AGMA 929- A06

AMERICAN GEAR MANUFACTURERS ASSOCIATION

Calculation of Bevel Gear Top Land and

Guidance on Cutter Edge Radius
AGMA 929- A06

AGMA INFORMATION SHEET

(This Information Sheet is NOT an AGMA Standard)
 American Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius
AGMA 929--A06
Gear
Manufacturers CAUTION NOTICE: AGMA technical publications are subject to constant improvement,
revision or withdrawal as dictated by experience. Any person who refers to any AGMA
Association
technical publication should be sure that the publication is the latest available from the As-
sociation on the subject matter.
[Tables or other self--supporting sections may be referenced. Citations should read: See
AGMA 929--A06, Calculation of Bevel Gear Top Land and Guidance on Cutter Edge
Radius, published by the American Gear Manufacturers Association, 500 Montgomery
Street, Suite 350, Alexandria, Virginia 22314, http://www.agma.org.]

Approved August 22, 2006

ABSTRACT
This information sheet supplements ANSI/AGMA 2005--D03 with calculations for bevel gear top land and guid-
ance for selection of cutter edge radius for determination of tooth geometry. It integrates various publications
with modifications to include face hobbing. It adds top land calculations for non--generated manufacturing me-
thods. It is intended to provide assistance in completing the calculations requiring determination of top lands
and cutter edge radii for gear capacity in accordance with ANSI/AGMA 2003--B97.
Published by

American Gear Manufacturers Association

500 Montgomery Street, Suite 350, Alexandria, Virginia 22314
Copyright © 2006 by American Gear Manufacturers Association
All rights reserved.
No part of this publication may be reproduced in any form, in an electronic
retrieval system or otherwise, without prior written permission of the publisher.
Printed in the United States of America
ISBN: 1--55589--873--4

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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Contents
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Symbols, terminology and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Input data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Annexes
A Additional equations from ANSI/AGMA 2005--D03 . . . . . . . . . . . . . . . . . . . . . . 18
B Stock allowance and standard cutter specifications . . . . . . . . . . . . . . . . . . . . . 23
C Spiral bevel example problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
D Hypoid example problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tables
1 Symbols and terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Input variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Symbols and terms from ANSI/AGMA 2005--D03, table 9 . . . . . . . . . . . . . . . . . 7
4 Gear rotation factor, kE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Suggested defaults for input data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

© AGMA 2006 ---- All rights reserved iii

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Foreword
[The foreword, footnotes and annexes, if any, in this document are provided for
informational purposes only and are not to be construed as a part of AGMA Information
Sheet 929--A06, Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius.]

The Bevel Gearing Committee recognized the need for additional equations to aid in the
design of bevel gears. The equations for geometry factors found in the annex of
ANSI/AGMA 2003--B97 require detailed information on the proposed cutting tool before a
proper calculation can be performed. In addition, the minimum top land thickness is
required to aid in determining the maximum case depth allowed on carburized bevel gears.
The equations required for these values were not published in AGMA documentation, but
could be found, for some cases, in the publications listed in the bibliography of this
information sheet. AGMA 929--A06 expands on those equations to include gears
manufactured with the face hobbing cutting method.

In the case of non--generated gears, the equations in this document may yield different
values for pinion top land thicknesses and gear tooth depth at the toe and heel than obtained
on some well known commercial software. The pinion top land thickness is reduced by
curvature added to the pinion, a natural consequence of the non--generated gear member
having no profile curvature on the teeth. For the gear member, the non--generating process
cuts a rootline tangent to the gear root cone, a rootline which does not wrap around the root
cone as in the generated case. This leaves the toe and heel ends of the tooth slots shallow
compared to the generated gear case, and the gear tooth space at the ends of the teeth
narrower. The non--generated gear is the imaginary generating gear for the pinion. So the
pinion teeth, which fit in the non--generated gear tooth slots, are thinner at the ends than
their generated gear counterparts.

The cutter edge radii calculated in this document are based on the geometrical conditions
present and include a manufacturing gauging flat. Individual blade manufacturers have
standard blade edge radii and manufacturing tolerances for their products which should be
considered when sourcing non--standard radii. It is recommended to work closely with the
blade supplier to ensure design specifications and sourced product specifications are
consistent.

The first draft of AGMA 929--A06 was made in February, 1999. It was approved by the
AGMA Technical Division Executive Committee in August, 2006.

Suggestions for improvement of this document will be welcome. They should be sent to the
American Gear Manufacturers Association, 500 Montgomery Street, Suite 350, Alexandria,
Virginia 22314.

iv © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

PERSONNEL of the AGMA Bevel Gear Committee

Chairman: Robert F. Wasilewski . . . . . . . . . . . . . . . . . . . . . . Arrow Gear Company

Vice Chairman: George Lian . . . . . . . . . . . . . . . . . . . . . . . . . Amarillo Gear Company

ACTIVE MEMBERS

T. Guertin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liebherr Gear Technology Company

J. Kolonko . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rexnord Geared Products
T.J. Krenzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gleason Corporation
P.A. McNamara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar, Inc.
K. Miller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Spicer Off Highway Products
W. Tsung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Corporation

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AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

(This page is intentionally blank)

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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

American Gear Manufacturers non--generated manufacturing methods, to achieve

compatibility between publications.
Association --
It is intended to provide assistance in completing the
calculations requiring determination of top lands and
Calculation of Bevel cutter edge radii in ANSI/AGMA 2003--B97, Rating
the Pitting Resistance and Bending Strength of
Gear Top Land and Generated Straight Bevel, Zerol Bevel and Spiral
Bevel Gear Teeth.
Guidance on Cutter Annexes are provided for additional related
information and calculation examples.
Edge Radius
2 Symbols, terminology and definitions

2.1 Symbols and terminology

1 Scope
The equations in this information sheet are written in
This information sheet provides a set of equations for terms generally used for hypoids. See table 1.
the calculation of bevel gear top land and guidance For other gears, the nomenclature from ANSI/AGMA
on cutter edge radius. It integrates the equations in 2005--D03, table 9 are used (see table 3).
ANSI/AGMA 2005--D03, Design Manual for Bevel
NOTE: Some of the symbols and terminology con-
Gears, and Gleason publication SD3124B,
tained in this document may differ from those used in
Formulas for Cutter Specifications and Tooth Thick- other documents and AGMA standards. Users of this
ness Measurements for Spiral Bevel and Hypoid standard should assure themselves that they are using
Gears, with modifications to include face hobbing, the symbols, terminology and definitions in the manner
and additions for the top land calculations for indicated herein.

Table 1 -- Symbols and terms

Symbol Term Units Where first
used
AiG, AiP Inner cone distance, gear or pinion inch Eq 7, Eq 1
AmG, AmP Mean cone distance, gear or pinion inch Eq 9, Eq 1
AoG, AoP Outer cone distance, gear or pinion inch Eq 7, Eq 3
AxG Cone distance for involute lengthwise curvature point inch Eq 31
where normal circular pitch and slot width is a maximum
aG, aP Mean addendum, gear or pinion inch Eq 50, Eq 50
aiG, aiP Inner addendum, gear or pinion inch Eq 78, Eq 77
a′iG, a′iP Adjusted inner addendum, gear or pinion inch Eq 82, Eq 81
aoG, aoP Outer addendum, gear or pinion inch Eq 163, Eq 162
B Outer normal backlash allowance inch Eq 6
bG, bP Mean dedendum, gear or pinion inch Eq 19, Eq 22
biG, biP Inner dedendum, gear or pinion inch Eq 25, Eq 24
boG, boP Outer dedendum, gear or pinion inch Eq 20, Eq 22
bxG, bxP Dedendum at cone distance AxG, gear or pinion inch Eq 44, Eq 45
b′oG Theoretical outer gear dedendum inch Eq 19
c Clearance inch Eq 77
(continued)

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AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Table 1 (continued)
Symbol Term Units Where first
used
D, d Pitch diameter, gear or pinion inch Eq 140, Eq 139
FG, FP Face width of gear or pinion inch Eq 25, Eq 2
FiP Hypoid pinion face width from calculation point to inside inch Eq 1
FoP Hypoid pinion face width from calculation point to outside inch Eq 3
FxG Distance from mean cone to cone distance at involute inch Eq 38
curvature
kE Gear rotation factor -- -- Eq 52
N, n Number of teeth, gear or pinion -- -- Eq 79, Eq 79
pm Mean circular pitch inch Eq 27
pn Mean normal circular pitch inch Eq 27
Q Intermediate factor inch Eq 35
q Generating angle at mean degrees Eq 9
qi Generating angle at inside degrees Eq 13
qo Generating angle at outside degrees Eq 11
qx Generating angle at involute curvature degrees Eq 39
RbNG1, RbNP2 Mean normal base radius, convex, gear or pinion inch Eq 143, Eq 142
RbNG2, RbNP1 Mean normal base radius, concave, gear or pinion inch Eq 144, Eq 141
RibVG, RibVP Inner base radius -- concave, gear or pinion inch Eq 90, Eq 87
RibXG, RibXP Inner base radius -- convex, gear or pinion inch Eq 89, Eq 88
RiG, RiP Original inner pitch radius, gear or pinion inch Eq 76, Eq 75
RioG, RioP Inner outside radius, gear or pinion inch Eq 86, Eq 85
RNG, RNP Mean normal pitch radius, gear or pinion inch Eq 140, Eq 139
RoNG, RoNP Mean normal outside radius, gear or pinion inch Eq 146, Eq 145
R′bNG1, Outer normal base radius, convex, gear or pinion inch Eq 160, Eq 159
R′bNP2
R′bNG2, Outer normal base radius, concave, gear or pinion inch Eq 161, Eq 158
R′bNP1
R′iG, R′iP New inner pitch radius, gear or pinion inch Eq 84, Eq 83
R′NG, R′NP Outer normal pitch radius, gear or pinion inch Eq 157, Eq 156
R′oNG, R′oNP Outer normal outside radius, gear or pinion inch Eq 163, Eq 162
R′′bNG1, Inner normal base radius, convex, gear or pinion inch Eq 179, Eq 178
R′′bNP2
R′′bNG2, Inner normal base radius, concave, gear or pinion inch Eq 180, Eq 177
R′′bNP1
R′′NG, R′′NP Inner mean normal pitch radius, gear or pinion inch Eq 176, Eq 175
R′′oNG, R′′oNP Inner normal outside radius, gear or pinion inch Eq 182, Eq 181
rc Cutter radius inch Eq 9
rTG, rTP Maximum blade edge radius, gear or pinion inch Eq 74, Eq 73
r1G, r1P Maximum blade edge radius for no running interference, inch Eq 74, Eq 73
gear or pinion
r1VG, r1VP Maximum blade edge radius for no running interference inch Eq 106, Eq 103
concave, gear or pinion
r1XG, r1XP Maximum blade edge radius for no running interference inch Eq 105, Eq 104
convex, gear or pinion
r2G, r2P Maximum blade edge radius that can be manufactured, inch Eq 74, Eq 73
gear or pinion
r2RG, r2RP Roughing cutter edge radius, gear or pinion inch Eq 113, Eq 114
(continued)

