BRITISH STANDARD BS 978-1:1968

Incorporating
Amendment No. 1
CONFIRMED
AUGUST 1990

Specification for

Fine pitch gears —

Part 1: Involute Spur and Helical Gears

UDC 621.833.1
BS 978-1:1968

Co-operating organizations

The Mechanical Engineering Industry Standards Committee, under whose

supervision this British Standard was prepared, consists of representatives
from the following Government departments and scientific and industrial
organizations:
Associated Offices’ Technical Committee Institution of Civil Engineers
Association of Consulting Engineers* Institution of Gas Engineers
Association of Mining Electrical and Institution of Heating and Ventilating
Mechanical Engineers* Engineers
Board of Trade Institution of Mechanical Engineers
British Chemical Plant Manufacturers’ Institution of Mechanical Engineers
Association (Automobile Division)
British Compressed Air Society Institution of Production Engineers*
British Electrical and Allied Manufacturers’ Locomotive and Allied Manufacturers’
Association* Association of Great Britain
British Gear Manufacturers’ Association* London Transport Board
British Internal Combustion Engine Machine Tool Trades Association*
Manufacturers’ Association Ministry of Defence
British Iron and Steel Federation Ministry of Labour (H.M. Factory Inspectorate)
British Mechanical Engineering Federation Ministry of Power
British Pump Manufacturers’ Association Ministry of Public Building and Works
Crown Agents for Oversea Governments and Ministry of Technology — National
Administrations Engineering Laboratory*
Electricity Council, the Central Electricity Ministry of Transport
Generating Board and the Area Boards National Coal Board
in England and Wales National Physical Laboratory (Ministry of
Engineering Equipment Users’ Association Technology)
Gas Council Radio Industry Council
Institute of Marine Engineers* Royal Institute of British Architects

The Government department and scientific and industrial organizations

marked with an asterisk in the above list, together with the following, were
directly represented on the committee entrusted with the preparation of this
standard:
British Horological Institute Ministry of Technology
Electronic Engineering Association Navy and Vickers Gearing Research
Institute of British Foundrymen Association
Institution of Engineering Inspection North-East Coast Institution of Engineers
Institution of Engineers and Shipbuilders in and Shipbuilders
Scotland Society of Motor Manufacturers and Traders
Milling Cutter and Reamer Association Ltd.
Ministry of Defence, Army Department University of Sheffield
Ministry of Defence, Navy Department Manufacturers of fine pitch gears
This British Standard, having
been approved by the
Mechanical Engineering
Industry Standards
Committee and endorsed by
the Chairman of the
Engineering Divisional
Council, was published under
the authority of the General
Council on
31 January 1968

© BSI 10-1999

First published October 1941

First revision January 1952 Amendments issued since publication
Second revision November 1962
Third revision January 1968
Amd. No. Date of issue Comments

The following BSI references 3305 May 1980 Indicated by a sideline in the margin
relate to the work on this
standard:
Committee reference MEE/17,
MEE/17/4
Draft for comment 66/14936

ISBN 580 00028 1

 BS 978-1:1968

Contents

Page
Co-operating organizations Inside front cover
Foreword iii
1 General
1.1 Scope 1
1.2 Terminology and notation 1
1.3 Preferred range of normal diametral pitches 2
1.4 Basic rack tooth profile 2
2 Design details
2.1 Outside diameter and centre distance 3
2.2 Modification of addendum and centre distance 3
3 Accuracy of gear blanks and gears
3.1 General 13
3.2 Dual flank composite testing 14
3.3 Limits of tolerance on blanks and gear elements 15
4 Limits and tolerances of assembly
4.1 Centre distance 17
4.2 Depth of engagement 18
5 Information to be given on drawings
Appendix A Centre distance and addendum modification 21
Appendix B Examples of calculations 23
Appendix C Comparable diametral pitches and metric modules 29

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
Appendix D Single flank composite testing: Limits of tolerance 29
Appendix E Calculation of measuring pin dimensions for external and
internal spur gears 29
Figure 1 — Basic rack tooth profile for unit normal diametral pitch 2
Figure 2 — Basic rack tooth profile for unit normal diametral pitch with
backlash allowance 2
Figure 3 — Limiting values of addendum modification coefficient 5
Figure 4 — Minimum permissible addendum modification coefficient for
helical pinions (!n = 20°) 6
Figure 5 — Tolerance zone for profile error 15
Figure 6 — Example of information to be given on drawings 20
Figure 7 — Chart for normal backlash when x1 + x2 = y 28
Table 1 — Normal diametral pitch Pn (inch units) 2
Table 2 — Data for spur pinions of unit diametral pitch having fewer
than 17 teeth 4
Table 3 — Centre distances for spur gear pairs of unit diametral pitch for
the conditions given in clause 2.2.4 7
Table 4 — Forces appropriate to the pitch suitable for brass and steel
product gears 14
Table 5 — Limits of tolerance 14
Table 6 — Limits of tolerance on gear blanks 15
Table 7 — Limits of tolerance on tooth profile 16
Table 8 — Limits of tolerance on pitch 16
Table 9 — Limits of tolerance on tooth alignment 16

