Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789

www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-011-0416-x

Effects of flank deviation on load distributions for helical gear†

Jing Wei1,2,*, Wei Sun1 and Licun Wang3
1
School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
2
The State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400044, China
3
School of Mechanical Engineering, Chongqing Technology and Business University, Chongqing 400067, China

(Manuscript Received October 29, 2010; Revised March 10, 2011; Accepted March 22, 2011)

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Abstract

Flank deviation is one of the important factors that greatly affect helical gear strength. A qualitative analysis is performed using finite
element method (FEM) for the effects of flank deviation on load distributions for helical gear based on ANSI/AGMA ISO 1328-1 (stan-
dard for cylindrical gears - ISO System of Accuracy - Part 1: Definitions and Allowable Values of Deviations Relevant to Corresponding
Flanks of Gear Teeth). To analyze the effects of flank deviation, tooth contact analysis (TCA) is developed and load distributions of heli-
cal gears with flank deviation are presented. Load distributions in contact lines are derived and compared to each other under grade 5 and
7 after taking five types of flank deviation, including single pitch deviation, profile form deviation, profile slope deviation and helix form
deviation as well as helix slope deviation, into account. It is found that the effects of individual flank deviation on load distribution have
the superposition property. Flank crowning and tip relief corrections must be carefully regarded in the design process because of the ef-
fects of flank deviation on load distributions.
Keywords: Flank deviation; Load distributions; Helical gear; Tooth contact analysis (TCA); Finite element method (FEM)
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many studies [6] conducted indirectly, for example, by analyz-

1. Introduction
ing the dynamic incentive generated by error to get the dy-
Flank deviation is one of the factors that greatly affect gear namic load, whereby the strength, noise, vibration, transmis-
strength. After many studies, Semba Seiso [1] thought that the sion errors, etc., have been studied.
gear strength calculation equation in every country is still not Except for random error, to reduce the partial load, transmis-
precise enough; the main reason for this is that the effect of sion error, dynamic load, noise, etc., as well as to improve the
flank deviation is not fully considered. He thought the stan- transmission performance of gears, modification techniques to
dard of gear accuracy should be calculated based on the ef- change the shape of the gear flank are also widely used in gear
fects of various errors on noise and strength instead of the size design. Many scholars [7, 8] studied gear modification in order
of various errors processed in various ways. Therefore, some to analyze the effect of different modification methods on gear
scholars [2] have put forward the concept of functional equi- strength using finite element method. As the effects induced by
valence among the same gear accuracy. The study of gear the errors and modifications on gear are interaction, in order to
errors is usually performed through experiments. For example, obtain the best modification effect, both must be considered. In
Velex and Ajmi [3] studied the relationship of the carrying 2001, Litvin et al. [9-11], used gear hobbling when they built
capacity of gears between different errors and transmission gear model, and considered the error and modification parame-
ratios, and they pointed out that it is difficult to avoid the ap- ters caused by axial and cross movement. Sun et al. [12] identi-
pearance of contact stress concentration because of manufac- fied principles with modification parameters of manufacturing
turing error, installation error, elastic deformation, etc. How- error gear modification for spur gears. In 2006, Mao [13] built
ever, it can be improved greatly through running-in operation. a finite element model for spur gears with axis deviation and
In 2005, Jui-Tang Tseng [4, 5] studied the actual gear form studied its effect on the fatigue properties by optimizing the
produced by cutting of different hobs and the effect of differ- modification parameters to improve fatigue performance. Shut-
ent assembly conditions on gear mesh status. There are also ing Li [14, 15] has used the finite element and experimental
†
This paper was recommended for publication in revised form by Associate Editor methods to analyze the effect of machining error, assembly
*
Jeong Sam Han error, and modification factors on load distribution, contact
Corresponding author. Tel.: +86 411 8470 7435, Fax.: +86 411 8470 8414
E-mail address: weijing@dlut.edu.cn
strength, bending strength and transmission error of spur gear.
© KSME & Springer 2011 It was found that the calculated results agreed well with the
1782 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789

