1 1! jf-33
O

o
1.25
o
erf
E-i O
W
S a
erf
< a'
a 1000 : 1
J
< '
o O 10
M
H CM
<3 m
S3 in
urn 5.0c < k ^ ^ > J J 3.03

UJ
Top

Limit Value Limit Value

F
e0/7 2.4 2.1 2.7 2.7 2.5I 2 0/7 3.3 3.2 2.4 3.1 3.012
f
tQ/4.5 2.3 1.8 2.7 2.5 2.3l3 0/4.5 2.7 2.7 2.2 2.3 2.5l3
f
Hf-6 -.6 - i -.31 1 +-6 .9 .911
 rO
DESIGN UNIT PITCH + RUNOUT TEST
Part No.: AMS6260/./. REMARKS: REF. 23 3RD
28 m= 3.1 75 mm - O'O'O" R d= 88.900 mm Date/lnsp.:Q7,Q3,igg7/RCF
fD f * Fpz/8 fn f * Fpz/8 Fr
E
Reqd. Qua!. 5 5 5 5 5 5 5 5 5 n.
Limit Value 5.0 6.0 20.0 12.0 5.0 6.0 20.0 12.a 14.0 CO
Act Value 2.3 3.2 10.3 5.6 1.9 2.2 10.4
CD
5.5
Act Qual. 2 3 3 3 2 1 3 2 2
TOOTH THICK: NOM.VAL. Min. Max.
co S MAX.T.NO.: 1 4.987 0 0
MEAS.VAL
4.877
o o
CD C
10
urn nnn_nnn n _ _ ,
(3 o 'I [ ' 1 1 1t j111111111 i

< CO 1T
-?
(N J
CO
05 to
CO o
2
El MIN.T.NO.: 21

BMIN.T.NO.: 21
S3.
-.
= a>
CO 3

31 -a Hnn
10 %
pm -1
O
E MAX.T.NO.: 9

0 MAX.T.NO.: 15

pi 10 I
o urn i
H
4> ro
O

o
0MIN.T.NO.: 28
Fp^
H
w 0MIN.T.NO.: 13
S
<
w
a

O 10
H-l
H pm
;
z

0MAX.T.NO.: 27

0MAX.T.NO.: 19

Fr
r-1 +
ai
10 r~lnn_f-in-n,
pm 'uUUir UU""^'
~6~

BMIN.T.NO.: 9
 If

RESULTS OF THE CALIBRI 0 N

7 Mar 139 7
04:15:24
PROBE NUMBER

PROBE ORIENTATION

CENTER OF THE MACHINE

Am = - . SbSb
-.1389
9 7.3903

REAL STYLUS DIAMETER

MEASURED PROBE DIAMETER
1 . 2002
1 . 200 0

PRELOAD

:ALIBRATION FACTOR
-!- 1

99 73
" j 9973
A4
V '1 C .1
'^ **
0394
 APPENDIX 5

FINAL SURFACE PROFILES OF GEARS

AMS6260 #11
#15
#20
#23
 (I) RD1070.FIL

V^'^VA'^V *i^it.\M IM
1/xm

100/xm
NASA gear #11 (polished) tooth 1/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.053/im/0.08mm cut

"~(b) ~~RD1073.FIL

100/xm
NASA gear #11 (polished) tooth 1/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.096tim/0.08mm ci

~(c) RD1067.FIL

I
lpim

100/xm
NASA gear #11 (polished) tooth 15/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.071itm/0.08mm ct

~(d) RD1076.FIL

1/xm

100 urn
NASA gear #11 (polished) TOOTH 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.067itm/0.08m
 ~(I) ~ RD1079.FIL

100/im
NASA gear #15 (polished) tooth 1/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.101/im/0.08mm cut

-(b) RD1082.FIL

I
lfim

100 ^m
NASA gear #15 (polished) tooth 15/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.053/mi/0.08mm ct

-($ RD1088.FIL

'utiM y <,. lumt^wij >!< t^t^ir-r^iiilnnrrnr'^i-iiiT\r r- * "'"i^r-*-if ' <* ~" y{~m'AX>!k*'" "^r*^"***' ' ***J'*"'
1/tm

100/zm
NASA gear #15 (polished) tooth 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.055/im/0.08mm (
 100 iim
NASA gear #20 (polished) tooth 1/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.076/xm/0.08mm cut

(b) RD1097.FIL

t*tru/tiiji<iMin"ti%>ir ^nmrt-!l i>yiff-i- i --vti"," , t r -,Tly**-ri**i' tytftl 'V t'if" "fr"l '"( ^1tfit *!^)' '"'1 'Hfft* I
1/jm

100/tm
NASA gear #20 (polished) tooth 1/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.057/im/0.08mm a

(c) RD1094.FIL

MV<">"m,*,tihr**i^pHVV-*y i *>tm/+**>*<>"+\

100/xm
NASA gear #20 (polished) tooth 15/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.078/xm/0.08mm a

(d) RD1100.FIL

**lp,*^*.w*.,m*f'H/i1*yl l^^n*i>i*ii*iiij#iHto'IIM>i'''*<Hd*M*>'*1'*"'*^*' '*WyV ifji*H--y&^mi"'*94i***^i\p*Xlr*V I

1/im

100/xm
NASA gear #20 (polished) tooth 15/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.059fim/0.08mm (
 ~ RD1103.FIL

I
l^m

100/im
NASA gear#23 (polished) toothl/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.063/tm/0.08mm cutol

(b) RD1109.FIL

I
1/zm

100/tm
NASA gear #23 (polished) tooth 1/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.064/im/0.08mm a

(c) RD1106.FIL

lfim

100 um
NASA gear #23 (polished) toothl5/left, x=-.lmm, y= 3.175mm (filtered: Ra=0.106/zm/0.08mm cui

(d) RD1112.FIL

1/un

100 um
NASA gear #23 (polished) toothl5/right, x=-.lmm, y= 3.175mm (filtered: Ra=0.073/an/0.08mm c