technical

Fully Automated Roughness Measurement

on Gears — Even on the Shop Floor
An Optimized System for Precision Measuring Centers
Georg Mies

Significance of Surface Roughness

For flawless operation of geared components in a transmission — not only
the component geometry, but also the surface quality of the functional sur-
faces — plays a decisive role. Precise inspection of the geometry has been
state-of-the-art for decades, and has since undergone further development;
by contrast, insights regarding the effects of surface quality are still rela-
tively recent. Just a few years ago, this aspect was not such a central topic for
series production of standard transmissions, but thanks to new or improved
machining technologies, smooth surfaces or defined surfaces can now be pro-
duced cost-effectively — even in large-scale production. Also, special manu-
facturing processes such as polish-grinding and chemical methods of polish-
ing have made a contribution in this respect.
Surface properties defined with maximum precision are a key variable, and
are frequently also the prerequisite for valuable improvements in drive engi- Figure 1 Polish-grinding with a combined grinding-
neering. Especially in the automotive industry, and particularly in the electric polishing worm.
mobility area, the surface quality of the gearing components is essential. In
combination with electric drives, extremely high rotation speeds are transmit-
ted, resulting in new challenges in transmission and gearing design. But even
in conventional drives with a combustion engine, smoother gearing can make
a significant contribution to the running properties. The production of sur-
faces with an Rz value of less than 1 µm are now possible in series production.

Conventional Roughness Measurement Methods

As a result, the importance of roughness measurement of gearing has grown
significantly. Although roughness can be measured on tooth flanks with the
common roughness measurement systems, these systems are not entirely suit-
able for serial measurements. They are difficult to operate and they require
trained technicians; measurements must be carried out in large part manually.
Quite a bit of skill is required to even conduct such measurements with stan- Figure 2 Reference plane scanning system.
dard feed systems, as the component alignment also plays an important part.
The setup procedure is particularly challenging with reference plane scan-
ning systems. Due to the involute bend of the tooth contour, a curve is traced
with the diamond needle. Because the feed unit executes a linear motion, the
alignment must be selected so that this curve remains in the measuring range
of the probe; a suitably larger measuring range is required. In addition, the
diamond needle changes its alignment with respect to the surface during the
motion.
When using a feed unit with a skid probe, the measuring range of the probe
needle can be significantly smaller and the resolution correspondingly higher.
The sensitive probe needle is protected by the skid. This makes the system
quite robust. This provides advantages in handling, since it prevents needle
damage when setting up the probe needle in the tooth space. Figures 2 and
3 show two linear feed systems measuring roughness on a gear. Regardless of Figure 3 Skid scanning system.
the sensor technology, however, the above-described disadvantages apply to
both systems; therefore the gear industry demanded an automated solution.

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Fifth Floor, Alexandria, VA 22314-1587. Statements
presented in this paper are those of the author(s) and may not represent the position or opinion of the American Gear Manufacturers Association.

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Figures 4 and 5 Roughness sensor mounted on the 3-D probe:
In addition to the roughness sensor technology, a precision swivel device is also integrated into the extremely compact
roughness sensor. The roughness probe can therefore be operated on the adapter plate like the tactile styluses and can
be changed automatically. An especially convenient feature of this is the automatic plug-in (right picture).

A Solution Optimized for Gears Due to this arrangement, the skid of the rough-
In order to realize an automated solution, it is ness sensor behaves like the ball of a tactile stylus
obvious to use a gear measuring machine and to mounted on the 3-D tracer head. As the point of
adapt a roughness sensor system. In this context contact of the skid is only a cut-out of a ball, the
the question arises, i.e. — which sensor technology swivel axis rotates the skid with the point of con-
is the most suitable for this combination of a gear tact perpendicular to the surface; the diamond
measuring machine and roughness sensor? needle is also twisted in the same direction. To
Automatic measuring cylcles, which can be understand this function, Figure 6 shows the front
done in combination with the gear measurement,
require a robust system in which the sensitive
probe needle cannot be damaged. This was the
main reason for the decision to use a skid system.
But the skid system has a well-known disadvan-
tage, i.e. — the signal corruption due to elevations
on the surface. This causes the skid to rise at a dif-
ferent time with respect to the needle during the
measured value logging process. The measurement
signal detects a recess that does not actually exist.
But on high-quality ground or polished tooth Figure 6 The front end of the roughness sensor shows the arrangement of the skid and
the diamond tip. The probing force of the diamond tip is less than 0.5 mN.
surfaces of gears, this effect is
very low. This is a positive pre-
condition that favors the use of
a skid scanning system for gear
measurement.
Figures 4 and 5 show how
the roughness probe that was
especially developed for use on
gearing components is adapted
on a gear measuring machine.
The roughness probe can be
mounted directly on the stan-
dard adapter plate of the 3-D
tracer head. In order to scan in
different directions, the rough-
ness probe is equipped with
an integrated swivel axis. The
adaption is possible because
the combination of roughness Figures 7 and 8 The arrangement of the roughness sensor on the gear measuring machine and the assignment
probe and swivel axis has been of the machine axes. The rotation direction of the sensor swivel axis is also marked. The
miniaturized very much. gear measuring machine complies with class 1 of VDI/VDE 2612 and 2613. The roughness
measuring system fulfills the requirements according to DIN/ISO 3274.