© BSI 10-1999 i
BS 978-1:1968

Page
Table 10 — Limits of tolerance on radial run-out of teeth 17
Table 11 — Limits of tolerance on tooth thickness 17
Table 12 — Limits of tolerance on centre distance of mounting 17
Table 13 — Minimum depth of engagement for spur gear pairs
with 28 to 33 teeth (z2 + z1) 18
Table 14 — Minimum depth of engagement for spur gear pairs with
more than 33 teeth (z2 + z1) 18

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

ii © BSI 10-1999
 BS 978-1:1968

Foreword

This standard makes reference to the following British Standards:

BS 978, Fine pitch gears.
BS 978-2, Cycloidal type gears.
BS 978-PD 3376, Addendum No. 1 to BS 978-2, Double circular arc type gears.
BS 978-3, Bevel gears.
BS 978-5, Hobs and cutters.
First published in 1952 and revised in 1962, this British Standard has been
further revised under the authority of the Mechanical Engineering Industry
Standards Committee.
In the 1962 edition, dual flank composite testing was introduced in the form of an
appendix to the specification. As this method of test became more widespread,
users of the standard were becoming confused between the application of the
composite tolerances and application of the individual elemental tolerances. The
prime reason for revision, therefore, has been to give dual flank testing the
importance it now deserves by placing it in the mandatory part of the standard as
the main accuracy testing procedure. Also care has been taken to ensure that the
user is not misled by attempting to reconcile composite errors with elemental
errors. It is necessary to retain the elemental tolerances because these will
continue to be used in some fields as acceptance criteria and because they are
essential as the basis for manufacturing gears and cutting tools1). Recognizing
also that single flank testing is used reference to this is made in an appendix.
Opportunity has been taken to effect improvements in presentation and in the
examples of calculations, and the terminology and notation is in accordance with

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
that agreed within the International Organization for Standardization (ISO).
This standard is a companion work to BS 978, “Fine pitch gears”,
Part 2, “Cycloidal type gears” (including addendum PD 3376, “Double circular arc
type gears”), Part 3, “Bevel gears”, and Part 5, “Hobs and cutters”.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 29 and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.

1)
BS 978, “Fine pitch gears”, Part 5, “Hobs and cutters”.

© BSI 10-1999 iii

 ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

iv blank
 BS 978-1:1968

1 General
1.1 Scope
This British Standard relates to involute spur, helical and crossed helical gears, having diametral pitches
finer than 20, in four accuracy grades. Examples of application are:
Class A. Astronomical apparatus and scientific instruments; colour printing machinery; control systems
(when multiple trains of gears are involved this grade would generally be used for low speed components
where the effect of positional accuracy is important).
Class B. Navigational instruments; high speed components of control systems where quietness and smooth
running are essential; machine tool speed control; photographic instruments.
Class C. General purpose instruments; accounting and calculating machinery; counters; clockwork
mechanisms.
Class D. Textile machinery; switch operating gear; clockwork mechanisms where accuracy is not the
primary consideration.
It is recommended that all spur, helical and crossed helical gears for use in horology should be produced to
this British Standard with the possible exception of gears for weight or spring-driven mechanisms in which
the pinion is the driven member and has 12 or fewer teeth. In such cases it may be preferable to use gears
conforming to BS 978-22).

1.2 Terminology and notation

As the first step towards achieving international understanding of gears terminology, the terms and
definitions of Draft ISO Recommendation No. 8883), “International vocabulary of gears”, have been
applied, together with corresponding notation derived from Draft ISO Recommendation No. 889,

a Centre distance
av Virtual centre distance
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
“International gear notation, symbols for geometrical data”3).
The notation used is as follows:

d Reference circle diameter

d1 Reference circle diameter: pinion
d2 Reference circle diameter: wheel
da Tip diameter
da1 Tip diameter: pinion
da2 Tip diameter: wheel
dR Measuring pin diameter
db Base circle diameter
jn Normal backlash
ja Coefficient for calculation of backlash
l Length of arc
Pn Normal diametral pitch
s Arc tooth thickness
s1 Arc tooth thickness: pinion
s2 Arc tooth thickness: wheel
x Addendum modification coefficient
x1 Addendum modification coefficient: pinion
x2 Addendum modification coefficient: wheel
%x1 Secondary addendum modification coefficient: pinion
%x2 Secondary addendum modification coefficient: wheel
y Centre distance modification coefficient

2)
BS 978, “Fine pitch gears”, Part 2, “Cycloidal type spur gears”.
3)
To be incorporated in BS 2519, “Glossary of terms for toothed gearing”.

