28 Backlash in Spur Gears Backlash can be generally defined as the play between a mating pair of gear teeth in assembled condition. It is the amount by which the width tooth space exceeds the thickness of the meshing tooth measured on the pitch circle. This is called the circumferential or torsional, or angular backlash, and is designated asj,, Ifthe backlash is measured on the line of action, itis. termed as the normal or linear backlash. These backlashes have been shown in Fig. 2.16. The relation between these two types of backlashes is given later. Unless otherwise specified, the values of backlash are given with reference to the pitch circles. Proper amount of backlash Fig.2.16 Backlash in gears228 Handbook of Gear Design ensures smooth running of the gear set. Except in case of timing gears, indexing and some other special purpose applications where the meshing gears have practically zero backlash, the main ‘purpose of providing backlash is to prevent jamming and to ensure that no contact is made on both sides ofthe teeth simultaneously. Too little backlash may lead to overloading, overheating, jamming and ultimately seizureand eventual failure ofthe system. Moreover, a tight mesh, may ‘result in objectionable noise during running. On the other hand, excessive backlash may cause non-uniform transmission of motion especially if the amount of backlash varies from tooth to tooth due to machining and other errors. Excessive backlash may also cause noise and impact loads in case of reversible drives. ‘Specification of proper amount of backlash, therefore, is of prime importance. Moreover, an unnecessarily small amount of backlash allowance should be avoided because this will inerease the cost of gears as allowances for run-out, pitch error, profile and mounting errors are also to be kept correspondingly smaller. In selecting the proper amount of backlash, many factors are to be taken into consideration. ‘They are the run-out and errors in tooth thickness, pitch tooth spacing, profile, helix angle, ete. It should be noted that backlash in no way affects the involute action. In the mounted condition, the backlash will consist of the amount by which the thickness of the teeth has been reduced as well as the tolerance on the centre distance. The tolerances specified on the teeth (which are always negative), either on individual teeth or on block measurement as described later in Sec. 2.28, determine the amount by which the tooth thicknesses are reduced. This will again depend on the quality and the zone of tolerance selected (see Secs 2.27 and 2.28). The reduction in tooth thickness is usually obtained by sinking the cutter deeper into the blank to correspond to the tolerance pre-selected. In some cases the eutter itself is s0 dimensioned that the tolerance is taken care of when the tool cuts up tothe relevant standard tooth depth. Determination of the final backlash in the mounted condition has been illustrated diagramatically in Fig. 2.17 For measurement of circumferential or torsional backlash, one gear of the pair is held stationary and the other one is rotated till its tooth touches the corresponding tooth face of the other component. The movement is then registered by a dial indicator suitably mounted. For ‘measuring normal backlash, suitable feeler-gauges or similar measuring instruments may be ‘employed. Gears, when meshed with a rack, have no backlash. When base circles are shifted away from each other, as inthe case of non-standard centre-distancegear systems, the matinginvolutes will have zero backlash with the theoretical rack as shown in Fig. 2.18 (b), but they will have an ac- tual backlash between themselves which is quite apparent from the figure. When the centre distance is non-standard, the working, i.e. the actual pressure angle a, is different from the nominal pressure angle of the basic rack. Under sch conditions, the individual mating gear tooth profiles have zero backlash with respect to the common reference profile of the rack, but they will contact the rack profile at different points, viz. A and B in Fig. 2.18(b). This displacement of the respective contact points, together with the lesser convexity of the tooth profiles incase of positively corrected gears, results in creating the backlash between the profiles of the mating teeth. 2.30 the conditions which prevail when two standard gears meshing at the standard centre distance have been shown schematically. As we have seen before, this standard centre distance is given by 1 a = 5 my + 3)| L |— GEAR ———— 112 Asam= == 1/2 Ase 1/2 Ast = 1/2 Ast BACKLASH FOR NORMAL SPUR GEAR = Ay + Ag + 2A, tan 20° WHERE As AND Ago = TOOTH THICKNESS TOLERANCE Aa =CENTRE DISTANCE TO LERANCE EFFECT OF CENTRE DISTANCE TOLERANCE Fig.2.17 Tolerance versus backlash228 Handbook of Gear Design ‘The backlash here is zero, that is, not considering the tooth thickness allowances or the tooth distance allowances and the centre distance allowances which cause the creation of backlash automatically, as will be seen later in the section on gear tooth tolerance, etc. Pressure angle a is the standard pressure angle, sometimes called the “in-built” pressure angle of the cutter, namely 14.5°, 15°, 