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end of the roughness sensor.

Since the roughness system is optimized for
recording roughness parameters specifically on
gears, the same measuring cycles can be used
for roughness measurement as for gear measure-
ment — thus ensuring optimal tracing conditions.
The tactile stylus and the roughness sensor can
be exchanged automatically within the measuring
process to have a fully automated measurement
cycle — including gear measurement, size, form
and position measurement — as well as roughness
measurement in a single clamping.
Thanks to this integrated solution and a fully
automated measurement cycle, serial measure-
ments can be performed even by untrained staff.
This requires a particularly robust system that can
also be used in a production environment. This
requirement is met through the arrangement of
the roughness sensor with the skid. The diamond
needle is actively protected from damage in cases
of a collision. In addition, by using a skid system
Figure 9 Gear measuring machines have for years been used directly in the production the roughness measurement is extremely insensi-
area. By adapting the roughness sensor on these machines, this is now also
practiced for roughness measurement. tive to vibrations.
This is an important
prerequisite for using
the setup directly in
production. For gear
measurement this is
already state-of-the-art.
Numerous user exam-
ples have confirmed
t hat it a ls o works
with the shown sys-
tem for the roughness
measurement.
Another advantage
of an integrated system
Figures 10 and 11 Owing to the optimized measurement and tracing strategies of the skid probing system, the curved is the chance to use the
surface behaves like an ideal plane relative to the roughness probe; illustrated here with a sample
profile measurement on involute gearing. possibilities of a four-
axis coordinate mea-
suring machine with
rotational axis. It allows keeping the diamond
needle always exactly in normal direction to the
surface, though it is an involute curvature. The
curvature is fully compensated by the generative
measuring movement, resulting in almost com-
plete linearization of the scan on the gear surface
(Figs. 10–11).
From the perspective of the roughness probe,
the curved surface behaves like an ideal plane. The
diamond needle records only the surface rough-
ness and can therefore use an extremely small
measuring range with a correspondingly high
resolution. This prevents errors filtering the long-
undulation curvature.
Figure 12 Graphic with the same magnification factor in all directions shows the correct
relation of the diamond tip to the deepest stria. The typical roughness profile
presentation has strong vertical scaling. The gaps appear much tighter than
they are.

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Figure 13 Input menu for roughness parameters and tolerances. Figure 14 Input menu for measuring length and filter parameters.

Influence of the Tip Radius

The DIN/ISO 3274 standard specifies under which
conditions a probe tip with 5 µm tip radius or with
2 µm tip radius is to be used; in both cases the
radii are very small. In order to get a better under-
standing of the influence of the probe tip radius
to the surface, the relation to each other must be
made clear.
Due to the radius of 2 µm, very fine stria can be
measured better. To illustrate this, it is advanta-
geous to represent the relation between the surface
in the longitudinal and vertical directions with the
same magnification.
In typical roughness profile charts a very strong
vertical scaling relative to the surface is used. This
makes stria that are just 0.5–1.5 µm deep appear
very narrow and seemingly impossible to measure
using a 90° or 60° diamond tip. By showing the
actual relation through the same magnification in
the lengthwise and vertical directions, the actual
appearance of the seemingly narrow compared
with the tip becomes apparent. In this case, the
stria could be measured with both — the 2 µm and
the 5 µm tip. In a case of even narrower gaps, the 5
µm tip would not reach the bottom, so that the 2
µm tip is needed; Figure 11 shows the influence of
the magnification.