2 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Table 1 (continued)
Symbol Term Units Where first
used
r3G, r3P Maximum blade edge radius to avoid mutilation, gear or inch Eq 74, Eq 73
pinion
r3VG, r3VP Maximum blade edge radius to avoid mutilation concave, inch Eq 136, Eq 133
gear or pinion
r3XG, r3XP Maximum blade edge radius to avoid mutilation convex, inch Eq 135, Eq 134
gear or pinion
r′2RG, r′2RP Maximum roughing blade edge radius which can be inch Eq 111, Eq 112
manufactured, gear or pinion
r′2VG, r′2VP Maximum finishing blade edge radius concave, defined by inch Eq 118, Eq 115
maximum roughing blade edge radius and minimum stock
allowance, gear or pinion
r′2XG, r′2XP Maximum finishing blade edge radius convex, defined by inch Eq 117, Eq 116
maximum roughing blade edge radius and minimum stock
allowance, gear or pinion
r′′2VG, r′′2VP Maximum finishing blade edge radius concave, gear or inch Eq 122, Eq 119
pinion
r′′2XG, r′′2XP Maximum finishing blade edge radius convex, gear or inch Eq 121, Eq 120
pinion
SAG, SAP Stock allowance, gear or pinion inch Eq 65, Eq 66
S1 Crown gear to cutter center distance inch Eq 34
Tmn, tmn Mean normal circular thickness at pitch line, gear or inch Eq 47, Eq 48
pinion
Tn Gear mean normal circular thickness without backlash inch Eq 47
tiNG, tiNP Inner normal circular thickness at pitch line, gear or pinion inch Eq 189, Eq 188
tLiNG, tLiNP Inner normal top land, gear or pinion inch Eq 192, Eq 190
tLNG, tLNP Mean normal top land, gear or pinion inch Eq 154, Eq 152
tLoNG, tLoNP Outer normal top land, gear or pinion inch Eq 173, Eq 171
tmP Mean pinion transverse circular thickness inch Eq 49
toNG, toNP Outer normal circular thickness at pitch line, gear or inch Eq 170, Eq 169
pinion
W Finishing point width gear (Unitool and single sided) inch Table 2
WBG, WBP Finishing blade point, gear or pinion inch Eq 69, Eq 70
WBRG, WBRP Roughing blade point, gear or pinion inch Eq 67, Eq 68
W′e Effective gear point width inch Eq 52
WiG, WiP Inner slot width, gear or pinion inch Eq 59, Eq 60
WLG, WLP Minimum slot width, gear or pinion inch Eq 61, Eq 62
WMG, WMP Maximum slot width, gear or pinion inch Eq 63, Eq 64
WmG, WmP Mean slot width, gear or pinion inch Eq 50, Eq 51
WoG, WoP Outer slot width, gear or pinion inch Eq 55, Eq 56
WRG, WRP Roughing point width, gear or pinion inch Eq 65, Eq 66
WxG, WxP Slot width at AxG (maximum gear or pinion slot) inch Eq 57, Eq 58
xiVG, xiVP Limit tooth height for interference concave, gear or pinion inch Eq 102, Eq 97
xiXG, xiXP Limit tooth height for interference convex, gear or pinion inch Eq 101, Eq 99
y Amount of fillet mutilation permitted inch Eq 129
Γ, γ Pitch angle, gear or pinion degrees Eq 76, Eq 75
ΓR Gear root angle degrees Eq 17
ΔaG, ΔaP Change in inner addendum, gear or pinion inch Eq 80, Eq 79
(continued)

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AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Table 1 (continued)

Symbol Term Units Where first

used
ΔbiG Depth reduction on non--generated gear at inside inch Eq 18
ΔboG Depth reduction on non--generated gear at outside inch Eq 17
ΔbxG Depth reduction on non--generated gear at involute inch Eq 42
curvature
ΔcG, ΔcP Change in clearance, gear or pinion inch Eq 7, Eq 6
Δf Width of blade flat inch Eq 111
Δqi Increment in generating angle at inside degrees Eq 16
Δqo Increment in generating angle at outside degrees Eq 15
Δqx Increment in generating angle at involute curvature degrees Eq 41
ΔW′G, ΔW′P Difference between minimum slot width and blade point, inch Eq 128, Eq 127
gear or pinion
Δφ2 Normal tilt of finishing cutter non--generated degrees Eq 8
δG, δP Dedendum angle of gear or pinion degrees Eq 19, Eq 22
ηi Generating angle at inside degrees Eq 14
ηo Generating angle at outside degrees Eq 12
ηx Generating angle at involute curvature, for face hobbing degrees Eq 34
η1 Second auxiliary angle degrees Eq 10
ρiVG, ρiVP Inner profile radius of curvature concave, gear or pinion inch Eq 96, Eq 93
ρiXG, ρiXP Inner profile radius of curvature convex, gear or pinion inch Eq 95, Eq 94
ξ Angle between gear root plane and plane in which taper is degrees Eq 53
specified
Σb Sum of pinion and gear mean dedendums inch Eq 28
Σbi Sum of pinion and gear inner dedendums inch Eq 30
Σbo Sum of pinion and gear outer dedendums inch Eq 29
Σbx Sum of pinion and gear dedendums at cone distance AxG inch Eq 46
Σφ Included pressure angle degrees Eq 5
φBXG Inside blade angle gear cutter (non--generating) degrees Eq 8
φiV Inner pinion pressure angle -- concave degrees Eq 91
φiX Inner pinion pressure angle -- convex degrees Eq 92
φ1 Normal pressure angle, concave, pinion degrees Eq 5
φ2 Normal pressure angle, convex, pinion degrees Eq 5
φ1TG, φ2TP Pressure angle at tip of tooth, convex gear or pinion degrees Eq 150, Eq 149
φ2TG, φ1TP Pressure angle at tip of tooth, concave gear or pinion degrees Eq 151, Eq 148
φ′1TG, φ′2TP Pressure angle at tip of tooth, outer convex gear or pinion degrees Eq 167, Eq 166
φ′2TG, φ′1TP Pressure angle at tip of tooth, outer concave gear or degrees Eq 168, Eq 165
pinion
φ′′1TG, φ′′2TP Pressure angle at tip of tooth, inner convex gear or pinion degrees Eq 186, Eq 185
φ′′2TG, φ′′1TP Pressure angle at tip of tooth, inner concave gear or degrees Eq 187, Eq 184
pinion
ψG, ψP Mean spiral angle, gear or pinion degrees Eq 9, Eq 139
ψiG, ψiP Inner spiral angle, gear or pinion degrees Eq 7, Eq 6
ψoG, ψoP Outer spiral angle, gear or pinion degrees Eq 7, Eq 6
ψxG Spiral angle at cone distance AxG degrees Eq 32
ΩVG, ΩVP Intermediate blade mutilation value concave, gear or inch2 Eq 132, Eq 129
pinion
ΩXG, ΩXP Intermediate blade mutilation value convex, gear or pinion inch2 Eq 131, Eq 130

4 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

2.2 Definitions 2.2.2 Bevel gear cutting method terminology

This clause provides supplemental definitions for completing. A machining process where the tooth
bevel gear cutter and cutting method terminologies space is completed in one machining setup. Unlike
referred to in this information sheet. The list of single side, single setting, or fixed setting methods
definitions given here is not intended to be all where the tooth space roughing and finishing are
inclusive. For more detailed information regarding a carried out in separate machining setups.
particular cutter design or cutting method, the user is cutter tilt. A change in the relative position between
encouraged to consult the cutter manufacturer’s workpiece and cutter, measured as an angle in the
data or machine tool manufacturer. normal, or axial, or both planes of the workpiece.
2.2.1 Bevel gear cutter terminology Formate. A term describing non--generated gear
alternate blade. Any multiple blade face cutter members whose teeth have surfaces of revolution,
having successive blades that cut on opposite sides and straight profiles in their normal sections. Pinions
of a tooth space. generated to run with such gears are called Formate
pinions.
blade flat. A flat land on the end of blades required
for blade manufacturing control. non--generated method. A gear cutting process
where the tooth space is machined without generat-
blade point. The length across the end surface of a ing motion (see Formate). The tooth surfaces are
blade or tool (measured along a radius of a circular formed by the sweep of a straight--sided cutting tool
cutter), bounded by the extension of the cutting edge and thus have straight profiles in any normal section.
and non--cutting edge of the blade.
single setting. A finishing method which is a
blade, inside. A blade of a circular face cutter with a variation of the spread blade method. It is used on
cutting edge that produces the convex side of a tooth wide face width gears to avoid having two cutter
surface. blades cutting in the same slot at the same time.
blade, outside. A blade of a circular face cutter with single side. A cutting method which uses an
a cutting edge that produces the concave tooth alternate blade cutter to separately cut the profiles
surface. on each side of a tooth space, with independent
machine settings.
coast side. The side of a tooth flank that is in contact
with the opposite flank of the mate when the gear set spread blade. A cutting method which uses a
is driven in the reverse direction. circular face cutter with alternate inside and outside
blades to cut both sides of a tooth space at the same
drive side. The side of a tooth flank that is in contact
time.
with the opposite flank of the mate when the gear set
is driven in the forward direction. Unitool. A method for producing pairs of spiral
bevel, zerol bevel or hypoid gears using the same
effective gear point width. Effective point width is
single face mill cutter for both members. The cutters
one half of the difference of the outside minus the
used with this method are designated as Unitool
inside point diameters of a cutter. The effective point
cutters.
width is not equal to the slot width produced on the
part when indexing motion occurs between drive and Versacut. A process which requires very few cutters
coast side generation. For spread blade cutters, the to accommodate a wide variety of spiral bevel gears.
effective point width equals the actual cutter point The cutters used with this method are designated as
width. When indexing accounts for part of the slot Versacut cutters.
width, the effective point width can be negative.
fillet mutilation. Fouling of tooth fillet by the 3 Input data
non--cutting side of the blade tip. This is caused by a
tool edge radius or a blade point which is too large.
The equations in this information sheet are intended
point width. One half of the difference between the to be as general as possible. Many of the
inside and outside point diameters of an alternate calculations require knowledge of the specific cut-
blade cutter. ting method used in manufacture. Supplemental

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AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

definitions to be used with the terms described in Γ Gear pitch angle

ANSI/AGMA 2005--D03 for proper input data selec- ΓR Gear root angle
tion based on the manufacturing method used can γ Pinion pitch angle
be found in 2.2. Δf Width of blade flat
δG Dedendum angle of gear
The tables in this clause describe the data necessary
δP Dedendum angle of pinion
to complete the calculations of this information
φBXG Inside blade angle, gear cutter
sheet. In most cases the values can be obtained
(non--generating)
from the calculations detailed in ANSI/AGMA
φ1 Concave pinion normal pressure
2005--D03. Many of those calculations are dupli-
angle
cated in annex A. Additional tables are provided
φ2 Convex pinion normal pressure
here to supplement those calculations. angle (always negative)
ψG Gear mean spiral angle
3.1 Input variables
ψP Pinion mean spiral angle
Table 2 contains all the input variables necessary for ψiG Inner gear spiral angle
the calculations used in this information sheet. ψiP Inner pinion spiral angle
ψoG Outer gear spiral angle
ψoP Outer pinion spiral angle
Additional input variables for face hobbing
Table 2 -- Input variables
Q Intermediate factor
Symbol Term S1 Crown gear to cutter center
distance
AiG Inner gear cone distance
ηi Generating angle at inside
AmG Gear mean cone distance
ηo Generating angle at outside
AmP Pinion mean cone distance
AoG Gear outer cone distance η1 Second auxiliary angle
aG Gear mean addendum Additional input variables for hypoids
aP Pinion mean addendum FiP Hypoid pinion face width from
calculation point to inside
aoG Outer gear addendum
FoP Hypoid pinion face width from
aoP Outer pinion addendum calculation point to outside
B Outer normal backlash allowance
bG Gear mean dedendum
3.2 Variable substitutions
bP Pinion mean dedendum
c Clearance The calculations in this information sheet are written
D Gear pitch diameter in terms of hypoid gears. Many of the variables for
d Pinion pitch diameter non--hypoid bevels are subscripted the same for
FG Gear face width pinion and gear. Table 3 provides a means for proper
FP Pinion face width substitution of these variables into the calculations
N Gear number of teeth for hypoids.
n Pinion number of teeth
pm Mean circular pitch 3.3 Gear rotation factor
rc Cutter radius
Table 4 provides for the proper selection of the input
SAG Stock allowance, gear
variable kE based on the cutting method to be used in
SAP Stock allowance, pinion
manufacture.
Tn Gear mean normal circular
thickness without backlash
3.4 Additional input data
W Gear finishing point width (Unitool
and single setting) Table 5 contains some suggested default values for
y Amount of fillet mutilation permitted variables not described in ANSI/AGMA 2005--D03.
Symbol Term Other values may be used if experience dictates.