measured ones and machining errors, assembly errors and Table 1. Parameters of the gear and pinion.
tooth modifications greatly affect the surface contact stress and
Power P (kW) 1200
root bending stress of the gears. Through experiments, the load
Normal module mn (mm) 5
distribution and bending stress of a helical gear with axis devia-
Normal pressure angle αn (°) 20
tion and gear modification were investigated by Hotait [16].
The results showed that the gear modification and axis devia- Helix angle β (°) 10
tion are interrelated, and the gear modification can avoid the Tooth width B (mm) 100
partial load behavior caused by axis deviation. Most research Center distance A (mm) 280
on gear transmissions have focused on dynamic analysis, in-
cluding reducing transmission error, dynamic load and noise Table 2. Material properties of 17CrNiMo6.
and other aspects. However, spur gear is still the main study Young’s modulus (GPa) 206
object. In this study, Tooth contact analysis (TCA) is devel- Poisson’s ratio 0.3
oped and load distributions are derived. The effects of different
Yield Strength (MPa) 785
deviations on contact stress and load distribution of helical gear
UTS (MPa) 930
are studied and several effects of load distribution by gear
flank deviation are deduced. Table 3. Flank deviations under grades 5 and 7.

2. Brief description of gear flank deviation Flank deviations

Grade 5 Grade 7
Pinion/Wheel Pinion/Wheel
Several types of individual flank deviations are provided in single pitch deviation ±fpt (um) 7/8 14/16
standard ANSI/AGMA ISO 1328-1. They are single pitch
profile form deviation ffα (um) 8/9 16/18
deviation, profile form deviation, profile slope deviation, helix
profile slope deviation ±fHα (um) 6.5/7.5 13/15
form deviation and helix slope deviation. Other types of inte-
helix form deviation ffβ (um) 8.5/9 17/18
grated flank deviations can be combined by these individual
types. The gear accuracy used in industrial production is main- helix slope deviation fHβ (um) 8.5/9 17/18
ly from grade 5 to 9. It is difficult to study the deviations be-
cause of their complex micro-geometry. Therefore, previous
studies [17] are mainly laboratory-based. The effect of devia-
tions is greatly influenced by processing and laboratory stud-
ies cannot accurately obtain the required gear flank deviation.
However, they provide an effective way to study flank devia-
tions and more accurate flank deviations can be found by nu-
merical method. There are some references [18, 19] that have
recently introduced related research in this area, but the devia-
tion types concerned are not comprehensive.
The two most common types of flank deviations, helix (a) Form deviation
slope and form deviations, are shown in Fig. 1. In Fig. 1(a),
the effective length LAE of the profiles is from the gear tip to
the top meshing point E of the matching gear. The measured
length LAF is defined as the effective length extending to the
direction of tooth root about 1mm. The assessment length Lα is
from point E to the extended point A1, i. e., the 92% of the
length LAE and the tooth profile is divided by the middle MM1.
The profile slope deviation fHα is defined as the distance from
the two end points in assessment length to the two intersected (b) Helix deviation
theory profiles M1N1. The profile form deviation ffα is defined
Fig. 1. Form and helix deviations.
as the distance between the two lines that contains the two
actual profiles CC and C1C1.
The helix deviation contains helix form deviation ffβ and he- two actual spirals CC and C1C1.
lix slope deviation fHβ. The assessment scope Lβ on helix de- The parameters of wheel and pinion used here are listed in
viation is shown in Fig. 1(b), and b is gear width. Similar to Table 1. Other parameters of wheel and pinion are as follows:
form deviation, the tooth profile is divided by the middle line Tooth numbers of pinion Z1 and wheel Z2 are 27 and 82, the
MM1. The helix form deviation ffβ is defined as the distance rotation speed of pinion and wheel are 1731.111 rpm and 570
from two end points in assessment length to the two inter- rpm, respectively. The material of the pinion and wheel in this
sected theoretical spiral M1N1. The helix slope deviation fHβ is study is 17CrNiMo6. The material properties of 17CrNiMo6
defined as the distance between the two lines that contains the are listed in Table 2. Table 3 is the flank deviations of the
 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789
(a) Contact lines in tooth surface
(b) Boundary conditions of TCA
Fig. 2. Contact lines in tooth surface and boundary conditions.
wheel and pinion under grade 5 and 7 based on ANSI/AGMA
ISO 1328-1.
3. Effect of helix slope and form deviations on contact
stress
3.1 Contact stresses caused by flank deviations
Usually, it is difficult to test three dimensional contact stress
because of the complex surface of gear tooth surface and time
variant characteristics of the contact stress. Therefore, in order
to verify the theoretical analysis, a qualitative analysis can be
performed using finite element method (FEM) for the effects
of flank deviation on load distributions for helical gear. The
contact lines in the tooth surface according to the parameters
in Table 1 are shown in Fig. 2(a).
Three teeth are engaged at this meshing state, in which con-
tact line 1 in tooth pair 1 and contact line 2 in tooth pair 2 pass
through the whole tooth surface, while contact line 3 in tooth
pair 3 degenerates to a point. Therefore, contact line 3 in tooth
pair 3 should be ignored under this analysis when simulating
the effects of flank deviation on load distributions. During
analysis, node forces and circumferential constraint are ap-
plied to the nodes on the circumferential surface of the pinion,
while the nodes on the circumferential surface of the wheel are
defined as fixed constraint. The boundary conditions of TCA
are shown in Fig. 2(b).
As shown in Fig. 3, the contact stress along the contact lines
of the two teeth pairs is relatively smooth in most places when
considering flank deviations. However, there are significant
changes at the start point or end point. The average contact
1783
(a) Tooth pair 1
(b) Tooth pair 2
Fig. 3. Contact stress distributions.
stress on tooth pair 1 is about 978 MPa and the average con-
tact stress on tooth pair 2 is about 1005 MPa. The maximum
contact stresses of two teeth pairs were located at the top posi-
tion and at the tooth root area, respectively. The maximum
contact stress at the contact line is about 2-3 times the average
stress in other areas of the tooth surface. This is because the
top of the gear experiences a shear stress with the tooth sur-
face and stress concentration is relatively serious.
Because the tooth contact stress at the contact line is larger
than that in other areas of the gear surface at any meshing state,
the stress caused by different flank deviations is given at the
contact line in this study.
3.2 Single pitch deviation fpt
The single pitch deviation is defined as the algebraic differ-
ence of actual pitch and theoretical pitch on the circle that is
close to the central of gear height at the end plane. In this
study, the single pitch deviation is obtained by offsetting an
equal distance to the theoretical profile flank, and it does not
involve other types of individual deviations because of the
equal offset.
Among all combinations of deviations, the single pitch de-
viation may not be considered when it is both “+” or both “-”
in the two gears because of the equal theoretical profiles. Here,
in Case A and Case B, the most unfavorable situations to the
load distribution are studied, as shown in Table 4. The two
cases with single pitch deviation are shown in Fig. 4. The
wheel is at the upper position and the pinion is below, the
1784 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789