Measuring Results
The evaluation and output of the roughness mea-
surement results are analogous to the toothing
evaluation. The roughness curves are shown in
corresponding diagrams. The calculated param-
eters are listed under the diagrams in tabular form.
The roughness measuring system fulfills the
requirements of DIN/ISO 3274. The filters work in
accordance with DIN/ISO 166110-21. The param- Figure 15 The picture shows the diagrams of the roughness measurement curves and
the measured parameters. If tolerances are entered, the parameters are
eters are calculated according to DIN/ISO 4287. printed in red when the tolerance is exceeded.
The desired roughness parameters, the measur-
ing lengths, the filter settings and the upper and
lower tolerances can be selected in the software;

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the corresponding input menus are shown values. Nevertheless an evaluation of the param-
(Figs. 13–14). eters Ra and Rz, which are very easy to describe,
To ensure that the measurement results agree is still commonly used. However, this does not
with the results of other measuring instruments a reveal the surface characteristic. Surfaces can have
number of comparative measurements were car- extremely different detailed structures — even
ried out with reference measuring systems. The though they have the same value for Ra or
difficulty is to measure exactly at the same posi- Rz — but in most cases different structures also
tion. Such measurements have been done several mean different characteristics.
times by customers; an example is shown (Fig. 16.) In addition to conventional evaluation of the
What is interesting is the correspondence of the roughness measurement curve via individual mea-
diagram, if you actually hit the same spot. suring sections, material ratio evaluation is now
being used increasingly. This provides additional,
Material Ratio Evaluation useful parameters for evaluating the surface prop-
Over the years, standards committees have con- erties to be determined.
tinually redefined new roughness parameters in This evaluation generates cross-sections along
order to express the surface characteristics in key the height of the recorded measurement curve,

Figure 16 This example comparative measurement conducted on a ground gear shows the correspondence between the measurement performed using
a reference measurement system (in red) and using the gear measuring machine (in black). This is true not only for the parameters, but also
for the characteristic of the two measurement curves.

Please note that the differences are in nanometer range. However, due to the small
roughness values, the percentage deviations appear large.

Figure 17 These three surface profiles illustrate the importance of the material ratio
In this older diagram format the measuring length of evaluation: although the characteristics of the surfaces are completely
Lt = 1.5 mm and the filter Lc = 0.25 mm are printed beside the different because of the different production processes, the same Ra value
diagram. was determined in all three cases.

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in which the material ratio is calculated as a per-
centage value. Based on this, a so-called Abbott-
Firestone curve is generated and is evaluated
according to a special method.
The advantage of the material ratio evaluation
is that it provides clear parameters resulting from
the varying material density over the height pro-
file — from the uppermost point on the surface to
the transition into the solid material. Since gear
manufacturers want to achieve very specific struc-
tures on the gear surface, this evaluation is helpful. Figure 18 Generation of an Abbott-Firestone curve used for surface characterization.
Characteristics such as high peaks with broad pla-
teaus, or broad plateaus with narrow grooves, are
described via the material ratio parameters Rk, Rvk
and Rpk, as well as MR1 and MR2. Accordingly,
these parameters would differ significantly for the
surfaces shown in Figure 16.
The parameters are calculated according to
DIN/ISO 13565; this standard describes the mean-
ing and the derivation of these parameters in
detail.