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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Table 3 -- Symbols and terms from ANSI/AGMA 2005--D03, table 9

Equivalent symbol
from ANSI/AGMA
Symbol 2005--D03 Term
AmG Am Gear mean cone distance
AmP Am Pinion mean cone distance
AoG Ao Gear outer cone distance
AoP Ao Pinion outer cone distance
FG F Gear face width
FP F Pinion face width
φ1 φ Pressure angle -- drive side
φ2 φ Pressure angle -- coast side, set φ2 to --φ1
ψG ψ Gear mean spiral angle
ψoG ψo Outer gear spiral angle
ψP ψ Pinion mean spiral angle

Table 4 -- Gear rotation factor, kE

Generating method Face hobbing Face milling kE

Spread blade X 0.0
Gleason and Klingelnberg X 1.0
Oerlikon not using a roughing blade X 1.0
Oerlikon using a roughing blade X 1.3
Straight bevels and planing generator 2 W mG
pn
Unitool and single setting X 2 W mG − W 
pn
Versacut and standard single side X 2W mG + b Gtan φ 1 − tan φ 2
pn

Table 5 -- Suggested defaults for input data

Symbol Term Units Suggested default

Inside blade angle of gear cutter (non--gener-
φBXG degrees Average pressure angle
ated gear only)
For completing, use 0.000
SAP Stock allowance, pinion inch For rough and finish, use
actual or see annex B
For completing, use 0.000
SAG Stock allowance, gear inch For rough and finish, use
actual or see annex B
y Amount of fillet mutilation permitted inch 0.002
Δf Width of blade flat inch 0.008
Cutter radius (straight bevels) 10000
rc inch
Cutter radius (all other bevels) See ANSI/AGMA 2005--D03

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AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

4 Calculations Face hobbing

qo = ηo (12)
4.1 General geometry Generating angle at inside

Inner pinion cone distance Face milling

Hypoids q i = arctan  r c cos ψ iG

A iG − r c sin ψ iG
 (13)
A iP = A mP − F iP (1)
Face hobbing
For all other bevels qi = ηi (14)
A iP = A mP − 0.5 F P (2) Increment in generating angle
Outer pinion cone distance Outside
Hypoids Δq o = q − q o (15)
A oP = A mP + F oP (3) Inside

For all other bevels Δq i = q i − q (16)

A oP = A mP + 0.5 F P Generated gears have slightly deeper teeth at the

(4)
toe and heel ends than non--generated gears
Included pressure angle caused by the relative rolling action between cutter
Σφ = φ 1 − φ 2 and work piece. For non--generated gear depth
(5)
reduction:
Change in clearance
Outside
Pinion 2
AoG − AmG tan Δφ 2 A oG sin 2 Δq o
B A iP cos ψ iP 1 Δb oG = +
Δc P = (6) 2 r c cos 2 ψ G 2 tan Γ R
A oP cos ψ oP sin φ 1 − sin φ 2
(17)
Gear
Inside
B A iG cos ψ iG 1
Δc G = (7) 2
A oG cos ψ oG sin φ 1 − sin φ 2 A mG − A iG tan Δφ 2 A iG sin 2 Δq i
Δb iG = +
2 r c cos2 ψ G 2 tan Γ R
If ΔcP is greater than 0.75 c, or if ΔcG is greater than
0.75 c, reduce B or increase the clearance c. (18)
Theoretical outer gear dedendum
For non--generated gears normal tilt of finishing
cutter b′ oG = b G + A oG − A mG tan δ G (19)

Δφ 2 = φ BXG − φ 1 (8) Outer gear dedendum

Generating angle at mean Non--generated gear

b oG = b′ oG − Δb oG (20)
Face milling
Generated gear
q = arctan  r c cos ψ G
A mG − r c sin ψ G
 (9) b oG = b′ oG (21)
Outer pinion dedendum
Face hobbing
Hypoid
q = η1 + ψG (10)
b oP = b P + F oP tan δ P (22)
Generating angle at outside All other bevels
Face milling b oP = b P + 0.5 F P tan δ P (23)

q o = arctan  r c cos ψ oG
A oG − r c sin ψ oG
 (11)
Inner pinion dedendum
b iP = b oP − F P tan δ P (24)

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Inner gear dedendum For the third and subsequent trials iterate.
Non--generated gear If AiG < AxG < AoG, calculate FxG, qx, Δqx, ΔbxG, bxP
and Σbx; otherwise, set these items to zero.
b iG = b′ oG − F G tan δ G − Δb iG (25)
Distance from mean cone to cone distance at
Generated gear
involute curvature
b iG = b oG − F G tan δ G (26)
F xG = A xG − A mG (38)
Mean normal circular pitch Generating angle at involute curvature

p n = p m cos ψ G (27) Face milling

Sum of pinion and gear mean dedendums q x = arctan  r c cos ψ xG

A xG − r c sin ψ xG
 (39)
Σb = b P + b G (28)
Face hobbing
Sum of pinion and gear outer dedendums
qx = ηx (40)
Σb o = b oP + b oG (29) Increment in generating angle at involute curvature
Sum of pinion and gear inner dedendums Δq x = q − q x (41)
Σb i = b iP + b iG (30) Depth reduction on gear at involute curvature

Cone distance for involute lengthwise curvature Non--generated gear

point where normal circular pitch and slot width is a F 2 tan Δφ 2 A xG sin 2 Δq x
xG
maximum for face milling Δb xG = + (42)
2 r c cos 2 ψ G 2 tan Γ R
A xG = A 2mG − 2 A mG r c sin ψ G + 2 r 2c (31) Generated gear

Spiral angle at cone distance AxG (face milling) Δb xG = 0 (43)

Gear dedendum at cone distance AxG
ψ xG = arcsin
rc
 
A xG
(32) b xG = b G + F xG tan δ G − Δb xG (44)
Pinion dedendum at cone distance AxG
For face hobbing iterate for cone distance and spiral
b xP = b P + F xG tan δ P (45)
angle at involute lengthwise curvature point,
AxG,where normal circular pitch is a maximum. Sum of pinion and gear dedendums at cone distance
AxG
Initial cone distance at involute lengthwise curvature
point Σb x = b xP + b xG (46)

A xG = A mG (33) 4.2 Slot width calculations and blade

specifications
Generating angle at involute curvature for face
hobbing 4.2.1 Slot width calculations, mean
The following calculations for the mean normal
A 2 + S 21 − r 2c
η x = arccos xG (34) circular thickness for the gear and pinion are
2 A xG S 1 modifications to the calculations in table 9 of
Spiral angle at cone distance AxG for face hobbing ANSI/AGMA 2005--D03. Backlash has been added
and the backlash is divided evenly between the two
A xG − Q cos η x members. If the mean normal circular tooth thick-
ψ xG = arctan (35)
Q sin η x nesses are otherwise available, bypass equations
Change AxG, until 47 and 48.

 ηx − ψ  ≤ 0.0001 (36) Mean normal gear circular thickness

xG
A mG B cos ψ G
For the second trial make T mn = T n − (47)
A xG = A xG + 0.0001 inch (37)
A oG
2 cosΣφ2  cos ψ oG

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Mean normal pinion circular thickness Outer pinion slot width

A mG B cos ψ G A cos ψ oG
t mn = p n − T mn − W oP = oG p − Σb otan φ 1 − tan φ 2
A mG cos ψ G n
A oG
Σφ2  cos ψ
cos oG
B
(48) − W oG + (56)
Σφ
Mean pinion transverse circular thickness cos
2
t mn If AiG < AxG < AoG, calculate WxG and WxP, otherwise,
t mP = (49)
cos ψ G set these items to zero
Mean gear slot width Slot width at AxG, gear (maximum gear slot width)
W mG = p n − T mn − Σb tan φ 1 − tan φ 2
2 
W xG = W′ e 1 −
A xG cos ψ xG
A mG cos ψ G
A
+ xG
− a P − a G tan
Σφ
2
  (50)
A mG
A xG cos ψ xG
× t mP cos ψ xG −
Mean pinion slot width A mG cos ψ G
W mP = p n − Σb tan φ 1 − tan φ 2 A xG cos ψ xG
× b G tan φ 1 − tan φ 2 +
A mG cos ψ G A oG cos ψ oG
+ B − W mG
A oG cos ψ oG
cos 
Σφ
2
(51) × B
 
Σφ
+ A mG − A xG
cos
2
Effective gear point width
kE pn
(52) × tan φ 1 − tan φ 2 tan ξ (57)
W′ e = W mG −
2 Slot width at AxG, pinion (maximum pinion slot
4.2.2 Slot width calculation, outer width)
Angle between gear root plane and plane in which A cos ψ xG
W xP = xG p − Σb xtan φ 1 − tan φ 2
taper is specified: A mG cos ψ G n
Single side and Versacut methods A cos ψ xG B
− W xG + xG
ξ = δG (53) A oG cos ψ oG Σφ
cos (58)
2
All other cutting methods.
4.2.3 Slot width calculation, inner
ξ=0 (54)
Inner gear slot width
Outer gear slot width

W oG = W′ e  A cos ψ oG
1 − oG
A

+ oG

W iG = W′ e 1 −
A iG cos ψ iG
A mG cos ψ G
 A
+ iG
A mG
A mG cos ψ G A mG
A iG cos ψ iG
A cos ψ oG × t mP cos ψ iG − b
A mG cos ψ G G
× t mP cos ψ oG − oG
A mG cos ψ G
A iG cos ψ iG
× tan φ 1 − tan φ 2 +
B A oG cos ψ oG
× b Gtan φ 1 − tan φ 2 +
cos 
Σφ
2 × B + A mG − A iG
cos 
Σφ
2
+ A mG − A oGtan φ 1 − tan φ 2 tan ξ
(55) × tan φ 1 − tan φ 2 tan ξ (59)

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Inner pinion slot width Pinion

A iG cos ψ iG W LP
W iP = p − Σb i tan φ 1 − tan φ 2 W BP = + 0.001 (70)
A mG cos ψ G n 2
A iG cos ψ iG B Maximum for rough and finish methods
− W iG +
A oG cos ψ oG
 
cos
Σφ
2
(60) Gear
W BG = W LG − S AG (71)
4.2.4 Slot widths, minimum and maximum
Pinion
Minimum gear slot width
W BP = W LP − S AP (72)
W LG = minimum of W oG, W mG, or W iG
(61)
4.2.6 Standard blade point
Minimum pinion slot width
Bevel gear blades are either sharpened on the rake
W LP = minimum of W oP, W mP, or W iP
(62) face or on the blade profile. For face sharpened
blades, the blade point and edge radius are formed
Maximum gear slot width by the blade manufacturer. For each distinct blade
W MG = maximum of W oG, W xG, W iG, or W mG point, a separate cutter blade would be required. A
(63) common practice is to consolidate similar sized
blade points into standard ones. A table of standard
Maximum pinion slot width blade points is included in annex B for reference.
W MP = maximum of W oP, W xP, W iP, or W mP When standard blade point is used, choose one that
satisfies the blade point equations given in 4.2.5.
(64)
Note that there may be more than one standard
4.2.5 Point width and blade point calculations blade point that would satisfy the blade point
equations. For profile sharpened blades, the
Roughing cutter calculations for processes with
required blade point and edge radii are formed at
separate rough and finish operations and cutters:
sharpening. Standardization of blade point is
Roughing point width generally not an issue.

