Program Metric Module Involute Splines
Program Metric Module Involute Splines
Program Metric Module Involute Splines
Introduction
The primary purpose of this model is to provide data from ANSI Standard B92.2M-
1980 for Involute Splines and Inspection (Including B92.2Ma-1984). This is the
standard for metric series splines based on metric modules and a series of basic
generating racks. It is possible to use the model to convert the dimensions to inches
but the basic calculations are always based on the metric module and the basic rack
system from the standard.
The model will automatically calculate data for splines and gages in accordance with
the standard. If data is entered for a modified spline the model will indicate that the
spline is not standard and will then calculate data for measurements and gages for
the modified spline.
Plots of the assembled and individual splines are available on the plot sheet. The
plots are of the mean actual tooth thickness.
For information on the proper use and interchangeability of splines and gages refer
to the standard.
In some cases the dimension given by the software may be slightly different from the
data in the tables of the standard. The software uses the equations given in Table 2
of the standard. The user must decide which value should be used.
The model contains two tables of standard pin diameters for checking tooth thickness
of the splines. Since, in the US, most gear facilities have inch series pins available
you may request that inch series pins be used in the pin measurement calculations.
Pins will then be selected from Table 1. If you desire metric series pins, they will be
selected from Table 2.
UTS Integrated Gear Software
Table 1
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60-720—Metric Module Involute Splines
Table 2
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Examples
Example 1
This is a 20 tooth, 10 mm module, flat root spline. The tolerance and fit class for the
internal will be “7H” and for the external will be “7d”. The spline length of
engagement is 150 mm. We wish to use the “Standard” gaging method and will print
all data needed to manufacture the gages, including tapered external master to
calibrate the ring gages for the external spline. We will use metric series pins for
measurement.
Using the wizard data entry form, enter the data as shown in Figure 1-1 Note that
metric units are used. Report 1-1 is the solved model.
Fig. 1-1
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60-720—Metric Module Involute Splines
Report 1-1
Number of Teeth 20
Module 10.000000 mm `
Diametral Pitch 2.540000 1/in `
Standard Pressure Angle 30 deg
Length of Engagement 150.0000 mm
Pitch Diameter 200.00000 mm
Base Dia 173.20510 mm
Max_Effective Clearance 0.5350 mm
Min_Effective Clearance 0.1700 mm
Max_Actual Clearance 0.7620 mm
Min_Actual Clearance 0.3980 mm
Radial Form Clearance (Standard) 1.0000 mm
Ref Line to Root TIF on Basic Rack 6.0000 mm
Inch('i) / Metric('m) Measuring Pins m
INTERNAL SPLINE
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60-720—Metric Module Involute Splines
Fillet_Radius 2.0000 mm
Minor Diameter - Min 184.190 mm
Tolerance and Fit Class "7d"
Tooth Thickness Reduction 0.17000 mm
Machining Tolerance 0.1820 mm
Effective Variation 0.1140 mm
Total Tolerance 0.2960 mm
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A plot of the teeth in assembly is available on the TK Solver Plot Sheet or Toolbar
list. (See Figure 1-2.) Individual plots of the internal and external splines are also
available.
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60-720—Metric Module Involute Splines
Fig. 1-2
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Example 2.
This is a 6 tooth, 1 mm module, 37.5 deg, fillet root spline. The tolerance and fit class
for the internal will be “4H” and for the external will be “4h". The spline length of
engagement is 4 mm. We wish to use the “A” gaging method and will print all data
needed to manufacture the gages including tapered external master to calibrate the
ring gages for the external spline. We will use inch series pins for measurement.
Using the wizard data entry form, enter the data as shown in Figure 2-1. The
application will attempt to solve the model automatically after the necessary data is
entered, but in this case a complete solution is not possible because of problem with
the pin diameter for some of the gages.
The model will stop the solution and give you an error message indicating that the
measuring pins would contact the NO GO Composite Ring Gage below the base
diameter. Sheet 2-1 shows the part of the TK Solver Variable Sheet where the
problem lies.
Sheet 2-1
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60-720—Metric Module Involute Splines
We will select the next smaller size pin from Table 1 and enter the value for “Pin
Diameter, inch” in the Power User form (Figure 2-2).