© BSI 10-1999 1
BS 978-1:1968

z Number of teeth
z1 Number of teeth: pinion
z2 Number of teeth: wheel
zv Virtual number of teeth
!n Normal pressure angle
!nw Normal pressure angle, operating
!t Transverse pressure angle
!tw Transverse pressure angle, operating
" Helix angle at reference cylinder
"b Helix angle at base cylinder
a BS 978, “Fine pitch gears”, Part 5, “Hobs and cutters”.

1.3 Preferred range of normal diametral pitches

The pitch shall be selected from the following preferred range.
Table 1 — Normal diametral pitch Pn
(inch units)
32 48 100 160
24 36 64 120 180
28 40 80 140 200

1.4 Basic rack tooth profile

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
The shape and proportions of the basic rack tooth for spur helical and crossed helical gears shall be as
shown either in Figure 1 or Figure 2. In the case of helical and crossed helical gears, the shape and
proportions of the tooth are on a section at right angles to the pitch cylinder helix.

Figure 1 — Basic rack tooth profile for unit normal diametral pitch

Figure 2 — Basic rack tooth profile for unit normal diametral pitch
with backlash allowance
Figure 1 shows the basic rack usually employed where it is desired to have minimum backlash, as in
servomechanisms.

2 © BSI 10-1999
 BS 978-1:1968

Figure 2 is used where it is desired to have backlash to avoid any risk of jamming and where the load is
usually uni-directional, for example, in clockwork mechanisms. When non-topping hobs are used it is
permissible to use a hob conforming to Figure 1 basic rack and to cut at greater depth than normal to obtain
the required tooth thickness.
For internal gears (Figure 1 and Figure 2 basic racks) the addendum shall normally be 0.850 instead
of 1.000. In cases when the tips of the teeth have a radius of 0.25 or greater (up to 0.3 max. as shown)
the 1.000 addendum may be applied.

2 Design details
2.1 Outside diameter and centre distance
For the normal case when both z1 sec3" and z2 sec3" are greater than 17 the dimensions are as follows:

(1) (2)

(3) (4)

(5)

(For spur gears, sec" = 1)

2.2 Modification of addendum and centre distance

see Appendix A. ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

2.2.1 For an explanation of the principles followed in connection with addendum modification

2.2.2 Where no limitations are imposed, the value of x for any gear whose virtual number of teeth zv is less
than 17 is given by the formulae:
2
z v sin µ n
- (See Table 2 and Figure 3 and Figure 4)
x = 1 – ------------------------ (6)
2
where zv = z sec" sec2"b . z sec3" (7)

This gives values in accordance with the lower limiting line XX in Figure 3 and a small and normally
negligible amount of undercutting is thereby permitted.
The addendum modification coefficient for helical pinions from 6 to 16 teeth and helix angles up to 45° is
shown in Figure 4.
2.2.3 When the pinion is modified as above and there are no other limitations, the wheel is unmodified and
its dimensions are obtained from the formulae in 2.1; but the dimensions of the pinion and centre distance
are as follows:

(8)

(Figure 1 type gears) (9)

(Figure 2 type gears) (10)

(11)

Parallel axis external gear pairs designed as above have backlash at this centre distance. (See Appendix A.)

© BSI 10-1999 3
BS 978-1:1968

Table 2 — Data for spur pinions of unit diametral pitch having fewer
than 17 teeth
No. of Addendum Tip Increase in circular Recommended minimum
teeth modification diameter tooth thickness at number
z1 coefficient da1 standard of teeth in
x1 pitch dia. mating wheel
z2

8a 0.5321 11.0642 0.3874 26

9a 0.4736 11.9472 0.3448 25
10 0.4151 12.8302 0.3022 24

11 0.3566 13.7132 0.2596 23

12 0.2982 14.5963 0.2170 22
13 0.2397 15.4793 0.1744 21

14 0.1812 16.3623 0.1319 20

15 0.1227 17.2453 0.0893 19
16 0.0642 18.1284 0.0467 18
a
Pinions having 8 or 9 teeth generated from basic rack Figure 1 have narrow crest width, as also have pinions of 10
and 11 teeth generated from basic rack Figure 2. 10 is the smallest number of teeth that can be generated at full
depth from basic rack Figure 2.