Table 4. Cases with single pitch deviation.

Pinion Wheel
Case A － ＋
Case B ＋ －

(a) Tooth pair 1

(a) Case A (b) Case B

Fig. 4. Cases with single pitch deviation.

(b) Tooth pair 2

Fig. 6. Load distributions of cases with single pitch deviation P=420

KW.

(a) Tooth pair 1

(a) Tooth pair 1

(b) Tooth pair 2

Fig. 5. Load distributions of cases with single pitch deviation P=1200

KW.

solid line denotes the theoretical profiles and the dashed line
denotes the actual profiles.
Load distributions on the contact line by axial direction are
shown in Figs. 5 and 6. Fig. 5 shows the load distributions
when input power P = 1200 KW and each curve is almost
parallel to each other. It shows that the effect of single pitch
deviation on the load distribution is not in the axial direction,
but mainly in a different tooth. The load on tooth pair 1 in
Case A and tooth pair 2 in Case B increases, and the load in-
creasing amplitude under grade 7 is twice that under grade 5.
It corresponds to the single pitch deviation of grades 5 and 7.
Fig. 6 shows the load distributions when input power P = 420
KW. There is only a small contact area in tooth pair 2 under
Case A grade 7, while there is almost no contact for tooth pair
1 in Case B grade 7. It leads to the single gear meshing state
because the pitch deviation and the load distribution become
very bad. It shows that the effect of single pitch deviation on
(b) Tooth pair 2
Fig. 7. Load distributions of cases with helix form deviation.
load distribution is greater for a smaller load.
3.3 Helix form deviation ffβ and profile form deviation ffα
For profile slope deviation, profile form deviation, helix
form deviation and helix slope deviation, the range of the pro-
file which is used to evaluate these deviations is 92% of the
actual length. The study here mainly considers load distribu-
tion affected by the changes of the gear tip. When calculating
the load distributions with helix form deviation and profile
form deviation, it can be assumed that the effects of the two
teeth pairs on load distribution is non-interference. Therefore,
 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789 1785

Table 5. Cases with profile slope deviation.