Gear The choice of blade point may affect maximum edge

W RG = W LG − S AG (65) radius that can be manufactured, see 4.3.2, and
maximum edge radius for avoiding mutilation, see
Pinion 4.3.3. In general, a larger blade point allows a larger
W RP = W LP − S AP (66) edge radius to be manufactured. However, the
larger blade point may reduce the maximum edge
Minimum roughing blade point radius for avoiding mutilation. It might be possible to
Gear select a blade point, standard or otherwise, in an
attempt to balance the maximum edge radius that
W RG can be manufactured and the maximum edge radius
W BRG = + 0.001 (67)
2 for avoiding mutilation.
Pinion
Cutters for the Unitool method use standard blades
W RP
W BRP = + 0.001 (68) exclusively. For each available cutter diameter, the
2
corresponding cutter blades have standard blade
Finishing blade point point and edge radius. When a cutter diameter is
Minimum for completing manufacturing methods chosen, the blade point and tool edge radii are also
defined.
Gear
W LG Consult the manufacturer for available cutter
W BG = + 0.001 (69)
2 information.

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4.3 Cutter edge radius calculation Inner pinion outside radius

The cutter edge radius for a bevel gear should not R ioP = R iP + a iP (85)
exceed the radius that would cause any of the Inner gear outside radius
following conditions: R ioG = R iG + a iG (86)
-- running interference, see 4.3.1; Inner pinion base radius
-- unable to manufacture radius on blade, see Concave
4.3.2; R ibVP = R iP cos φ 1 (87)
-- fillet mutilation, see 4.3.3. Convex
Maximum pinion blade edge radius R ibXP = R iP cos φ 2 (88)

r TP = minimum of r 1P, r 2P, or r 3P (73) Inner gear base radius

Maximum gear blade edge radius Convex

R ibXG = R iG cos φ 1 (89)
r TG = minimum of r 1G, r 2G, or r 3G (74)
Concave
4.3.1 Cutter edge radius for no running
R ibVG = R iG cos φ 2 (90)
interference
Inner pinion pressure angle
Virtual gear calculations
Concave
Original inner pinion pitch radius

R iP =
A iP tan γ
(75)
φ iV = arccos  
R ibVP
R′ iP
(91)
cos2 ψ iP
Convex
Original inner gear pitch radius

R iG =
A iG tan Γ φ iX = arccos  
R ibXP
R′ iP
(92)
cos 2 ψ iG (76)
Inner pinion profile radius of curvature
Pinion inner addendum
Concave
a iP = b iG − c (77)
à iVP = R′ iP sin φ iV − R2ioG − R2ibXG + R′iG sin φiV
Gear inner addendum
(93)
a iG = b iP − c (78) Convex
Change in inner pinion addendum
à iXP = R′ iP sin φ iX − R2ioG − R2ibVG + R′iG sin φiX
Δa P = Δc G n cos Γ (79) (94)
n cos Γ + N cos γ
Change in inner gear addendum Inner gear profile radius of curvature

N cos γ Convex
Δa G = Δc P (80)
n cos Γ + N cos γ Ã iXG = R′ iG sin φ iV − R2ioP − R2ibVP + R′iP sin φiV
Adjusted inner pinion addendum
(95)
a′ iP = a iP + Δa P (81)
Concave
Adjusted inner gear addendum
à iVG = R′ iG sin φ iX − R2ioP − R2ibXP + R′iP sin φiX
a′ iG = a iG + Δa G (82)
(96)
New inner pinion pitch radius Limit tooth height for interference, pinion, concave
R′ iP = R iP − Δa P (83) Generated gear
New inner gear pitch radius x iVP = R ibVP cos φ 1 + Ã iVP sin φ 1 − R iP + b iP
R′ iG = R iG − Δa G (84) (97)

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Non--generated gear otherwise,

x iVP = c − Δc P (98) r 1G = r 1XG (110)
Limit tooth height for interference, pinion, convex 4.3.2 Cutter edge radius which can be
manufactured
Generated gear
4.3.2.1 Roughing
x iXP = R ibXP cos φ 2 − Ã iXP sin φ 2 − R iP + b iP
(99) Maximum gear roughing blade edge radius which
can be manufactured
Non--generated gear
W BRG − Δf
x iXP = c − Δc P (100) r′ 2RG = (111)
sec φ 1 − tan φ 1
Limit tooth height for interference, gear
Maximum pinion roughing blade edge radius which
Convex can be manufactured
x iXG = R ibXG cos φ 1 + Ã iXG sin φ 1 − R iG + b iG W BRP − Δf
r′ 2RP = (112)
(101) sec φ 1 − tan φ 1
Concave
Gear roughing cutter edge radius
x iVG = R ibVG cos φ 2 − Ã iVG sin φ 2 − R iG + b iG r 2RG = maximum of r′ 2RG or 0.010 inches
(102) (113)
Maximum blade edge radius for no running Pinion roughing cutter edge radius
interference on pinion tooth
r 2RP = maximum of r′ 2RP or 0.010 inches
Concave (114)
x iVP 4.3.2.2 Finishing
r 1VP = (103)
1 − sin φ 1 The following four r′ finishing cutter calculations are
Convex each defined by the roughing blade edge radius and
x iXP stock allowance for cutting processes that use
r 1XP = (104) separate rough and finish operations and cutters:
1 + sin φ 2
Maximum blade edge radius for no running Maximum pinion finishing blade edge radius defined
interference on gear tooth by maximum roughing blade radius and minimum
stock allowance
Convex
x iXG Concave
r 1XG = (105) S AP
1 − sin φ 1
r′ 2VP = + r 2RP (115)
Concave 2 sec φ 1 − tan φ 1
x iVG Convex
r 1VG = (106)
1 + sin φ 2 S AP
r′ 2XP = + r 2RP (116)
Maximum blade edge radius for no running 2 sec φ 2 + tan φ 2
interference on pinion tooth
Maximum gear finishing blade edge radius defined
if, r1VP < r1XP by maximum roughing blade radius and minimum
r 1P = r 1VP (107) stock allowance

otherwise, Convex
r 1P = r 1XP (108) S AG
r′ 2XG = + r 2RG (117)
Maximum blade edge radius for no running 2 sec φ 1 − tan φ 1
interference on gear tooth Concave
if, r1VG < r1XG S AG
r′ 2VG = + r 2RG (118)
r 1G = r 1VG (109) 2 sec φ 2 + tan φ 2

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The following four r′′ calculations are as defined by If any of the following Ω values are negative, reduce
the finishing cutter: WBP or WBG accordingly:

The values of r′′ are never negative; if necessary Pinion intermediate blade mutilation value
reduce Δf:
Concave
Maximum pinion finishing blade edge radius
Ω VP = y 2 + 2y ΔW′ P sec φ 1 − tan φ 1 (129)
Concave
Convex
W BP − Δf
r″ 2VP =
sec φ 1 − tan φ 1
(119) Ω XP = y 2 + 2y ΔW′ P sec φ 2 + tan φ 2 (130)

Convex Gear intermediate blade mutilation value

W BP − Δf Convex
r″ 2XP = (120)
sec φ 2 + tan φ 2
Ω XG = y 2 + 2yΔW′ G sec φ 1 − tan φ 1 (131)
Maximum gear finishing blade edge radius
Concave
Convex
Ω VG = y 2 + 2 yΔW′ Gsec φ 2 + tan φ 2 (132)
W BG − Δf
r″ 2XG = (121) Maximum pinion blade edge radius to avoid
sec φ 1 − tan φ 1
mutilation
Concave
Concave
W BG − Δf
r″ 2VG = (122)
sec φ 2 + tan φ 2 y + ΔW′ Psec φ 2 + tan φ 2 + Ω XP
r 3VP = 2
Maximum pinion blade edge radius which can be sec φ 2 + tan φ 2
manufactured (133)
Rough and finish Convex
r 2P = minimum of r′ 2VP, r′ 2XP, r′′ 2VP, or r′′ XP
y + ΔW′ Psec φ 1 − tan φ 1 + Ω VP
(123) r 3XP = 2
sec φ 1 − tan φ 1
Completing (134)
r 2P = minimum of r′′ 2VP, or r′′ 2XP (124) Maximum gear blade edge radius to avoid mutilation
Maximum gear blade edge radius which can be Convex
manufactured
y + ΔW′ Gsec φ 2 + tan φ 2 + Ω VG
Rough and finish r 3XG = 2
r 2G = minimum of r′ 2VG, r′ 2XG, r′′ 2VG, or r′′ XG
sec φ 2 + tan φ 2
(135)
(125) Concave
Completing
y + ΔW′ Gsec φ 1 − tan φ 1 + Ω XG
r 2G = minimum of r′′ 2VG, or r′′ 2XG (126) r 3VG = 2
sec φ 1 − tan φ 1
4.3.3 Cutter edge radius to avoid mutilation (136)

Difference between pinion minimum slot width and Therefore, maximum pinion blade edge radius to
finishing blade point avoid mutilation

ΔW′ P = W LP − W BP (127) r 3P = minimum of r 3VP, or r 3XP (137)

Difference between gear minimum slot width and Therefore, maximum gear blade edge radius to
finishing blade point avoid mutilation
ΔW′ G = W LG − W BG (128) r 3G = minimum of r 3VG, or r 3XG (138)

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4.4 Top land formulas Concave

4.4.1 Mean top lands φ 2TG = arccos  R bNG2

R oNG
 (151)
Mean normal pinion pitch radius
Mean normal pinion top land
0.5 d A mP
R NP = Generated
cos γ cos ψ P A oP
2 (139)

Mean normal gear pitch radius t LNP = Rt mn

NP
+ invφ 1 − invφ 1TP + inv− φ 2

R NG = 0.5 D A mG
cos Γ cos ψ G A oG
2 (140)
− invφ 2TP R oNP  (152)
NOTE: “inv” is the mathematical function involute. It is
Mean normal pinion base radius the tangent of the angle minus the angle in radians.
Concave Non--generated
R bNP1 = R NP cos φ 1
Convex
(141)
t LNP = Rt mn
NP
+ invφ 1 − invφ 1TP + inv− φ 2

R bNP2 = R NP cos φ 2 (142) 

− invφ 2TP R oNP − T mn + a P tan φ 1

Mean normal gear base radius

− tan φ 2  − RT mn
NG
+ invφ 1 − invφ 1TG
Convex
R bNG1 = R NG cos φ 1 (143) + inv −φ 2 − invφ 2TG R oNG   (153)
Concave Mean normal gear top land
R bNG2 = R NG cos φ 2 (144) Non--generated
t LNG = T mn − a Gtan φ 1 − tan φ 2 (154)
Mean normal pinion outside radius
Generated
R oNP = R NP + a P (145)
Mean normal gear outside radius t LNG = T mn
R NG
+ invφ 1 − invφ 1TG + inv−φ 2
Generated
R oNG = R NG + a G (146) − inv φ 2TG R oNG (155)

Non--generated 4.4.2 Outer top lands

R oNG = R NG − a P (147) Outer normal pinion pitch radius

Pressure angle at tip of pinion tooth (mean) R′ NP = 0.5 d (156)

cos γ cos 2 ψ oP
Concave
Outer normal gear pitch radius
R

φ 1TP = arccos bNP1
R oNP
 (148) R′ NG = 0.5 D
cos Γ cos2 ψ oG
(157)

Convex Outer normal pinion base radius

Concave
φ 2TP = arccos RR bNP2
oNP
(149) R′ bNP1 = R′ NP cos φ 1 (158)
Convex
Pressure angle at tip of gear tooth (mean)
R′ bNP2 = R′ NP cos φ 2 (159)
Convex Outer normal gear base radius

φ 1TG = arccos  R bNG1

R oNG
 (150)
Convex
R′ bNG1 = R′ NG cos φ 1 (160)

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Concave Non--generated
R′ bNG2 = R′ NG cos φ 2 (161)
Outer normal pinion outside radius
t LoNP =  t oNP
R′ NP
+ invφ 1 − invφ′ 1TP + inv−φ 2