2.2.4 Enlarged spur pinions with minimum backlash. Spur pinions enlarged according to Table 2 may
be engaged with wheels in which x2 is zero, at centre distance derived from Table 3. Gears derived
from Figure 1 basic rack will have no backlash at this centre distance. A small and negligible reduction of

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
tip-to-root clearance is obtained at this centre distance.
Table 2 is not applicable to helical gears, for which the formulae in Appendix A are required.
Alternatively, spur pinions enlarged according to Table 2 or helical pinions enlarged according to Figure 4
may be engaged with wheels in which x2 = – x1, in which case the centre distance is as obtained in 2.1, and

(Figure 1 type gears) (12)

(Figure 2 type gears) (13)

(14)

Such gears derived from Figure 1 basic rack will have zero backlash at nominal dimensions.

4 © BSI 10-1999
© BSI 10-1999

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

Figure 3 — Limiting values of addendum modification coefficient

BS 978-1:1968
5
6

BS 978-1:1968
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

Figure 4 — Minimum permissible addendum modification coefficient for helical pinions (!n = 20°)
© BSI 10-1999
 BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the
conditions given in clause 2.2.4
z1 = 10; x1 = 0.4151
z2 10 20 30 40 50 60 70 80 90 100

0 10.6845 15.3814 20.3887 25.3934 30.3963 35.3987 40.4004 45.4019 50.4032 55.4043
1 11.1460 15.8822 20.8893 25.8938 30.8966 35.8980 40.9005 45.9020 50.9033 55.9044
2 11.6060 16.3851 21.3898 26.3941 31.3968 36.3991 41.4007 46.4022 51.4034 56.4045
3 12.0644 16.8839 21.8904 26.8944 31.8971 36.8993 41.9008 46.9022 51.9035 56.9046
4 12.5213 17.3846 22.3909 27.3947 32.3974 37.3994 42.4010 47.4024 52.4036 57.4046

5 12.9767 17.8854 22.8913 27.8950 32.8976 37.8996 42.9012 47.9026 52.9038 57.9047
6 13.4307 18.3861 23.3918 28.3953 33.3978 38.3998 43.4013 48.4027 53.4039 58.4048
7 13.8833 18.8868 23.8922 28.8956 33.8981 38.9000 43.9014 48.9028 53.9040 58.9049
8 14.3795 19.3875 24.3927 29.3958 34.3982 39.4000 44.4016 49.4029 54.4041 59.4050
9 14.8804 19.8881 24.8931 29.8961 34.8985 39.9002 44.9017 49.9031 54.9042 59.9051

z2 110 120 130 140 150 160 170 180 190 200

0 60.4052 65.4059 70.4066 75.4071 80.4076 85.4080 90.4083 95.4086 100.4089 105.4092
1 60.9052 65.9060 70.9066 75.9071 80.9076 85.9080 90.9084 95.9087 100.9090 105.9092
2 61.4053 66.4060 71.4067 76.4072 81.4076 86.4080 91.4084 96.4087 101.4090 106.4092
3 61.9054 66.9062 71.9067 76.9072 81.9077 86.9081 91.9084 96.9087 101.9090 106.9093
4 62.4055 67.4062 72.4068 77.4073 82.4077 87.4081 92.4085 97.4088 102.4091 107.4093

5
6
7
8
62.9056
63.4056
63.9057
64.4058
67.9062
68.4064
68.9063
69.4064
72.9068
73.4069
73.9069
74.4070
77.9073
78.4074
78.9074
79.4075
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
82.9078
83.4078
83.9078
84.4079
87.9082
88.4082
88.9082
89.4083
92.9085
93.4085
93.9086
94.4086
97.9088
98.4088
98.9088
99.4089
102.9091
103.4091
103.9091
104.4092
107.9093
108.4093
108.9093
109.4094
9 64.9058 69.9065 74.9070 79.9075 84.9079 89.9083 94.9086 99.9089 104.9092 109.9094

© BSI 10-1999 7
BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the conditions given
in clause 2.2.4
z1 = 11; x1 = 0.3566
z2 10 20 30 40 50 60 70 80 90 100