Tooth pair 1 Tooth pair 2

Pinion Wheel Pinion Wheel
Case A ＋ － 0 0
Case B － ＋ 0 0 (a) Case A (b) Case B
Case C 0 0 ＋ －
Case D 0 0 － ＋
Case E ＋ － － ＋

(c) Case C (d) Case D

(a) Tooth pair 1

(e) Case E

Fig. 9. Cases with profile slope deviation.

(b) Tooth pair 2

Fig. 8. Load distributions of cases with profile form deviation.

there is only need to study one tooth pair with flank deviations,
while the other teeth pairs can use the theoretical involute
profiles.
(a) Tooth pair 1
3.4 Profile slope deviation fHα

Profile slope deviation always appears with single pitch de-

viation. In order to study profile slope deviation independently,
it should be kept at the same pitch circle when building mod-
els with profile slope deviation. The combinations of single
tooth pair profile slope deviation are shown in Table 5.
The load distribution curves of tooth pair 2 in Cases A and
B and tooth pair 1 in Cases C and D are basically parallel.
Because there are no deviations on these tooth pairs, the load
distributions between the two teeth pairs experiences rela- (b) Tooth pair 2
tively small changes, though these curves does not coincide.
The load distribution curves of tooth pair 1 in Cases A and B Fig. 10. Load distributions of cases A and B with profile slope devia-
tion.
and tooth pair 2 in Cases C and D have an obvious intersec-
tion point close to the pitch circle caused by the same pitch
circle when building model. The load distributions with pro- ger load. When building the worst load distribution model,
file slope deviation are shown in Figs. 10 and 11. Case E, the profile slope deviation on tooth pair 1 should be
Figs. 10 and 11 show that in these four Cases (Cases A, B, the same as that in Case A, and the profile slope deviation on
C and D) with profile slope deviation, the maximum load on tooth pair 2 should be same as that in Case D (shown in Table
tooth pair 2 is significantly higher than that on tooth pair 1. 5).
Therefore, the worst load situation should be on tooth pair 2 Fig. 12 shows the comparison of the load distributions in
when these two tooth pairs both have deviations because the Case E, Case A and Case D. From Fig. 12, the load case of the
load distribution of tooth pair 2 in Cases A and D have a lar- tooth pair in Case E is the worst condition. Meanwhile, com-
1786 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789

Table 6. Cases with helix slope deviation.

Tooth pair 1 Tooth pair 2

Pinion Wheel Pinion Wheel
Case A ＋ － － ＋
Case B － ＋ ＋ －
Case C － ＋ － ＋
Case D ＋ － ＋ －

(a) Tooth pair 1

(a) Tooth pair 1

(b) Tooth pair 2

Fig. 11. Load distributions of cases C and D with profile slope devia-
tion.

(b) Tooth pair 2

Fig. 13. Load distributions of cases A and B with helix slope deviation.