Fig. 2-2
Another attempt at a solution produces another problem and error message: the
measuring pins contact below the base diameter of the sector ring gage. Sheet 2-2
shows the problem.
Sheet 2-2
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Once again we will select the next smaller size pin from Table 1 and enter the value
for “Pin Diameter, inch” (Figure 2-3).
Fig. 2-3
Solve again and this time you should be successful (Report 2).
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60-720—Metric Module Involute Splines
Report 2
Number of Teeth 6
Module 1.000000 mm `
Diametral Pitch 25.400000 1/in `
Standard Pressure Angle 37.5 deg
Length of Engagement 4.0000 mm
Pitch Diameter 6.00000 mm
Base Dia 4.76010 mm
Max_Effective Clearance 0.0360 mm
Min_Effective Clearance 0.0000 mm
Max_Actual Clearance 0.0580 mm
Min_Actual Clearance 0.0230 mm
Radial Form Clearance (Standard) 0.1000 mm
Ref Line to Root TIF on Basic Rack 0.5500 mm
Inch('i) / Metric('m) Measuring Pins i
INTERNAL SPLINE
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60-720—Metric Module Involute Splines
Fillet_Radius 0.3000 mm
Minor Diameter - Min 4.450 mm
Tolerance and Fit Class "4h"
Tooth Thickness Reduction 0.00000 mm
Machining Tolerance 0.0180 mm
Effective Variation 0.0110 mm
Total Tolerance 0.0290 mm
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A plot of the teeth in assembly is available on the plot sheet. (See Figure 2-4.)
Figure 2-5 shows all the teeth. Individual plots of the internal and external splines
are also available.
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60-720—Metric Module Involute Splines
Fig. 2-4
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Fig. 2-5
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60-720—Metric Module Involute Splines
Example 3
This is a 10 tooth, 45 degree, fillet root spline. The tolerance and fit class for the
internal will be “4H” and for the external will be “4d". The spline length of
engagement is 12 mm. We do not need any gages or analytical inspection data for
this example and will request only the basic spline data and size over and between
pins to control manufacturing. (However, the model will still calculate the gage data
and so we will enter “std” for the gage method. We will use metric series pins for
measurement.
Using the wizard data entry form, enter the data as shown in Figure 3-1. Report 3-1
shows the solved model.
Fig. 3-1
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Report 3-1
Number of Teeth 10
Module 2.000000 mm `
Diametral Pitch 12.700000 1/in `
Standard Pressure Angle 45 deg
Length of Engagement 12.0000 mm
Pitch Diameter 20.00000 mm
Base Dia 14.14210 mm
Max_Effective Clearance 0.1120 mm
Min_Effective Clearance 0.0650 mm
Max_Actual Clearance 0.1430 mm
Min_Actual Clearance 0.0950 mm
Radial Form Clearance (Standard) 0.2000 mm
Ref Line to Root TIF on Basic Rack 1.0000 mm
Inch('i) / Metric('m) Measuring Pins m
INTERNAL SPLINE
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60-720—Metric Module Involute Splines
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Fillet_Radius 0.5000 mm
Minor Diameter - Min 17.380 mm
Tolerance and Fit Class "4d"
Tooth Thickness Reduction 0.06500 mm
Machining Tolerance 0.0240 mm
Effective Variation 0.0150 mm
Total Tolerance 0.0390 mm
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A plot of the teeth in assembly is available on the plot sheet (see Figure 3-2). This
time we have plotted all 10 teeth.
Fig. 3-2
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60-720—Metric Module Involute Splines
Example 4
This is a 28 tooth, 1 module, fillet root spline. A Class “4H” tolerance is desired on
the internal spline and a Class “4d” on the external spline. (Different tolerance
classes can be used on each spline if desired.) We also wish to use dimensioning
method “A” gaging method and will print all data needed to manufacture the splines
and the gages.
Enter the data shown in Figure 4-1 in the wizard data entry form. This will give us a
standard spline. The solved model is shown in Report 4-1.