0 11.1461 15.8315 20.8366 25.8402 30.8427 35.8445 40.8460 45.8471 50.8480 55.8488
1 11.6060 16.3321 21.3370 26.3405 31.3429 36.3447 41.3461 46.3472 51.3481 56.3488
2 12.0644 16.8327 21.8374 26.8408 31.8431 36.8448 41.8462 46.8473 51.8482 56.8489
3 12.5213 17.3333 22.3378 27.3410 32.3433 37.3450 42.3463 47.3474 52.3483 57.3490
4 12.9767 17.8338 22.8382 27.8413 32.8435 37.8451 42.8464 47.8474 52.8483 57.8490

5 13.4307 18.3343 23.3385 28.3416 33.3437 38.3453 43.3465 48.3475 53.3484 58.3491
6 13.8833 18.8348 23.8389 28.8418 33.8438 38.8454 43.8466 48.8476 53.8485 58.8492
7 14.3344 19.3353 24.3392 29.3421 34.3440 39.3456 44.3468 49.3477 54.3486 59.3492
8 14.8302 19.8358 24.8395 29.8423 34.8442 39.8457 44.8469 49.8478 54.8486 59.8493
9 15.3309 20.3362 25.3399 30.3425 35.3444 40.3458 45.3470 50.3479 55.3487 60.3493

z2 110 120 130 140 150 160 170 180 190 200

0 60.8494 65.8500 70.8504 75.8508 80.8512 85.8515 90.8518 95.8520 100.8522 105.8523
1 61.3495 66.3500 71.3505 76.3509 81.3512 86.3515 91.3518 96.3520 101.3522 106.3523
2 61.8495 66.8500 71.8505 76.8509 81.8513 86.8516 91.8518 96.8520 101.8522 106.8523
3 62.3496 67.3501 72.3506 77.3510 82.3513 87.3516 92.3518 97.3520 102.3522 107.3523
4 62.8496 67.8502 72.8506 77.8510 82.8513 87.8516 92.8518 97.8520 102.8522 107.8524

5
6
7
8
63.3497
63.8498
64.3498
64.8498
68.3502
68.8502
69.3503
69.8504
73.3506
73.8507
74.3507
74.8508
78.3510
78.8511
79.3511
79.8512
83.3514
83.8514
84.3514
84.8514
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
88.3516
88.8517
89.3517
89.8517
93.3518 98.3520
93.8519 98.8521
94.3519 99.3521
94.8519 99.8521
103.3522
103.8523
104.3523
104.8523
108.3524
108.8524
109.3524
109.8524
9 65.3499 70.3504 75.3508 80.3512 85.3515 90.3518 95.3519 100.3521 105.3523 110.3524

8 © BSI 10-1999
 BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the conditions given
in clause 2.2.4
z1 = 12; x1 = 0.2982
z2 10 20 30 40 50 60 70 80 90 100

0 11.6060 16.2806 21.2844 26.2868 31.2884 36.2896 41.2905 46.2913 51.2919 56.2925
1 12.0644 16.7811 21.7847 26.7870 31.7885 36.7897 41.7906 46.7914 51.7920 56.7925
2 12.5213 17.2815 22.2850 27.2872 32.2886 37.2898 42.2907 47.2914 52.2921 57.2926
3 12.9767 17.7826 22.7852 27.7874 32.7888 37.7899 42.7908 47.7915 52.7921 57.7926
4 13.4307 18.2827 23.2855 28.2876 33.2889 38.2900 43.2909 47.2916 53.2922 58.2927

5 13.8833 18.7828 23.7858 28.7877 33.7890 38.7901 43.7909 48.7916 53.7922 58.7927
6 14.3344 19.2831 24.2860 29.2879 34.2891 39.2902 44.2910 49.2917 54.2923 59.2928
7 14.7841 19.7835 24.7862 29.7880 34.7892 39.7903 44.7911 49.7918 54.7923 59.7928
8 15.2796 20.2838 25.2864 30.2882 35.2893 40.2904 45.2912 50.2918 55.2924 60.2928
9 15.7801 20.7841 25.7866 30.7883 35.7894 40.7905 45.7912 50.7919 55.7924 60.7929

z2 110 120 130 140 150 160 170 180 190 200

0 61.2929 66.2933 71.2936 76.2939 81.2942 86.2944 91.2946 96.2948 101.2949 106.2950
1 61.7930 66.7934 71.7937 76.7940 81.7942 86.7944 91.7946 96.7948 101.7949 106.7950
2 62.2930 67.2934 72.2937 77.2940 82.2942 87.2944 92.2946 97.2948 102.2949 107.2950
3 62.7930 67.7934 72.7937 77.7940 82.7942 87.7944 92.7946 97.7948 102.7949 107.7950
4 63.2931 68.2934 73.2938 78.2940 83.2942 88.2944 93.2946 98.2948 103.2950 108.2950

