Program 60-720—Metric Module Involute Splines · PDF fileProgram 60-720—Metric Module Involute Splines Introduction The primary purpose of this model is to provide data from ANSI

Program 60-720—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

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Table 1

60-720—Metric Module Involute Splines

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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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Report 1-1

Model Title : Program 60-720 Unit System: US Description Value Unit Comment

COMMON

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

Internal Spline ANSI B92.2M-1980? Yes

Fillet or Flat Root ('fil/'flt) flt

Major Diameter - Max 215.510 mm

Form Diameter 212.000 mm


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Roll Angle at Form Diameter 40.439 deg

Fillet_Radius 2.0000 mm

Minor Diameter - Min 191.150 mm

Minor Diameter - Max 192.070 mm

Tolerance and Fit Class: "7H"

Tooth Thickness Reduction 0.00000 mm

Machining Tolerance 0.1820 mm

Effective Variation 0.1140 mm

Total Tolerance 0.2960 mm

Min_Effective_Space Width 15.7080 mm

Specification Required or Reference Required

Plug Gage Type-Composite or Sector GO Cmp

Max_Effective_Space Width 15.8900 mm

Specification Required or Reference Reference

Plug Gage Type-Composite or Sector None

Min_Actual_Space Width 15.8220 mm



Max_Actual_Space Width 16.0040 mm


Plug Gage Type-Composite or Sector NO GO Sec INTERNAL SPLINE Size Between Pins

Pin Diameter, mm 18.0000 mm `

Pin Diameter, inch 0.70866 in `


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Min_Between 2 Pins 172.6830 mm

Max_Between 2 Pins 173.0590 mm

Min_Diameter Under 3 Pins 172.6830 mm

Max_Diameter Under 3 Pins 173.0590 mm

Min_Pin Contact Diameter 198.8850 mm

Max_Pin Contact Diameter 199.3250 mm INTERNAL SPLINE Analytical Inspection

Total_Index Variation 0.1440 mm

Total_Profile Variation 0.1190 mm

Lead Variation 0.0340 mm EXTERNAL SPLINE

External Spline ANSI B92.2M-1980? Yes

Fillet or Flat Root ('fil/'flt) flt


Major Diameter - Min 208.780 mm





Tolerance and Fit Class "7d"






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Max_Eff_Tooth Thickness 15.5380 mm


Ring Gage Type-Composite or Sector GO Cmp

Min_Eff_Tooth Thickness 15.3560 mm

Specification Required or Reference REF

Ring Gage Type-Composite or Sector None

Max_Actual_Tooth Thickness 15.4240 mm



Min_Actual_Tooth Thickness 15.2420 mm


Ring Gage Type-Composite or Sector NO GO Sec EXTERNAL SPLINE Size Over Pins



Max_Over 2 Pins 234.6920 mm

Min_Over 2 Pins 234.4220 mm

Max Pin Contact Diameter 201.8320 mm

Min Pin Contact Diameter 201.5950 mm EXTERNAL SPLINE Analytical Inspection



Lead Variation 0.0340 mm


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Model Title : Program 60-720 Unit System: US Description Value Unit Comment Plot Data

Mark mod/inv/fil intersections? y

Number of teeth on plot 1

GAGES

Dimensioning Method (Def='std, 'A, 'B) std

INTERNAL SPLINE GAGES

Major Diameter External 212.0500 mm

Major Diameter Internal 212.0040 mm


Minor Diameter, Max 188.1450 mm

Tooth Thickness External, New 15.7210 mm

Tooth Thickness Internal, New 15.7110 mm

Tooth Thickness, Wear Limit 15.7070 mm

Effective Gage Variation 0.00800 mm

Min Gage Length 60.000 mm



Max Size Over Pins - New 235.13140 mm

Min Size Over Pins - New 235.11660 mm

Size Over Pins - Wear Limit 235.11070 mm NOT GO Composite Plug Gage

Major Diameter External mm

Major Diameter Internal mm


10


Form Diameter mm

Minor Diameter, Max mm

Tooth Thickness External mm

Tooth Thickness Internal mm

Effective Gage Variation mm

Min Gage Length mm



Max Size Over Pins mm

Min Size Over Pins mm NOT GO Sector Plug Gage





Tooth Thickness External 16.0050 mm

Tooth Thickness Internal 15.9950 mm





Max Size Over Pins 235.54970 mm

Min Size Over Pins 235.53500 mm

Number of Teeth in Sector 2


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Model Title : Program 60-720 Unit System: US Description Value Unit Comment EXTERNAL SPLINE GAGES


Minor Diameter, Min 188.8770 mm


Major Diameter, Min 212.7060 mm

Space Width External, New 15.5370 mm

Space Width Internal, New 15.5230 mm

Space Width, Wear Limit 15.5410 mm





Min Size Between Pins - New 172.05950 mm

Max Size Between Pins - New 172.08890 mm

Size Between Pins - Wear Limit 172.09740 mm Tapered External Master For GO Composite Ring Gage




Minor Diameter, Max Tooth Thickness 186.9100 mm

End of Lead Length, CC 15.5230 mm

End of Fit Range, BB 15.5370 mm

End of Wear Range, AA 15.5410 mm



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Taper On One Side of Teeth 0.02 %

Ball Diameter 21.20000 mm

Size Over Balls at CC 234.83890 mm

Size Over Balls at BB 234.85960 mm

Size Over Balls at AA 234.86550 mm Tapered External Master NOT GO Composite Ring Gage