Fig. 4-1
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Report 4-1
Number of Teeth 28
Module 1.000000 mm `
Diametral Pitch 25.400000 1/in `
Standard Pressure Angle 30 deg
Length of Engagement 20.0000 mm
Pitch Diameter 28.00000 mm
Base Dia 24.24870 mm
Max_Effective Clearance 0.1020 mm
Min_Effective Clearance 0.0650 mm
Max_Actual Clearance 0.1350 mm
Min_Actual Clearance 0.0970 mm
Radial Form Clearance (Standard) 0.1000 mm
Ref Line to Root TIF on Basic Rack 0.6000 mm
Inch('i) / Metric('m) Measuring Pins i
INTERNAL SPLINE
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Fillet_Radius 0.4000 mm
Minor Diameter - Min 25.850 mm
Tolerance and Fit Class "4d"
Tooth Thickness Reduction 0.06500 mm
Machining Tolerance 0.0190 mm
Effective Variation 0.0160 mm
Total Tolerance 0.0350 mm
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Figure 4-2 is a plot of the teeth in assembly for the standard spline.
Fig. 4-2
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60-720—Metric Module Involute Splines
Note that the minimum effective clearance is 0.065 mm. Let us assume that this is
not enough clearance and we wish to increase the minimum effective clearance to
0.120 mm.
To increase the effective clearance by 0.055 mm we will reduce the tooth thickness of
the external spline by 0.030 mm and increase the space width of the internal spline
by 0.025. (Usually the external spline is modified and the internal left standard. We
will change both for illustration purposes.) We will assume that a “standard” shaper
cutter will be used to manufacture the internal and a “standard” hob will be used to
manufacture the external.
To increase the space width of the internal by 0.025 mm the shaper cutter will need
to be fed deeper by 0.022 mm (.5 * space width change / tan(PA)). This will increase
the major and form diameters. We will also increase the minor diameter to insure
clearance between the external form diameter and the minor diameter. (This does
not always have to be done but should be checked to insure that there will be no
interference if the relative movement of the spline is maximum.)
To decrease the tooth thickness of the external by 0.030 mm the hob will need to be
fed deeper by 0.026 mm (.5 * tooth thick change / tan(PA)). This will decrease the
minor and form diameters. We will also decrease the major diameter to insure
clearance between the internal form diameter and the major diameter. (This does
not always have to be done but should be checked to insure that there will be no
interference if the relative movement of the spline is maximum.)
Enter the new data in the Power User form as shown in Figures 4-3a and 4-3b, and
solve the model. Caution messages state that the internal and external splines do
not conform with ANSI B92.2M. After solving you should have the data in Report 4-
2.
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Fig. 4-3a
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60-720—Metric Module Involute Splines
Fig. 4-3b
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Report 4-2
Number of Teeth 28
Module 1.000000 mm `
Diametral Pitch 25.400000 1/in `
Standard Pressure Angle 30 deg
Length of Engagement 20.0000 mm
Pitch Diameter 28.00000 mm
Base Dia 24.24870 mm
Max_Effective Clearance 0.1570 mm
Min_Effective Clearance 0.1200 mm
Max_Actual Clearance 0.1900 mm
Min_Actual Clearance 0.1520 mm
Radial Form Clearance (Standard) 0.1000 mm
Ref Line to Root TIF on Basic Rack 0.6000 mm
Inch('i) / Metric('m) Measuring Pins i
INTERNAL SPLINE
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Fillet_Radius 0.4000 mm
Minor Diameter - Min 25.820 mm
Tolerance and Fit Class "4d"
Tooth Thickness Reduction 0.06500 mm
Machining Tolerance 0.0187 mm
Effective Variation 0.0162 mm
Total Tolerance 0.0349 mm
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Note that the minimum effective clearance is now 0.120 mm. Note that the internal
and external spline gage dimensions have been modified to reflect the change in
spline specifications. Also, as discussed above, both splines have been designated as
not standard. The marking designations for the gages no longer include “ANSI
B92.2M”, as the splines no longer meet this standard.
Figure 4-4 is a plot of the teeth in assembly for the modified spline.
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60-720—Metric Module Involute Splines
Fig. 4-4
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