20°.,25°, 30° as the case maybe. In the above condition, the mating gears will operate at this particular standard pressure angle. The pitch circles in this condition meet atthe pitch point P and are the standard pitch circles or the cutting pitch circles as the gears were cut ‘at these pitch circles. Note that in this condition, the standard pitch circles and the working or ‘operating circles are identical. In Fig. 2.18 (a) the two gears have been pulled apart and the centre distance has now been increased. It is clear from the figure that now backlash exists between the mating pair of teeth. Restricting our discussion here only on standard gears and not considering the corrected gearsSTANDARD. PITCH CIRCLE WORKING ‘CIRCLE STANDARD PITCH CIRCLE f@) COM! REFERENCE PROFILE (a = 30°) Fig. 2.18 Backlash due to extended centresSpurGears 229 (which will be taken up later) where gearsare “pushed” tomake upfor the backlash (as explained in See. 2.13), we ean arrive at the following relations: Ifthe gears (now situated at extended centres) are made to mate, the standard pitch circles no longer touch each other. Instead, the tooth profiles touch at a point other than the standard point. Ifeircles are now passed through the new pointof eontact, we can call the resulting circles as working circles with radii’, andr’_,(The symbols, and r,, are not used here because they are used in connection with corrected gears after “pushing” as detailed in Sec. 2.13.) ‘The new contact point divides the new centre distance, called a’ into segments which are inversely proportional to the angular velocities of the gears. That is = Seah (2.14) a MO Also for + Faw (2.15) Joining the two base circles of the ’s by a common tangent, we get the new line of action and ‘a new working pressure angle a’, Since and & (r, +17) c08 @=(r',, +1) cosa’, or a, cos a= a’eosa,, or cos a, = % cosa (2.16) a From the above equations, the following relations ean be established an Due to faulty mounting or otherwise, sometimes the standard gears are operated at such extended centre distance, in which cases the determination of backlash may become necessary. ‘An expression for such backlash ean be arrived at as shown unde: ‘The sum of tooth thicknesses measured on the working circle + Backlash = Circular pitch measured on the working circle2.30 Handbook of Gear Design That is, referring to Fig.2.18 (a), Si ag + Backlash = p’ = 2BtE ~ Bete Recalling Eq. 2.8, we have sf = 2r,|42 + inv a - inv af 2n, 8 = 2, [s + iny @ ~ inv «| FromEq.2.17,wehave 1% 2 ian pe lxpe em & where p and p’ are the circular pitches on the pitch circle and the working circle respectively. ‘ Backlash = PETE gj — aj = pi ah a 1 = Dam 2x 9+ 201, (invay — inva) a, 5 ~ x + 20, (inva - inva) 4 ‘ a , Nz = + am- © (s, +) + 2a" (inva, - inva) % % < [em — (a+ 5) + 2a, (inva, inva)] (2.18) For standard gears, 2, zm he gess te Backlash = 2a'(inv a, ~inv @) (2.19) It has been mentioned before that two kinds of backlash measurements are done—the norm: backlash j, and the torsional backlash j,. The magnitude of both the kinds of backlashes depend upon the tolerances on tooth thickness and centre distance. These aspects have been dealt with in detail in Secs 2.27 and 2.28. When these grades and tolerances are fixed from various design considerations, the magnitudes of the backlashes become automatically fixed. General guidelines for determination of the proper amount of backlash will be given later in this section. Expressions of backlashes for spur gears are given in Eqs 2.20 to 2.23. These are to be read along with Secs 2.27 and 2.28, Subscripts U and L stand for the upper and the lower values of the tolerance which is represented by the general symbol A, 1 and 2 for pinion and gear, S for tooth thickness anda for centre distance. Thus A,,, denotes the lower value (L of tooth thickness (S) tolerance (A) of gear (2).SpurGears 231 Almin) = ~Agy, +Ag,) 608 a+ 2A, sin G, 220) J,(max) = - (Ag, +Ag,) €08 a+ 2A,, sin 21) Jlmin) = ~(Agy, + Agyy) + 2A,, tana, (2.22) dilmax) = —(Ag, +g.) + 2Ay tana, (2.23) Itisimportant to note here that all the tolerances are to be entered in the above formulae with the proper algebraic sign they carry (+ or-). ‘The centre distance tolerance A,, for example, carry + sign (see Appendix L). For general engineering applications, the values of backlash as per IS: 4460 given in Table 2.2 serve the purpose adequately. Otherwise the amount of backlash is determined from the tolerances on tooth thickness and centre distance, as indicated earlier. For specifying the proper amount of backlash, the undermentioned salient points are to be kept in mind. 1. The maximum permissible run-out is one of the most important criteria for the determi- nation of the magnitude of backlash, followed by allowable errors in profile, pitch, tooth thick- ness and helix angle. 2. Gears which rotate in slow speed generally require the least backlash. 3. Maintenance of the proper lubricant film is another important consideration. Backlash should be so chosen that there is adequate clearance for an oil film. To avoid generation of heat and excessive loading on teeth, oil should not be allowed to be trapped at the root of the teeth.