R′ oNP = R′ NP + a oP (162) − invφ′ 2TP  R′ oNP

Outer normal gear outside radius
Generated − t 
oNG + a oP tan φ 1 − tan φ 2

R′ oNG = R′ NG + a oG (163)
Non--generated
−  t oNG
R′ NG
+ invφ 1 − invφ′ 1TG + inv−φ 2

R′ oNG = R′ NG − a oP (164)
Pressure angle at tip of pinion tooth (outer)
− invφ′ 2TG  R′ oNG (172)

Concave Outer normal gear top land

R′ bNP1 Generated
φ′ 1TP = arccos (165)
R′ oNP
Convex t LoNG =  t oNG
R′ NG
+ invφ 1 − invφ′ 1TG + inv−φ 2

R′ bNP2
φ′ 2TP = arccos
R′ oNP
(166)
− invφ′ 2TG  R′ oNG
(173)
Pressure angle at tip of gear tooth (outer) Non--generated
Convex t LoNG = t oNG − a oGtan φ 1 − tan φ 2 (174)
R′
φ′ 1TG = arccos bNG1 (167)
R′ oNG
4.4.3 Inner top lands
Concave
Inner mean normal pinion pitch radius
R′
φ′ 2TG = arccos bNG2 (168) 0.5 d A iP
R′ oNG R″ NP =
cos γ cos ψ iP A oP
2 (175)
Outer normal pinion circular thickness at pitch line
Inner mean normal gear pitch radius
t oNP = b oG tan φ 1 − tan φ 2 + W oG A iG
R″ NG = 0.5 D
− B cos Γ cos 2 ψ iG A oG (176)
cos
Σφ
2
  (169)
Inner normal pinion base radius

Outer normal gear circular thickness at pitch line Concave

R″ bNP1 = R″ NP cos φ 1 (177)
t oNG = b oP tan φ 1 − tan φ 2 + W oP
Convex
− B
R″ bNP2 = R″ NP cos φ 2 (178)
cos
Σφ
2
  (170)
Inner normal gear base radius
Outer normal pinion top land Convex
Generated R″ bNG1 = R″ NG cos φ 1 (179)
Concave
t LoNP =  t oNP
R′ NP
+ invφ 1 − invφ′ 1TP + inv−φ 2 R″ bNG2 = R″ NG cos φ 2 (180)
Inner normal pinion outside radius
− invφ′ 2TP  R′ oNP (171)
R″ oNP = R″ NP + a iP (181)

16 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Inner normal gear outside radius Inner normal gear thickness at pitch line
A iG
Generated t iNG = b iPtan φ 1 − tan φ 2 + W iP −
A oG
R″ oNG = R″ NG + a iG (182) cos ψ iG B
×
Non--generated
cos ψ oG
cos  
Σφ
2
(189)

R″ oNG = R″ NG − a iP (183) Inner normal pinion top land

Pressure angle at tip of pinion tooth (inner) Generated

Concave
t LiNP = t iNP
R″ NP
+ invφ 1 − invφ″ 1TP + inv−φ 2

φ″ 1TP = arccos R″ bNP1

R″ oNP
 (184) − invφ″ 2TP  R″ oNP (190)

Convex Non--generated

φ″ 2TP = arccos R″ bNP2

R″ oNP
 (185) t LiNP = t iNP
R″ NP
+ invφ 1 − invφ″ 1TP + inv−φ 2

Pressure angle at tip of gear tooth (inner) − invφ″ 2TP  R″ oNP

Convex − t 
iNG + a iP tan φ 1 − tan φ 2


φ″ 1TG = arccos  R″ bNG1

R″ oNG
 (186) −  t iNG
R″ NG
+ invφ 1 − invφ″ 1TG + inv−φ 2

Concave − invφ″ 2TG  R″  oNG (191)

φ″ 2TG = arccos  R″ bNG2

R″ oNG
 (187)
Inner normal gear top land
Generated

Inner normal pinion thickness at pitch line

t LiNG =  t iNG
R″ NG
+ invφ 1 − invφ″ 1TG + inv−φ 2
A iP
t iNP = b iGtan φ 1 − tan φ 2 + W iG −
A oP − invφ″ 2TG  R″ oNG (192)
cos ψ iP B
× Non--generated
cos ψ oP
cos  
Σφ
2
(188)
t LiNG = t iNG − a iG tan φ 1 − tan φ 2 (193)

© AGMA 2006 ---- All rights reserved 17

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Annex A
(informative)
Additional equations from ANSI/AGMA 2005--D03
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 929--A06,
Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius.]

A.1 Purpose
This annex is to provide the user additional equa- 2005--D03. The additional symbols used in the
tions that are in or derived from those in ANSI/AGMA equations are defined in table A.1. Also see table 1.

Table A.1 -- Symbols

Symbol Term Units First used
E Hypoid offset in (mm) Eq. A.12
NS Number of blade groups -- -- Eq. A.3
Nc Number of crown gear teeth -- -- Eq. A.3
RoG Outside gear pitch radius in (mm) Eq. A.17
Z Gear pitch apex beyond crossing point in (mm) Eq. A.12
γi Pinion inside pitch angle deg (rad) Eq. A.14
γoo Outer pinion pitch angle deg (rad) Eq. A.20
γR Pinion root angle deg (rad) Eq. A.23
ΔΣ Shaft angle departure from 90° deg (rad) Eq. A.12
εi Pinion offset angle in axial plane at inside deg (rad) Eq. A.13
εi’ Pinion offset angle in pitch plane at inner end deg (rad) Eq. A.15
εo Pinion offset angle in face plane deg (rad) Eq. A.19
εo’ Pinion offset angle in pitch plane at outer end deg (rad) Eq. A.21
η1 Second auxiliary angle deg (rad) Eq. A.8
ζi Intermediate angle deg (rad) Eq. A.12
ζo Intermediate angle deg (rad) Eq. A.18

A.2 Common equations inner gear spiral angle (face hobbing)

inner gear cone distance
A iG = A mG − 0.5 F G (A.1) ψ iG = arctan  A iG − Q cos η i
Q sin η i
 (A.5)

inner gear spiral angle (face milling)

generating angle at outside (face hobbing)

ψ iG = arcsin  2A mG r c sin ψ G − A 2
2A iG r c
mG
+ A2
iG
 η o = arccos  A 2 + S 21 − r 2c
oG
 (A.6)
2 A oG S 1
(A.2)
intermediate variable (face hobbing) outer gear spiral angle (face hobbing)
S1
Q=
N
1+ S
Nc
(A.3) ψ oG = arctan  A oG − Q cos η o
Q sin η o
 (A.7)

generating angle at inside (face hobbing)

second auxiliary angle (face hobbing)

η i = arccos A 2 + S 21 − r 2c
iG
2A iG S 1
 (A.4)
cos η 1 =
A mG cos ψ G
S1 Nc
N c + N S (A.8)

18 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

A.3 Spiral bevels inner pinion spiral angle

inner pinion spiral angle equals inner gear spiral ψ iP = ψ iG + ε′ i (A.16)
angle
outside gear pitch radius
ψ iP = ψ iG (A.9)
R oG = A oG sin Γ (A.17)
outer pinion spiral angle equals outer gear spiral
angle intermediate angle
ψ oP = ψ oG (A.10)
A.4 Hypoids

ζ o = arctan E tan ΔΣ cos Γ
A oG − Z cos Γ
 (A.18)

inside gear pitch radius

pinion outer offset angle in axial plane
R iG = A iG sin Γ (A.11)

intermediate angle ε o + ζ o = arcsin 

A oG − Z cos Γ

E cos ζ o sin Γ
(A.19)


ζ i = arctan E tan ΔΣ cos Γ
A iG − Z cos Γ
 (A.12) outer pinion pitch angle
γ oo = arcsinsin ΔΣ sin Γ + cos ΔΣ cos Γ cos ε o
pinion inner offset angle in axial plane
(A.20)
ε i + ζ i = arcsin 
E cos ζ i sin Γ
A iG − Z cos Γ
 (A.13) pinion offset angle in pitch plane at outer end

pinion inside pitch angle 

sin ε
ε′ o = arcsin cos γ o
oo
 (A.21)

γ i = arcsinsin ΔΣ sin Γ + cos ΔΣ cos Γ cos ε i

outer pinion spiral angle
(A.14)
ψ oP = ψ oG + ε′ o (A.22)
pinion offset angle in pitch plane at inner end

 
sin ε
ε′ i = arcsin cos γi
i
(A.15)
pinion dedendum angle
δP = γ − γR (A.23)

© AGMA 2006 ---- All rights reserved 19

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Annex B
(informative)
Stock allowance and standard cutter specifications
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 929--A06,
Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius.]

B.1 Purpose Consult the manufacturer for accurate cutter

This annex provides information on typical stock information.
allowance and standard cutter specifications.
B.2 Stock allowance
Table B.2 -- Standard blade specifications, face
For rough and finish cutting methods, if the informa- milled (inch)
tion on the stock allowance is not available, the
following default stock allowance can be used for
Point width range Blade point
calculating point width and blade point (see 4.2.5).
0.015 -- 0.015 0.010
0.020 -- 0.020 0.012
Table B.1 -- Default stock allowances (inch)
0.025 -- 0.025 0.015
Diametral pitch Pinion Gear 0.030 -- 0.035 0.020
Pd < 3.0 0.025 0.030 0.040 -- 0.045 0.025
3.0 ≤ Pd < 7.0 0.025 0.020 0.050 -- 0.055 0.030
7.0 ≤ Pd < 10.0 0.010 0.010 0.060 -- 0.070 0.040
10.0 ≤ Pd 0.000 0.000 0.080 -- 0.090 0.050
0.100 -- 0.120 0.065
0.130 -- 0.130 0.080
B.3 Standard blade point table
0.160 -- 0.160 0.100
The following table of standard blade points is used
0.170 -- 0.170 0.110
for some of the face milling cutting methods dis-
cussed in AGMA 929--A06. The table should not be 0.190 -- 0.190 0.125
construed to be all inclusive. 0.210 -- 0.210 0.150

20 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Annex C
(informative)
Spiral bevel example problem
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 929--A06,
Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius.]