Minor Diameter, Max mm

Minor Diameter, Min mm

Form Diameter mm

Major Diameter, Min mm

Space Width External mm

Space Width Internal mm


Min Gage Length mm



Min Size Between Pins mm

Max Size Between Pins mm Tapered External Master For NOT GO Composite Ring Gage

Major Diameter External mm

Major Diameter Internal mm

Form Diameter mm

Minor Diameter, Max Tooth Thickness mm

End of Lead Length, CC mm


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End of Fit Range, BB mm


Taper On One Side of Teeth %


Size Over Balls at CC mm

Size Over Balls at BB mm

Tapered External Master NOT GO Sector Ring Gage





Space Width External 15.2530 mm

Space Width Internal 15.2390 mm





Min Size Between Pins 171.45740 mm

Max Size Between Pins 171.48730 mm

Number of Teeth in Sector 2 Tapered External Master For NOT GO Sector Ring Gage





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Number of Teeth in Master 2 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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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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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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Report 2


COMMON

Number of Teeth 6

Module 1.000000 mm `


Standard Pressure Angle 37.5 deg



Base Dia 4.76010 mm







Inch('i) / Metric('m) Measuring Pins i

INTERNAL SPLINE


Fillet or Flat Root ('fil/'flt) fil




20
















Plug Gage Type-Composite or Sector NO GO Cmp










21



















Tolerance and Fit Class "4h"






22







Ring Gage Type-Composite or Sector NO GO Cmp

















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Model Title : Program 60-720 Unit System: US Description Value Unit Comment Plot Data



GAGES

Dimensioning Method (Def='std, 'A, 'B) A



















24











Min Size Over Pins 12.10610 mm NOT GO Sector Plug Gage















25

Model Title : Program 60-720 Unit System: US Description Value Unit Comment EXTERNAL SPLINE GAGES
























26


















Max Size Between Pins 3.18550 mm Tapered External Master For NOT GO Composite Ring Gage







27


























28










Number of Teeth in Master 2 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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Fig. 2-4


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Fig. 2-5


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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

Model Title : Program 60-720 Unit System: Metric Description Value Unit Comment

COMMON

Number of Teeth 10













Inch('i) / Metric('m) Measuring Pins m

INTERNAL SPLINE






33


























34

























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Model Title : Program 60-720 Unit System: Metric Description Value Unit Comment Max_Eff_Tooth Thickness 3.0770 mm Specification Required or Reference Required Ring Gage Type-Composite or Sector GO Cmp Min_Eff_Tooth Thickness 3.0530 mm Specification Required or Reference REF Ring Gage Type-Composite or Sector None Max_Actual_Tooth Thickness 3.0610 mm Specification Required or Reference REF Ring Gage Type-Composite or Sector None Min_Actual_Tooth Thickness 3.0380 mm Specification Required or Reference Required Ring Gage Type-Composite or Sector NO GO Sec EXTERNAL SPLINE Size Over Pins Pin Diameter, mm 6.0000 mm ` Pin Diameter, inch 0.23622 in ` Max_Over 2 Pins 30.8200 mm Min_Over 2 Pins 30.8010 mm Max Pin Contact Diameter 20.1810 mm Min Pin Contact Diameter 20.1640 mm EXTERNAL SPLINE Analytical Inspection Total_Index Variation 0.0200 mm Total_Profile Variation 0.0140 mm Lead Variation 0.0070 mm Plot Data Mark mod/inv/fil intersections? y Number of teeth on plot 10


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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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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


COMMON

Number of Teeth 28














INTERNAL SPLINE






39


























40

























41
























42

Model Title : Program 60-720 Unit System: Metric Description Value Unit Comment Plot Data



GAGES

Dimensioning Method (Def='std, 'A, 'B) A



















43











Min Size Over Pins 31.60470 mm NOT GO Sector Plug Gage















44

Model Title : Program 60-720 Unit System: Metric Description Value Unit Comment EXTERNAL SPLINE GAGES
























45


















Max Size Between Pins 24.64140 mm Tapered External Master For NOT GO Composite Ring Gage







46


























47










Number of Teeth in Master 2


48

Figure 4-2 is a plot of the teeth in assembly for the standard spline. Fig. 4-2


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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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Fig. 4-3b


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Report 4-2


COMMON

Number of Teeth 28














INTERNAL SPLINE

Internal Spline ANSI B92.2M-1980? No





53


























54











External Spline ANSI B92.2M-1980? No














55













Ring Gage Type-Composite or Sector NO GO Sec EXTERNAL SPLINE Size Over Pins Pin Diameter, mm 2.1336 mm ` Pin Diameter, inch 0.08400 in ` Max_Over 2 Pins 31.4082 mm Min_Over 2 Pins 31.3788 mm Max Pin Contact Diameter 28.1348 mm Min Pin Contact Diameter 28.1082 mm EXTERNAL SPLINE Analytical Inspection Total_Index Variation 0.0229 mm Total_Profile Variation 0.0122 mm Lead Variation 0.0076 mm Plot Data Mark mod/inv/fil intersections? y Number of teeth on plot 1


56

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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Fig. 4-4

Documents

Program 60-720—Metric Module Involute Splines · PDF fileProgram 60-720—Metric Module Involute Splines Introduction The primary purpose of this model is to provide data from ANSI