(a) Tooth pair 1

(b) Tooth pair 2
Fig. 12. Load distributions of case E with profile slope deviation.
pared to the incremental load without deviation, the incre-
mental load in Case E is approximately equal to the accumula-
tion of that in Cases A and D. Thus, the load distribution
curves of Case E grade 7 is almost the overlapping of Cases A
and D.
3.5 Helix slope deviation fHβ
Similar to profile slope deviation, in order to avoid the in-
fluence of single pitch deviation when analyzing the helix
slope deviation, the offset of the axial direction in the middle
section of the gear is defined as zero, then an offset of equal
distance but in the opposite direction from the middle section
to the two cross-sections is performed.
Taking the four Cases with helix slope deviation in Table 6
into account, the load distribution curves are shown in Figs. 13
and 14. These curves are very similar to the curves of profile
slope deviation, and the maximum load appears on tooth pair
2 in Case D. However, the amplitude is greater than that of the
latter. It shows that the effect of helix slope deviation on the
load distribution is larger than that affected by the profile
slope deviation under the same accuracy grade. These load
distribution curves intersect at the same point located at the
middle section in the axial direction.
Cases A and B are studied in Ref. [18] and their load distri-
butions are shown in Fig. 15. There are some differences with
the results calculated in this paper. It is mainly due to use of a
different helix slope deviation in Ref. [18]. The helix slope
deviation in one section is zero while in the other it is maxi-
mum, which is equivalent to the load distributions affected by
the overlapping of the helix slope deviation and single pitch
deviation. As the single pitch deviation can lead to some
 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789
(a) Tooth pair 1
(b) Tooth pair 2
Fig. 14. Load distributions of cases C and D with helix slope deviation.
(a) Tooth pair 1
(b) Tooth pair 2
Fig. 15. Load distributions of cases with helix slope deviation in Ref.
[18].
changes of load distribution between two teeth pairs, the de-
rived curve can be regarded as the overlapping of load distri-
butions of the helix slope deviation and single pitch deviation.
4. Profile relief considering effects of flank deviations
The parabolic relief method and the long relief method [22]
are used in this paper to calculate the position the start and end
1787
(a) Tooth pair 1
(b) Tooth pair 2
Fig. 16. Contact pressure distributions after profile relief.
points of engagement according to the parameters of gears.
The distributions of contact stress on tooth pairs 1 and 2 are
shown in Fig. 16 after profile relief when considering the ef-
fects of flank deviations. Fig. 16 shows that stress concentra-
tions have been greatly reduced, while there is still contact
stress in addendum. This is caused by the tooth pairs becom-
ing thinner, which causes decreased stiffness and increased
deformation after relief. However, it does not form a signifi-
cant stress concentration and it can reduce the scratches at the
top edge and the impact of the engagement and disengage-
ment of gear due to the small contact pressure in addendum.
5. Conclusions
The above studies show that flank deviations have great ef-
fects on helical gear load distribution, and the following con-
clusions can be drawn:
(1) The load increasing amplitude under grade 7 is twice
that under grade 5 when considering the effects of flank devia-
tions. A lower load will induce a larger effect by flank devia-
tions though there is only a small deformation in contact areas.
(2) The effect of single pitch deviation on the load distribu-
tion is not in the axial direction, but mainly in a different tooth.
There is little effect of load distribution affected by profile
form deviation and helix form deviation while it is affected by
profile slope deviation and helix slope deviation.
(3) For equal loads, the effect of single pitch deviation on
load distribution along the direction of tooth width is overall
larger or smaller, while there is a larger effect by the helix
deviations. Form deviation can lead to great changes of load
distribution along the direction of tooth width, while it is less
affected by helix deviations.
(4) According to the comparative analysis of profile slope
deviation and helix slope deviation, it is inferred that the ef-
1788 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789
fects of individual deviation on load distribution have the su-
perposition property, but whether it is suitable for other flank
deviations needs further study.
Acknowledgments
This work is supported by the opening foundation of the
State Key Laboratory of Mechanical Transmission, Chongqing
University, China (No.: SKLMT-KFKT-200906). The authors
would also like to acknowledge grant No.: 20100471443 from
China Postdoctoral Science Foundation. The authors would
like to take this opportunity to express their sincere apprecia-
tion.
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Jing Wei, born in June 1978, received his
doctor's degree in engineering from the
State Key Laboratory of Mechanical
Transmission, Chongqing University,
China, in 2008. Dr. Wei is currently a lec-
ture in School of Mechanical and Engineer-
ing, Dalian University of Technology,
China. His research areas of interest include
structural design and optimization, mechanical transmissions, es-
pecially in gear transmission.
Wei Sun, born in 1967, is currently a pro-
fessor and a Ph.D candidate supervisor in
School of Mechanical and Engineering,
Dalian University of Technology, China.
His main research domains include design
and optimization of complex mechanical
equipment, mechanical transmission and
structure CAD/CAE.
 J. Wei et al. / Journal of Mechanical Science and Technology 25 (7) (2011) 1781~1789 1789

Licun Wang, born in February 1978,

Ph.D., Associate Professor, the director of
institute of scroll compressor, Chongqing
Technology and Business University, the
Assistant Director of Department of Sci-
ence and Research. Undertake or partici-
pate in national and provincial level project
more than 10 items.