Symbol Description Equation Variables Units

Type of gears Spiral
Face hobbing or face milling Face milled
Generated or non--generated Generated
Completing or rough and finish, pinion Completing
Completing or rough and finish, gear Completing
Table 2
AiG Inner gear cone distance 2.69971 inch
AmG Gear mean cone distance 3.19971 inch
AmP Pinion mean cone distance 3.19971 inch
AoG Gear outer cone distance 3.69971 inch
aG Gear mean addendum 0.06259 inch
aP Pinion mean addendum 0.19043 inch
aoG Outer gear addendum 0.08122 inch
aoP Outer pinion addendum 0.24734 inch
B Outer normal backlash allowance 0.00500 inch
bG Gear mean dedendum 0.22206 inch
bP Pinion mean dedendum 0.09422 inch
c Clearance 0.03163 inch
D Gear pitch diameter 6.96429 inch
d Pinion pitch diameter 2.50000 inch
FG Gear face width 1.00000 inch
FP Pinion face width 1.00000 inch
N Gear number of teeth 39.00000 -- --
n Pinion number of teeth 14.00000 -- --
pm Mean circular pitch 0.48518 inch
rc Cutter radius table 5 inch
SAP Pinion stock allowance table 5 inch
SAG Gear stock allowance table 5 inch
Tn Gear mean normal zero backlash circular thickness at pitch line 0.14817 inch
W Gear finishing point width table 5 inch
y Amount of fillet mutilation permitted table 5 inch
Γ Gear pitch angle 70.25316 degrees
ΓR Gear root angle 63.75967 degrees
Δf Width of blade flat table 5 inch
γ Pinion pitch angle 19.74684 degrees
δG Dedendum angle of gear 6.49349 degrees
δP Dedendum angle of pinion 2.13424 degrees
φ1 Concave pinion normal pressure angle 20.00000 degrees
φ2 Convex pinion normal pressure angle --20.00000 degrees
ψG Gear mean spiral angle 35.00000 degrees
ψP Pinion mean spiral angle 35.00000 degrees
ψiG Inner gear spiral angle 33.94561 degrees

© AGMA 2006 ---- All rights reserved 21

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Symbol Description Equation Variables Units

ψiP Inner pinion spiral angle 33.94561 degrees
ψoG Outer gear spiral angle 36.84576 degrees
ψoP Outer pinion spiral angle 36.84576 degrees
Additional input variables for face hobbing (Table 2)
Q Intermediate factor Not applicable
S1 Crown gear to cutter center dist Not applicable inch
η1 Second auxiliary angle Not applicable degrees
ηo Generating angle at outside Not applicable degrees
ηi Generating angle at inside Not applicable degrees
Additional input for hypoids
FoP Hypoid pinion face width from calculation point to outside Not applicable degrees
FiP Hypoid pinion face width from calculation point to inside Not applicable degrees
Table 4
Method Cutting method Spread blade
kE Gear rotation factor 0.00000
Table 5
φBXG Inside blade angle gear cutter (non--generated) Not applicable degrees
SAP Pinion stock allowance 0.00000 inch
SAG Gear stock allowance 0.00000 inch
y Amount of fillet mutilation permitted 0.00200 inch
Δf Width of blade flat 0.00800 inch
rc Cutter radius 4.50000 inch
4 Calculations
4.1 General geometry
AiP Inner pinion cone distance (eq 1 or 2) 2.69971 inch
AoP Outer pinion cone distance (eq 3 or 4) 3.69971 inch
Σφ Included pressure angle (eq 5) 40.00000 degrees
ΔcP Change in pinion clearance (eq 6) 0.00553 inch
ΔcG Change in gear clearance (eq 7) 0.00553 inch
Δφ2 Normal tilt of finishing cutter (non--generated) (eq 8) Not applicable degrees
q Generating angle at mean (eq 9 or 10) 80.47339 degrees
qo Generating angle at outside (eq 11 or 12) 74.46243 degrees
qi Generating angle at inside (eq 13 or 14) 87.13405 degrees
Δqo Increment in generating angle at outside (eq 15) 6.01095 degrees
Δqi Increment in generating angle at inside (eq 16) 6.66066 degrees
ΔboG Depth reduction on non--generated gear at (eq 17) Not applicable inch
outside
ΔbiG Depth reduction on non--generated gear at (eq 18) Not applicable inch
inside
b′oG Theoretical outer gear dedendum (eq 19) 0.27897 inch
boG Outer gear dedendum (eq 20 or 21) 0.27897 inch
boP Outer pinion dedendum (eq 22 or 23) 0.11285 inch
biP Inner pinion dedendum (eq 24) 0.07559 inch
biG Inner gear dedendum (eq 25 or 26) 0.16515 inch
pn Mean normal circular pitch (eq 27) 0.39744 inch
Σb Sum of pinion and gear mean dedendums (eq 28) 0.31628 inch
Σbo Sum of pinion and gear outer dedendums (eq 29) 0.39182 inch
Σbi Sum of pinion and gear inner dedendums (eq 30) 0.24074 inch

22 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Symbol Description Equation Variables Units

AxG Cone distance for involute lengthwise curvature (eq 31) 5.84984 inch
point where normal circular pitch and slot width
is a maximum
ψxG Spiral angle at cone distance AxG (eq 32 or 35) 50.28674 degrees
ηx Generating angle at involute curvature (eq 34) Not applicable degrees
FxG Distance from mean cone to cone distance at (eq 38) 0.00000 inch
involute curvature
qx Generating angle at involute curvature (eq 39 or 40) 0.00000 degrees
Δqx Increment in generating angle at involute (eq 41) 0.00000 degrees
curvature
ΔbxG Depth reduction on non--generated gear at (eq 42 or 43) 0.00000 inch
involute curvature
bxG Gear dedendum at cone distance AxG (eq 44) 0.00000 inch
bxP Pinion dedendum at cone distance AxG (eq 45) 0.00000 inch
Σbx Sum of pinion and gear dedendums at cone (eq 46) 0.00000 inch
distance AxG
4.2 Slot width calculations and blade specifications
4.2.1 Slot width calculations, mean
Tmn Mean normal gear circular thickness (eq 47) 0.14581 inch
tmn Mean normal pinion circular thickness (eq 48) 0.24691 inch
tmP Mean pinion transverse circular thickness (eq 49) 0.30142 inch
WmG Mean gear slot width (eq 50) 0.08997 inch
WmP Mean pinion slot width (eq 51) 0.08194 inch
W′e Effective gear point width (eq 52) 0.08997 inch
4.2.2 Slot width calculation, outer
ζ Angle between gear root plane and plane in (eq 53 or 54) 0.00000 degrees
which taper is specified
WoG Outer gear slot width (eq 55) 0.08997 inch
WoP Outer pinion slot width (eq 56) 0.07906 inch
WxG Slot width at AxG, gear (maximum gear slot (eq 57) 0.00000 inch
width)
WxP Slot width at AxG, pinion (maximum pinion slot (eq 58) 0.00000 inch
width)
4.2.3 Sloth width calculation, inner
WiG Inner gear slot width (eq 59) 0.08997 inch
WiP Inner pinion slot width (eq 60) 0.07840 inch
4.2.4 Sloth widths, minimum and maximum
WLG Minimum gear slot width (eq 61) 0.08997 inch
WLP Minimum pinion slot width (eq 62) 0.07840 inch
WMG Maximum gear slot width (eq 63) 0.08997 inch
WMP Maximum pinion slot width (eq 64) 0.08194 inch
4.2.5 Point width and blade point calculations
WRG Gear roughing point width (eq 65) 0.08997 inch
WRP Pinion roughing point width (eq 66) 0.07840 inch
WBRG Minimum gear roughing blade point (eq 67) 0.04599 inch
WBRP Minimum pinion roughing blade point (eq 68) 0.04020 inch
WBG Gear finishing blade point (eq 69 or 71) 0.04599 inch
WBP Pinion finishing blade point (eq 70 or 72) 0.04020 inch

© AGMA 2006 ---- All rights reserved 23

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Symbol Description Equation Variables Units

4.3 Cutter edge radius calculations
rTP Maximum pinion blade edge radius (eq 73) 0.04063 inch
rTG Maximum gear blade edge radius (eq 74) 0.05425 inch
4.3.1 Cutter edge radius for no running interference
RiP Original inner pinion pitch radius (eq 75) 1.40824 inch
RiG Original inner gear pitch radius (eq 76) 10.92822 inch
aiP Pinion inner addendum (eq 77) 0.13352 inch
aiG Gear inner addendum (eq 78) 0.04396 inch
ΔaP Change in inner pinion addendum (eq 79) 0.00063 inch
ΔaG Change in inner gear addendum (eq 80) 0.00490 inch
a′iP Adjusted inner pinion addendum (eq 81) 0.13415 inch
a′iG Adjusted inner gear addendum (eq 82) 0.04885 inch
R′iP New inner pinion pitch radius (eq 83) 1.40761 inch
R′iG New inner gear pitch radius (eq 84) 10.92333 inch
RioP Inner pinion outside radius (eq 85) 1.54176 inch
RioG Inner gear outside radius (eq 86) 10.97218 inch
RibVP Inner pinion base radius, concave (eq 87) 1.32331 inch
RibXP Inner pinion base radius, convex (eq 88) 1.32331 inch
RibXG Inner gear base radius, convex (eq 89) 10.26917 inch
RibVG Inner gear base radius, concave (eq 90) 10.26917 inch
φiV Inner pinion pressure angle, concave (eq 91) 19.92929 degrees
φiX Inner pinion pressure angle, convex (eq 92) 19.92929 degrees
ρiVP Inner pinion profile radius of curvature, concave (eq 93) 0.33882 inch
ρiXP Inner pinion profile radius of curvature, convex (eq 94) 0.33882 inch
ρiXG Inner gear profile radius of curvature, convex (eq 95) 3.41201 inch
ρiVG Inner gear profile radius of curvature, concave (eq 96) 3.41201 inch
xiVP Limit tooth height for interference pinion, (eq 97 or 98) 0.02674 inch
concave
xiXP Limit tooth height for interference pinion, convex (eq 99 or 100) 0.02674 inch
xiXG Limit tooth height for interference gear, convex (eq 101) 0.05377 inch
xiVG Limit tooth height for interference gear, concave (eq 102) 0.05377 inch
r1VP Maximum blade edge radius for no running (eq 103) 0.04063 inch
interference pinion, concave
r1XP Maximum blade edge radius for no running (eq 104) 0.04063 inch
interference pinion, convex
r1XG Maximum blade edge radius for no running (eq 105) 0.08171 inch
interference gear, convex
r1VG Maximum blade edge radius for no running (eq 106) 0.08171 inch
interference gear, concave
r1P Maximum blade edge radius for no running (eq 107 or 108) 0.04063 inch
interference on pinion
r1G Maximum blade edge radius for no running (eq 109 or 110) 0.08171 inch
interference on gear

24 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Symbol Description Equation Variables Units

4.3.2 Cutter edge radius which can be manufactured
4.3.2.1 Roughing
r′2RG Maximum gear roughing blade edge radius (eq 111) 0.05425 inch
which can be manufactured
r′2RP Maximum pinion roughing blade edge radius (eq 112) 0.04599 inch
which can be manufactured
r2RG Gear roughing cutter edge radius (eq 113) 0.05425 inch
r2RP Pinion roughing cutter edge radius (eq 114) 0.04599 inch
4.3.2.2 Finishing
r′2VP Maximum pinion finishing blade edge radius (eq 115) 0.04599 inch
defined by maximum roughing blade radius and
minimum stock allowance, concave
r′2XP Maximum pinion finishing blade edge radius (eq 116) 0.04599 inch
defined by maximum roughing blade radius and
minimum stock allowance, convex
r′2XG Maximum gear finishing blade edge radius (eq 117) 0.05425 inch
defined by maximum roughing blade radius and
minimum stock allowance, convex
r′2VG Maximum gear finishing blade edge radius (eq 118) 0.05425 inch
defined by maximum roughing blade radius and
minimum stock allowance, concave
r′′2VP Maximum pinion finish blade edge radius (eq 119) 0.04599 inch
concave
r′′2XP Maximum pinion finish blade edge radius (eq 120) 0.04599 inch
convex
r′′2XG Maximum gear finish blade edge radius, convex (eq 121) 0.05425 inch
r′′2VG Maximum gear finish blade edge radius, (eq 122) 0.05425 inch
concave
r2P Maximum pinion blade edge radius that can be (eq 123 or 124) 0.04599 inch
manufactured
r2G Maximum gear blade edge radius that can be (eq 125 or 126) 0.05425 inch
manufactured
4.3.3 Cutter edge radius to avoid mutilation
ΔW′P Difference between pinion minimum slot width (eq 127) 0.03820 inch
and finishing blade point
ΔW′G Difference between gear minimum slot width (eq 128) 0.04399 inch
and finishing blade point
ΩVP Pinion intermediate blade mutilation value, (eq 129) 0.00011 inch2
concave
ΩXP Pinion intermediate blade mutilation value, (eq 130) 0.00011 inch2
convex
ΩXG Gear intermediate blade mutilation value, (eq 131) 0.00013 inch2
convex
ΩVG Gear intermediate blade mutilation value, (eq 132) 0.00013 inch2
concave
r3VP Maximum pinion blade edge radius to avoid (eq 133) 0.08013 inch
mutilation, concave