5
6
7
8
63.7931
64.2932
64.7932
65.2932
68.7935
69.2935
69.7935
70.2936
73.7938
74.2938
74.7938
75.2939
78.7941
79.2941
79.7941
80.2941
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
85.7943
84.2943
84.7943
85.2943
88.7945
89.2945
89.7945
90.2945
93.7947
94.2947
94.7947
98.7949 103.7950
99.2949 104.2950
99.7949 104.7950
95.2947 100.2949 105.2950
108.7951
109.2951
109.7951
110.2951
9 65.7933 70.7936 75.7939 80.7942 85.7944 90.7946 95.7948 100.7949 105.7950 110.7951

© BSI 10-1999 9
BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the
conditions given in clause 2.2.4
z1 = 13; x1 = 0.2397
z2 10 20 30 40 50 60 70 80 90 100

0 12.0644 16.7282 21.7306 26.7322 31.7333 36.7341 41.7347 46.7352 51.7356 56.7359
1 12.5213 17.2285 22.2308 27.2323 32.2334 37.2342 42.2348 47.2353 52.2357 57.2360
2 12.9767 17.7288 22.7310 27.7325 32.7335 37.7343 42.7348 47.7353 52.7357 57.7360
3 13.4307 18.2291 23.2312 28.2326 33.2336 38.2344 43.2349 48.2353 53.2357 58.2360
4 13.8833 18.7293 23.7314 28.7327 33.7337 38.7344 43.7349 48.7354 53.7358 58.7361

5 14.3344 19.2296 24.2316 29.2328 34.2338 39.2344 44.2350 49.2354 54.2358 59.2361
6 14.7841 19.7298 24.7317 29.7329 34.7338 39.7345 44.7350 49.7355 54.7358 59.7361
7 15.2324 20.2300 25.2318 30.2330 35.2339 40.2346 45.2351 50.2355 55.2358 60.2362
8 15.7276 20.7302 25.7320 30.7331 35.7340 40.7346 45.7351 50.7355 55.7359 60.7362
9 16.2280 21.2304 26.2321 31.2332 36.2340 41.2347 46.2352 51.2356 56.2359 61.2362

z2 110 120 130 140 150 160 170 180 190 200

0 61.7362 66.7365 71.7367 76.7369 81.7371 86.7372 91.7373 96.7374 101.7375 106.7376
1 62.2363 67.2366 72.2368 77.2370 82.2371 87.2372 92.2373 97.2374 102.2375 107.2376
2 62.7363 67.7366 72.7368 77.7370 82.7371 87.7372 92.7373 97.7374 102.7375 107.7376
3 63.2363 68.2366 73.2368 78.2370 83.2371 88.2372 93.2373 98.2374 103.2375 108.2376
4 63.7364 68.7366 73.7368 78.7370 83.7372 88.7372 93.7374 98.7374 103.7376 108.7376

5
6
7
8
64.2364
64.7364
65.2364
65.7365
69.2366
69.7366
70.2367
70.7367
74.2368
74.7368
75.2369
75.7369
79.2370
79.7370
80.2371
80.7371
84.2372
84.7372
85.2372
85.7372
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
89.2373
89.7373
90.2373
90.7373
94.2374 99.2375 104.2376
94.7374 99.7375 104.7376
95.2374 100.2375 105.2376
95.7374 100.7375 105.7376
109.2376
109.7376
110.2376
110.7377
9 66.2365 71.2367 76.2369 81.2371 86.2372 91.2373 96.2374 101.2375 106.2376 111.2377

10 © BSI 10-1999
 BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the
conditions given in clause 2.2.4
z1 = 14; x1 = 0.1812
z2 10 20 30 40 50 60 70 80 90 100

0 12.5213 17.1746 22.1760 27.1769 32.1775 37.1780 42.1784 47.1787 52.1789 57.1791
1 12.9767 17.6748 22.6761 27.6770 32.6776 37.6781 42.6784 47.6787 52.6789 57.6791
2 13.4307 18.1749 23.1762 28.1770 33.1776 38.1781 43.1785 48.1787 53.1789 58.1791
3 13.8833 18.6751 23.6763 28.6771 33.6777 38.6781 45.6785 48.6788 53.6790 58.6792
4 14.3344 19.1752 24.1764 29.1772 34.1777 39.1782 44.1785 49.1788 54.1790 59.1792