Gears with Small Modules

The roughness probe design shown in Figure 6
cannot be used in combination with extremely Figure 19 The front end of the roughness probe shows the arrangement of the skid and
the diamond tip. The position of the skid is beside the diamond tip. On the
small tooth spaces, as it does not fit in the small other side there is a collision protector to protect the tip.
gaps. For this reason another roughness probe was
developed with a special skid design and a paral-
lel arrangement of the diamond needle for use on
gearing as small as module 0.9 mm; the special
design is shown (Fig. 19).
Because of the short distance between the tooth
ground and the tooth tip, the parallel design of
the needle and the skid was necessary. This design
ensures that the biggest possible proportion of
the short measuring section that is available with
small gearing can be recorded. Because of the
extremely compact design (Fig. 20), a ratio of
1:1000 was achieved between the probe tip radius
(2 µm) and the skid radius (2 mm). The distance
between the skid and the needle was also further
reduced.
The small stylus tip radius shown (Fig. 20) is not
a prerequisite for the measurement of small mod-
ules; the radius of the tip to be used is specified in
the standard ISO 3274. That’s why the roughness Figure 20 A close-up image of the roughness probe for gearing starting
probes are optionally available with 2 µm and 5 at module 0.9 mm shows the skid in relation to the diamond
µm tip radius. tip. Because of the extremely small dimensions of the overall
system, a ratio of 1:1000 was achieved between the tip radius
and the skid radius. This roughness probe comes equipped
Internal Gears with the 2 µm/60º diamond tip as standard.
Measuring internal gears represents another chal-
lenge in that the use of reference plane scanning
systems is even more complicated in the case of
internal gears than for external gears.
Thanks to the highly compact roughness probe
with integrated swivel device, it was possible to
develop an overall system that can also be used
in an automated setting. Combined with the

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Figures 21 and 22 Roughness measurement of internal gears.

roughness probe for external gears starting with module 0.9 mm, the typical Due to the automatic change between the tactile
internal gears in complex passenger cars with automatic transmissions can stylus and the roughness sensor, measurements with
also be measured. Figures 21 and 22 show the design of the system for rough- automated processes and the combination with geo-
ness measurement of internal gearing and internal gears. metrical measurements are possible with this system.
Due to the special scanning conditions, the usage of a skidded probe with The programming of the measuring processes can
a parallel arrangement of skid and diamond needle is advantageous. In this be carried out by the operator of the gear measuring
way, shaft collisions can be avoided through a significantly greater degree of machine analogous to the gearing measurement.
freedom in the scanning angles. Also, a much larger measuring range can be For the measurement of gears with small mod-
executed relative to the tooth depth. ules, an additional roughness probe with a special
The probe rods with the roughness probe for internal gears can also be skid design has been developed. This makes mea-
changed automatically. The electrical connection via the plug is also plugged surements from module 0.9 mm possible.
in automatically, as with the other roughness probes. The roughness of internal gears can now also be
measured with the same ease. In addition to the
Summary conventional evaluation of Ra, Rz, Rt and Rmax,
The properties of the gear transmission can be improved by reducing the surface etc. contact ratio parameters such as Rk, Rpk, Rvk,
roughness of gears or by producing optimized surfaces. Among other things, this MR1 and MR2 can also be evaluated. The contact
has a positive effect on the efficiency, power density, wear and running behavior. ratio parameters are evaluated according to the
With modern manufacturing processes, such surfaces can be produced economi- DIN/ISO 13565 standard. The roughness param-
cally and reliably. In order to control the results of machining the surfaces, rough- eters are evaluated according to DIN/ISO 4287.
ness measurement of gears gains importance. For more information. Comments or ques-
With the known roughness measuring devices, these measurements are very tions regarding this paper? Contact Georg Mies at
time-consuming and require trained personnel. For series surveillance, the pre- g.mies@klingelnberg.com.
sented fully automatic system is better suited.
Since this system is based on a gear measuring machine, all measuring For Related Articles Search
tasks of the gear measurement can be used. The developed roughness sensor
with skid system is highly miniaturized so that the sensor can be adapted on roughness
the 3-D touch probe. In this case the roughness sensor is used instead of the at www.geartechnology.com
tactile stylus. The skid and the diamond needle can be automatically rotated
perpendicular to the tooth surface by means of a swivel axis integrated in the
roughness sensor; the roughness sensor system complies with the DIN/ISO Dipl. Ing. Georg Mies is Head of
Research and Development Precision
3274 standard.
Measuring Centers. Since his 1985
The use of the skid system protects the sensitive diamond needle of the Graduation as Dipl.-Ing. in Electrical
roughness sensor against collision during the measurement. This makes the Engineering and Automation Technology,
system very robust. The gear measuring machine is suitable for use in produc- he has worked at Klingelnberg in the
development of measuring machines.
tion. The combination with the robust roughness sensor and the automatic His fields of development are CNC-
measuring sequences analogous to the gear measurements now makes the controller, sensor technology, machine concepts and
roughness measurement possible in the production area. compensation methods for improving accuracy. Mies
is the inventor of over 30 national and international
Klingelnberg patents and is considered the “father” of the
well-known P26 measuring machine and all Klingelnberg
touch probes.

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