© AGMA 2006 ---- All rights reserved 25

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Symbol Description Equation Variables Units

r3XP Maximum pinion blade edge radius to avoid (eq 134) 0.08013 inch
mutilation, convex
r3XG Maximum gear blade edge radius to avoid (eq 135) 0.08990 inch
mutilation, convex
r3VG Maximum gear blade edge radius to avoid (eq 136) 0.08990 inch
mutilation, concave
r3P Maximum pinion blade edge radius to avoid (eq 137) 0.08013 inch
mutilation
r3G Maximum gear blade edge radius to avoid (eq 138) 0.08990 inch
mutilation
4.4 Top land formulas
4.4.1 Mean top lands
RNP Mean normal pinion pitch radius (eq 139) 1.71177 inch
RNG Mean normal gear pitch radius (eq 140) 13.28366 inch
RbNP1 Mean normal pinion base radius, concave (eq 141) 1.60853 inch
RbNP2 Mean normal pinion base radius, convex (eq 142) 1.60853 inch
RbNG1 Mean normal gear base radius, convex (eq 143) 12.48256 inch
RbNG2 Mean normal gear base radius, concave (eq 144) 12.48256 inch
RoNP Mean normal pinion outside radius (eq 145) 1.90220 inch
RoNG Mean normal gear outside radius (eq 146 or 147) 13.34625 inch
φ1TP Pressure angle at tip of pinion tooth, concave (eq 148) 32.26164 degrees
φ2TP Pressure angle at tip of pinion tooth, convex (eq 149) 32.26164 degrees
φ1TG Pressure angle at tip of gear tooth, concave (eq 150) 20.72564 degrees
φ2TG Pressure angle at tip of gear tooth, convex (eq 151) 20.72564 degrees
tLNP Mean normal pinion top land (eq 152 or 153) 0.07175 inch
tLNG Mean normal gear top land (eq 154 or 155) 0.09992 inch
4.4.2 Outer top lands
R′NP Outer normal pinion pitch radius (eq 156) 2.07384 inch
R′NG Outer normal gear pitch radius (eq 157) 16.09347 inch
R′bNP1 Outer normal pinion base radius, concave (eq 158) 1.94878 inch
R′bNP2 Outer normal pinion base radius, convex (eq 159) 1.94878 inch
R′bNG1 Outer normal gear base radius, convex (eq 160) 15.12291 inch
R′bNG2 Outer normal gear base radius, concave (eq 161) 15.12291 inch
R′oNP Outer normal pinion outside radius (eq 162) 2.32118 inch
R′oNG Outer normal gear outside radius (eq 163 or 164) 16.17469 inch
φ′1TP Pressure angle at tip of pinion tooth outer, (eq 165) 32.90619 degrees
concave
φ′2TP Pressure angle at tip of pinion tooth outer, (eq 166) 32.90619 degrees
convex
φ′1TG Pressure angle at tip of gear tooth outer, convex (eq 167) 20.77605 degrees
φ′2TG Pressure angle at tip of gear tooth outer, (eq 168) 20.77605 degrees
concave
toNP Pinion outer normal circular thickness at pitch (eq 169) 0.28773 inch
line
toNG Gear outer normal circular thickness at pitch line (eq 170) 0.15589 inch

26 © AGMA 2006 ---- All rights reserved

AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 929--A06

Symbol Description Equation Variables Units

tLoNP Outer normal pinion top land (eq 171 or 172) 0.05345 inch
tLoNG Outer normal gear top land (eq 173 or 174) 0.09614 inch
4.4.3 Inner top lands
R′′NP Inner mean normal pinion pitch radius (eq 175) 1.40824 inch
R′′NG Inner mean normal gear pitch radius (eq 176) 10.92822 inch
R′′bNP1 Inner normal pinion base radius, concave (eq 177) 1.32331 inch
R′′bNP2 Inner normal pinion base radius, convex (eq 178) 1.32331 inch
R′′bNG1 Inner normal gear base radius, convex (eq 179) 10.26916 inch
R′′bNG2 Inner normal gear base radius, concave (eq 180) 10.26916 inch
R′′oNP Inner normal pinion outside radius (eq 181) 1.54176 inch
R′′oNG Inner normal gear outside radius (eq 182 or 183) 10.97217 inch
φ′′1TP Pressure angle at tip of pinion tooth inner, (eq 184) 30.87230 degrees
concave
φ′′2TP Pressure angle at tip of pinion tooth inner, (eq 185) 30.87230 degrees
convex
φ′′1TG Pressure angle at tip of gear tooth inner, convex (eq 186) 20.62140 degrees
φ′′2TG Pressure angle at tip of gear tooth inner, (eq 187) 20.62140 degrees
concave
tiNP Inner normal pinion thickness at pitch line (eq 188) 0.20617 inch
tiNG Inner normal gear thickness at pitch line (eq 189) 0.12940 inch
tLiNP Inner normal pinion top land (eq 190 or 191) 0.08972 inch
tLiNG Inner normal gear top land (eq 192 or 193) 0.09731 inch

© AGMA 2006 ---- All rights reserved 27

AGMA 929--A06 AMERICAN GEAR MANUFACTURERS ASSOCIATION

Annex D
(informative)
Hypoid example problem
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 929--A06,
Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius.]

Symbol Description Equation Variables Units

Type of gears Hypoid
Face hobbing or face milling Face milled
Generated or non--generated Non--generated
Completing or rough and finish, pinion Completing
Completing or rough and finish, gear Completing
Table 2
AiG Inner gear cone distance 4.04868 inch
AmG Gear mean cone distance 4.84349 inch
AmP Pinion mean cone distance 5.06560 inch
AoG Gear outer cone distance 5.64868 inch
aG Gear mean addendum 0.08460 inch
aP Pinion mean addendum 0.27708 inch
aoG Outer gear addendum 0.10327 inch
aoP Outer pinion addendum 0.33072 inch
B Outer normal backlash allowance 0.00600 inch
bG Gear mean dedendum 0.31520 inch
bP Pinion mean dedendum 0.12902 inch
c Clearance 0.04442 inch
D Gear pitch diameter 10.77070 inch
d Pinion pitch diameter 3.45020 inch
FG Gear face width 1.60000 inch
FP Pinion face width 1.83628 inch
N Gear number of teeth 45.00000 -- --
n Pinion number of teeth 11.00000 -- --
pm Mean circular pitch 0.64475 inch
rc Cutter radius table 5 inch
SAP Pinion stock allowance table 5 inch
SAG Gear stock allowance table 5 inch
Tn Gear mean normal zero backlash circular thickness at pitch line 0.18870 inch
W Gear finishing point width table 5 inch
y Amount of fillet mutilation permitted table 5 inch
Γ Gear pitch angle 72.43638 degrees
ΓR Gear root angle 68.18198 degrees
Δf Width of blade flat table 5 inch
γ Pinion pitch angle 16.75611 degrees
δG Dedendum angle of gear 4.25440 degrees
δP Dedendum angle of pinion 1.27592 degrees
φ1 Concave pinion normal pressure angle 15.44545 degrees
φ2 Convex pinion normal pressure angle --24.55455 degrees
ψG Gear mean spiral angle 30.02788 degrees
ψP Pinion mean spiral angle 47.99638 degrees
ψiG Inner gear spiral angle 23.83723 degrees

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Symbol Description Equation Variables Units

ψiP Inner pinion spiral angle 44.98259 degrees
ψoG Outer gear spiral angle 36.53169 degrees
ψoP Outer pinion spiral angle 51.88843 degrees
Additional input variables for face hobbing (Table 2)
Q Intermediate factor Not applicable
S1 Crown gear to cutter center distance Not applicable inch
η1 Second auxiliary angle Not applicable degrees
ηo Generating angle at outside Not applicable degrees
ηi Generating angle at inside Not applicable degrees
Additional input for hypoids
FoP Hypoid pinion face width from calculation point to outside 0.84044 degrees
FiP Hypoid pinion face width from calculation point to inside 0.82960 degrees
Table 4
Method Cutting method Spread
kE Gear rotation factor 0.00000
Table 5
φBXG Inside blade angle gear cutter (non--generated) 22.00000 degrees
SAP Pinion stock allowance 0.00000 inch
SAG Gear stock allowance 0.00000 inch
y Amount of fillet mutilation permitted 0.00200 inch
Δf Width of blade flat 0.00800 inch
rc Cutter radius 4.50000 inch
4 Calculations
4.1 General geometry
AiP Inner pinion cone distance (eq 1 or 2) 4.23600 inch
AoP Outer pinion cone distance (eq 3 or 4) 5.90604 inch
Σφ Included pressure angle (eq 5) 40.00000 degrees
ΔcP Change in pinion clearance (eq 6) 0.00723 inch
ΔcG Change in gear clearance (eq 7) 0.00718 inch
Δφ2 Normal tilt of finishing cutter (non--generated) (eq 8) 6.55455 degrees
q Generating angle at mean (eq 9 or 10) 56.36854 degrees
qo Generating angle at outside (eq 11 or 12) 50.60129 degrees
qi Generating angle at inside (eq 13 or 14) 61.55194 degrees
Δqo Increment in generating angle at outside (eq 15) 5.76725 degrees
Δqi Increment in generating angle at inside (eq 16) 5.18341 degrees
ΔboG Depth reduction on non--generated gear at (eq 17) 1.28684 inch
outside
ΔbiG Depth reduction on non--generated gear at (eq 18) 0.99546 inch
inside
b′oG Theoretical outer gear dedendum (eq 19) 0.37510 inch
boG Outer gear dedendum (eq 20 or 21) 0.35264 inch
boP Outer pinion dedendum (eq 22 or 23) 0.14774 inch
biP Inner pinion dedendum (eq 24) 0.10684 inch
biG Inner gear dedendum (eq 25 or 26) 0.23870 inch
pn Mean normal circular pitch (eq 27) 0.55821 inch
Σb Sum of pinion and gear mean dedendums (eq 28) 0.44422 inch
Σbo Sum of pinion and gear outer dedendums (eq 29) 0.50038 inch
Σbi Sum of pinion and gear inner dedendums (eq 30) 0.34554 inch

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Symbol Description Equation Variables Units

AxG Cone distance for involute lengthwise curvature (eq 31) 6.49194 inch
point where normal circular pitch and slot width
is a maximum
ψxG Spiral angle at cone distance AxG (eq 32 or 35) 43.88132 degrees
ηx Generating angle at involute curvature (eq 34) Not applicable degrees
FxG Distance from mean cone to cone distance at (eq 38) 0.00000 inch
involute curvature
qx Generating angle at involute curvature (eq 39 or 40) 0.00000 degrees
Δqx Increment in generating angle at involute (eq 41) 0.00000 degrees
curvature
ΔbxG Depth reduction on non--generated gear at (eq 42 or 43) 0.00000 inch
involute curvature
bxG Gear dedendum at cone distance AxG (eq 44) 0.00000 inch
bxP Pinion dedendum at cone distance AxG (eq 45) 0.00000 inch
Σbx Sum of pinion and gear dedendums at cone (eq 46) 0.00000 inch
distance AxG
4.2 Slot width calculations and blade specifications
4.2.1 Slot width calculations, mean
Tmn Mean normal gear circular thickness (eq 47) 0.18575 inch
tmn Mean normal pinion thickness in gear normal (eq 48) 0.36656 inch
plane
tmP Mean pinion transverse circular thickness (eq 49) 0.42339 inch
WmG Mean gear slot width (eq 50) 0.13956 inch
WmP Mean pinion slot width (eq 51) 0.09886 inch
W′e Effective gear point width (eq 52) 0.13956 inch
4.2.2 Slot width calculation, outer
ζ Angle between gear root plane and plane in (eq 53 or 54) 0.00000 degrees
which taper is specified
WoG Outer gear slot width (eq 55) 0.14151 inch
WoP Outer pinion slot width (eq 56) 0.10221 inch
WxG Slot width at AxG, gear (maximum gear slot (eq 57) 0.00000 inch
width)
WxP Slot width at AxG, pinion (maximum pinion slot (eq 58) 0.00000 inch
width)
4.2.3 Slot width calculation, inner
WiG Inner gear slot width (eq 59) 0.14115 inch
WiP Inner pinion slot width (eq 60) 0.10369 inch
4.2.4 Slot widths, minimum and maximum
WLG Minimum gear slot width (eq 61) 0.13956 inch
WLP Minimum pinion slot width (eq 62) 0.09886 inch
WMG Maximum gear slot width (eq 63) 0.14151 inch
WMP Maximum pinion slot width (eq 64) 0.10369 inch
4.2.5 Point width and blade point calculations
WRG Gear roughing point width (eq 65) 0.13956 inch
WRP Pinion roughing point width (eq 66) 0.09886 inch
WBRG Minimum gear roughing blade point (eq 67) 0.07078 inch
WBRP Minimum pinion roughing blade point (eq 68) 0.05043 inch