5 14.7841 19.6754 24.6765 29.6773 34.6778 39.6782 44.6786 49.6788 54.6790 59.6792
6 15.2324 20.1755 25.1766 30.1773 35.1778 40.1782 45.1786 50.1788 55.1790 60.1792
7 15.6793 20.6756 25.6766 30.6774 35.6779 40.6783 45.6786 50.6788 55.6790 60.6792
8 16.1740 21.1758 26.1767 31.1774 36.1779 41.1783 46.1787 51.1789 56.1791 61.2792
9 16.6744 21.6759 26.6768 31.6775 36.6780 41.6784 46.6787 51.6789 56.6791 61.6792

z2 110 120 130 140 150 160 170 180 190 200

0 62.1792 67.1794 72.1794 77.1796 82.1797 87.1798 92.1799 97.1799 102.1800 107.1800
1 62.6793 67.6794 72.6795 77.6796 82.6797 87.6798 92.6799 97.6799 102.6800 107.6800
2 63.1793 68.1794 73.1795 78.1796 83.1797 88.1798 93.1799 98.1799 103.1800 108.1800
3 63.6793 68.6794 73.6795 78.6796 83.6797 88.6798 93.6799 98.6799 103.6800 108.6800
4 64.1793 69.1794 74.1795 79.1796 84.1797 89.1798 94.1799 99.1799 104.1800 109.1800

5
6
7
8
64.6793
65.1793
65.6793
66.1793
69.6794
70.1794
70.6794
71.1794
74.6795
75.1795
75.6795
76.1795
79.6796
80.1796
80.6796
81.1796
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
84.6797
85.1797
85.6797
86.1798
89.6798
90.1798
90.6798
91.1798
94.6799
95.1799
95.6799
96.1799
99.6799
100.1800
100.6800
101.1800
104.6800
105.1800
105.6800
106.1800
109.6800
110.1801
110.6801
111.1801
9 66.6793 71.6794 76.6795 81.6796 86.6798 91.6799 96.6799 101.6800 106.6800 111.6801

© BSI 10-1999 11
BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the
conditions given in clause 2.2.4
z1 = 15; x1 = 0.1227
z2 10 20 30 40 50 60 70 80 90 100

0 12.9767 17.6195 22.6202 27.6207 32.6210 37.6212 42.6214 47.6215 52.6216 57.6217
1 13.4307 18.1196 23.1203 28.1207 33.1210 38.1212 43.1214 48.1215 53.1216 58.1217
2 13.8833 18.6197 23.6203 28.6207 33.6210 38.6212 43.6214 48.6215 53.6216 58.6217
3 14.3344 19.1198 24.1204 29.1208 34.1210 39.1212 44.1214 49.1215 54.1216 59.1217
4 14.7841 19.6199 24.6204 29.6208 34.6211 39.6213 44.6214 49.6215 54.6216 59.6217

5 15.2324 20.1200 25.1205 30.1208 35.1211 40.1213 45.1214 50.1216 55.1216 60.1218
6 15.6793 20.6200 25.6205 30.6208 35.6211 40.6213 45.6215 50.6216 55.6217 60.6218
7 16.1248 21.1201 26.1205 31.1209 36.1211 41.1213 46.1215 51.1216 56.1217 61.1218
8 16.6192 21.6201 26.6206 31.6209 36.6212 41.6214 46.6215 51.6216 56.6217 61.6218
9 17.1193 22.1202 27.1206 32.1209 37.1212 42.1214 47.1215 52.1216 57.1217 62.1218

z2 110 120 130 140 150 160 170 180 190 200

0 62.6218 67.6218 72.6219 77.6220 82.6220 87.6220 92.6221 97.6221 102.6221 107.6222
1 63.1218 68.1219 73.1219 78.1220 83.1220 88.1220 93.1221 98.1221 103.1221 108.1222
2 63.6218 68.6219 73.6219 78.6220 83.6220 88.6220 93.6221 98.6221 103.6221 108.6222
3 64.1218 69.1219 74.1219 79.1220 84.1220 89.1220 94.1221 99.1221 104.1221 109.1222
4 64.6218 69.6219 74.6219 79.6220 84.6220 89.6220 94.6221 99.6221 104.6221 109.6222

5
6
7
8
65.1218
65.6218
66.1218
66.6218
70.1219
70.6219
71.1219
71.6219
75.1219
75.6219
76.1220
76.6220
80.1220
80.6220
81.1220
81.6220
85.1220
85.6220
86.1220
86.6220
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
90.1220
90.6221
91.1221
91.6221
95.1221
95.6221
96.1221
96.6221
100.1221
100.6221
101.1221
101.6221
105.1222
105.6222
106.1222
106.6222
110.1222
110.6222
111.1222
111.6222
9 67.1218 72.1219 77.1220 82.1220 87.1220 92.1221 97.1221 102.1221 107.1222 112.1222