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Symbol Description Equation Variables Units

WBG Gear finishing blade point (eq 69 or 71) 0.07078 inch
WBP Pinion finishing blade point (eq 70 or 72) 0.05043 inch
4.3 Cutter edge radius calculations
rTP Maximum pinion blade edge radius (eq 73) 0.05069 inch
rTG Maximum gear blade edge radius (eq 74) 0.08248 inch
4.3.1 Cutter edge radius for no running interference
RiP Original inner pinion pitch radius (eq 75) 2.54922 inch
RiG Original inner gear pitch radius (eq 76) 15.28824 inch
aiP Pinion inner addendum (eq 77) 0.19428 inch
aiG Gear inner addendum (eq 78) 0.06242 inch
ΔaP Change in inner pinion addendum (eq 79) 0.00051 inch
ΔaG Change in inner gear addendum (eq 80) 0.00672 inch
a′iP Adjusted inner pinion addendum (eq 81) 0.19479 inch
a′iG Adjusted inner gear addendum (eq 82) 0.06914 inch
R′iP New inner pinion pitch radius (eq 83) 2.54871 inch
R′iG New inner gear pitch radius (eq 84) 15.28153 inch
RioP Inner pinion outside radius (eq 85) 2.74350 inch
RioG Inner gear outside radius (eq 86) 15.35066 inch
RibVP Inner pinion base radius, concave (eq 87) 2.45715 inch
RibXP Inner pinion base radius, convex (eq 88) 2.31868 inch
RibXG Inner gear base radius, convex (eq 89) 14.73610 inch
RibVG Inner gear base radius, concave (eq 90) 13.90567 inch
φiV Inner pinion pressure angle, concave (eq 91) 15.40361 degrees
φiX Inner pinion pressure angle, convex (eq 92) 24.52927 degrees
ρiVP Inner pinion profile radius of curvature, concave (eq 93) 0.43599 inch
ρiXP Inner pinion profile radius of curvature, convex (eq 94) 0.90042 inch
ρiXG Inner gear profile radius of curvature, convex (eq 95) 3.51569 inch
ρiVG Inner gear profile radius of curvature, concave (eq 96) 5.93591 inch
xiVP Limit tooth height for interference pinion, (eq 97 or 98) 0.03719 inch
concave
xiXP Limit tooth height for interference pinion, convex (eq 99 or 100) 0.03719 inch
xiXG Limit tooth height for interference gear, convex (eq 101) 0.09066 inch
xiVG Limit tooth height for interference gear, concave (eq 102) 0.06530 inch
r1VP Maximum blade edge radius for no running (eq 103) 0.05069 inch
interference pinion, concave
r1XP Maximum blade edge radius for no running (eq 104) 0.06363 inch
interference pinion, convex
r1XG Maximum blade edge radius for no running (eq 105) 0.12356 inch
interference gear, convex
r1VG Maximum blade edge radius for no running (eq 106) 0.11173 inch
interference gear, concave
r1P Maximum blade edge radius for no running (eq 107 or 108) 0.05069 inch
interference on pinion
r1G Maximum blade edge radius for no running (eq 109 or 110) 0.11173 inch
interference on gear

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Symbol Description Equation Variables Units

4.3.2 Cutter edge radius which can be manufactured
4.3.2.1 Roughing
r′2RG Maximum gear roughing blade edge radius (eq 111) 0.08248 inch
which can be manufactured
r′2RP Maximum pinion roughing blade edge radius (eq 112) 0.05574 inch
which can be manufactured
r2RG Gear roughing cutter edge radius (eq 113) 0.08248 inch
r2RP Pinion roughing cutter edge radius (eq 114) 0.05574 inch
4.3.2.2 Finishing
r′2VP Maximum pinion finishing blade edge radius (eq 115) 0.05574 inch
defined by maximum roughing blade radius and
minimum stock allowance, concave
r′2XP Maximum pinion finishing blade edge radius (eq 116) 0.05574 inch
defined by maximum roughing blade radius and
minimum stock allowance, convex
r′2XG Maximum gear finishing blade edge radius (eq 117) 0.08248 inch
defined by maximum roughing blade radius and
minimum stock allowance, convex
r′2VG Maximum gear finishing blade edge radius (eq 118) 0.08248 inch
defined by maximum roughing blade radius and
minimum stock allowance, concave
r′′2VP Maximum pinion finish blade edge radius, (eq 119) 0.05574 inch
concave
r′′2XP Maximum pinion finish blade edge radius, (eq 120) 0.06603 inch
convex
r′′2XG Maximum gear finish blade edge radius, convex (eq 121) 0.08248 inch
r′′2VG Maximum gear finish blade edge radius, (eq 122) 0.09770 inch
concave
r2P Maximum pinion blade edge radius that can be (eq 123 or 124) 0.05574 inch
manufactured
r2G Maximum gear blade edge radius that can be (eq 125 or 126) 0.08248 inch
manufactured
4.3.3 Cutter edge radius to avoid mutilation
ΔW′P Difference between pinion minimum slot width (eq 127) 0.04843 inch
and finishing blade point
ΔW′G Difference between gear minimum slot width (eq 128) 0.06878 inch
and finishing blade point
ΩVP Pinion intermediate blade mutilation value, (eq 129) 0.00015 inch2
concave
ΩXP Pinion intermediate blade mutilation value, (eq 130) 0.00013 inch2
convex
ΩXG Gear intermediate blade mutilation value, (eq 131) 0.00021 inch2
convex
ΩVG Gear intermediate blade mutilation value, (eq 132) 0.00018 inch2
concave
r3VP Maximum pinion edge radius to avoid mutilation, (eq 133) 0.10767 inch
concave

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Symbol Description Equation Variables Units

r3XP Maximum pinion edge radius to avoid mutilation, (eq 134) 0.08832 inch
convex
r3XG Maximum gear edge radius to avoid mutilation, (eq 135) 0.14445 inch
convex
r3VG Maximum gear edge radius to avoid mutilation, (eq 136) 0.11903 inch
concave
r3P Maximum pinion blade edge radius to avoid (eq 137) 0.08832 inch
mutilation
r3G Maximum gear blade edge radius to avoid (eq 138) 0.11903 inch
mutilation
4.4 Top land formulas
4.4.1 Mean top lands
RNP Mean normal pinion pitch radius (eq 139) 3.45071 inch
RNG Mean normal gear pitch radius (eq 140) 20.41456 inch
RbNP1 Mean normal pinion base radius, concave (eq 141) 3.32609 inch
RbNP2 Mean normal pinion base radius, convex (eq 142) 3.13865 inch
RbNG1 Mean normal gear base radius, convex (eq 143) 19.67727 inch
RbNG2 Mean normal gear base radius, concave (eq 144) 18.56839 inch
RoNP Mean normal pinion outside radius (eq 145) 3.72779 inch
RoNG Mean normal gear outside radius (eq 146 or 147) 20.13748 inch
φ1TP Pressure angle at tip of pinion tooth, concave (eq 148) 26.84382 degrees
φ2TP Pressure angle at tip of pinion tooth, convex (eq 149) 32.65236 degrees
φ1TG Pressure angle at tip of gear tooth, concave (eq 150) 12.27271 degrees
φ2TG Pressure angle at tip of gear tooth, convex (eq 151) 22.76775 degrees
tLNP Mean normal pinion top land (eq 152 or 153) 0.10537 inch
tLNG Mean normal gear top land (eq 154 or 155) 0.12372 inch
4.4.2 Outer top lands
R′NP Outer normal pinion pitch radius (eq 156) 4.72947 inch
R′NG Outer normal gear pitch radius (eq 157) 27.64037 inch
R′bNP1 Outer normal pinion base radius, concave (eq 158) 4.55866 inch
R′bNP2 Outer normal pinion base radius, convex (eq 159) 4.30177 inch
R′bNG1 Outer normal gear base radius, convex (eq 160) 26.64212 inch
R′bNG2 Outer normal gear base radius, concave (eq 161) 25.14074 inch
R′oNP Outer normal pinion outside radius (eq 162) 5.06019 inch
R′oNG Outer normal gear outside radius (eq 163 or 164) 27.30965 inch
φ′1TP Pressure angle at tip of pinion tooth outer, (eq 165) 25.72501 degrees
concave
φ′2TP Pressure angle at tip of pinion tooth outer, (eq 166) 31.77535 degrees
convex
φ′1TG Pressure angle at tip of gear tooth outer, convex (eq 167) 12.69412 degrees
φ′2TG Pressure angle at tip of gear tooth outer, (eq 168) 22.98885 degrees
concave
toNP Pinion outer normal circular thickness at pitch (eq 169) 0.39368 inch
line
toNG Gear outer normal circular thickness at pitch line (eq 170) 0.20414 inch

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Symbol Description Equation Variables Units

tLoNP Outer normal pinion top land (eq 171 or 172) 0.08697 inch
tLoNG Outer normal gear top land (eq 173 or 174) 0.12842 inch
4.4.3 Inner top lands
R′′NP Inner mean normal pinion pitch radius (eq 175) 2.58275 inch
R′′NG Inner mean normal gear pitch radius (eq 176) 15.28824 inch
R′′bNP1 Inner normal pinion base radius, concave (eq 177) 2.48947 inch
R′′bNP2 Inner normal pinion base radius, convex (eq 178) 2.34918 inch
R′′bNG1 Inner normal gear base radius, convex (eq 179) 14.73609 inch
R′′bNG2 Inner normal gear base radius, concave (eq 180) 13.90566 inch
R′′oNP Inner normal pinion outside radius (eq 181) 2.77703 inch
R′′oNG Inner normal gear outside radius (eq 182 or 183) 15.09396 inch
φ′′1TP Pressure angle at tip of pinion tooth inner, (eq 184) 26.30451 degrees
concave
φ′′2TP Pressure angle at tip of pinion tooth inner, (eq 185) 32.22794 degrees
convex
φ′′1TG Pressure angle at tip of gear tooth inner, convex (eq 186) 12.50133 degrees
φ′′2TG Pressure angle at tip of gear tooth inner, (eq 187) 22.88704 degrees
concave
tiNP Inner normal pinion thickness at pitch line (eq 188) 0.31092 inch
tiNG Inner normal gear thickness at pitch line (eq 189) 0.17681 inch
tLiNP Inner normal pinion top land (eq 190 or 191) 0.13357 inch
tLiNG Inner normal gear top land (eq 192 or 193) 0.13105 inch

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Bibliography

The following documents are either referenced in the text of AGMA 929--A06, Calculation of Bevel Gear Top
Land and Guidance on Cutter Edge Radius, or indicated for additional information.

Gleason Bevel & Hypoid Gear Terminology, Publication No. SD 4053A--1971--C&T, Gleason Works.
Formulas for Cutter Specifications and Tooth Thickness Measurements for Spiral Bevel and Hypoid Gears, SD
3124B, Jan 1982, Gleason Works.

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