12 © BSI 10-1999
 BS 978-1:1968

Table 3 — Centre distances for spur gear pairs of unit diametral pitch for the
conditions given in clause 2.2.4
z1 = 16; x1 = 0.0642
z2 10 20 30 40 50 60 70 80 90 100

0 13.4307 18.0633 23.0635 28.0636 33.0637 38.0638 43.0638 48.0639 53.0639 58.0639
1 13.8833 18.5634 23.5635 28.5636 33.5637 38.5638 43.5638 48.5639 53.5639 58.5639
2 14.3344 19.0634 24.0635 29.0636 34.0637 39.0638 44.0638 49.0639 54.0639 59.0639
3 14.7841 19.5634 24.5636 29.5636 34.5637 39.5638 44.5638 49.5639 54.5639 59.5639
4 15.2524 20.0634 25.0636 30.0657 35.0637 40.0638 45.0638 50.0639 55.0639 60.0639

5 15.6793 20.5634 25.5636 30.5637 35.5637 40.5638 45.5638 50.5639 55.5639 60.5639
6 16.1248 21.0635 26.0636 31.0637 36.0638 41.0638 46.0638 51.0639 56.0639 61.0639
7 16.5688 21.5635 26.5636 31.5637 36.5638 41.5638 46.5638 51.5639 56.5639 61.5639
8 17.0633 22.0635 27.0636 32.0637 37.0638 42.0638 47.0638 52.0639 57.0639 62.0639
9 17.5633 22.5635 27.5636 32.5637 37.5638 42.5638 47.5639 52.5639 57.5639 62.5639

z2 110 120 130 140 150 160 170 180 190 200

0 63.0639 68.0640 73.0640 78.0640 83.0640 88.0640 93.0640 98.0640 103.0640 108.0641
1 63.5639 68.5640 73.5640 78.5633 83.5640 88.5640 93.5640 98.5640 103.5640 108.5641
2 64.3639 69.0640 74.0640 79.0640 84.0640 89.0640 94.0640 99.0640 104.0640 109.0641
3 64.5640 69.5640 74.5640 79.5640 84.5640 89.5640 94.5640 99.5640 104.5640 109.5641
4 65.0640 70.0640 75.0640 80.0640 85.0640 90.0640 95.0640 100.0640 105.0640 110.0641

5
6
7
8
65.5640
66.0640
66.5640
67.0640
70.5640
71.0640
71.5640
72.0640
75.5640
76.0640
76.5640
77.0640
80.5640
81.0640
81.5640
82.0640
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
85.5640
86.0640
86.5640
87.0640
90.5640
91.0640
91.5640
92.0640
95.5640
96.0640
96.5640
97.0640
100.5640
101.0640
101.5640
102.0640
105.5640
106.0641
106.5641
107.0641
110.5641
111.0641
111.5641
112.0641
9 67.5640 72.5640 77.5640 82.5640 87.5640 92.5640 97.5640 102.5640 107.5641 112.5641

3 Accuracy of gear blanks and gears

3.1 General
The measurement of individual elemental errors in fine pitch gears is sometimes difficult and often
involves the use of equipment which may not readily be available. Furthermore, the individual limits of
tolerance may be so very minute as to render them unrealistic as inspection criteria.
The acceptance criteria of this British Standard are therefore based on dual flank composite error testing,
by which product gears are rotated in close mesh with master gears of known error, and the results given
in terms of the measured variations in centre distance appropriate to the combination of master gear and
product gear.
It is necessary, however, to appreciate that the variation in centre distance so measured, may include the
combined effects of profile, tooth thickness, adjacent pitch and tooth alignment errors but will not
necessarily be the sum of such errors. Under some circumstances, therefore, it may be necessary to control
and assess elemental errors and, for this reason, coupled with the need to provide an adequate basis for
accurate manufacture of the related hobs and cutters, the limits of tolerance for each possible contributing
source of error are also given.
Therefore, the test methods embraced within this British Standard are:
a. limits of tolerance on gear blanks (when applicable)
b. dual flank composite testing
c. assessment of elemental errors
d. combinations of b and c.

However, recognizing the development of the single flank composite testing procedure, tolerances are given
in Appendix D.

© BSI 10-1999 13
BS 978-1:1968

Additionally, pin dimensions for taking measurements over pins in respect of spur gears, are given
in Appendix E. It should be appreciated, however, that owing to radial run-out errors, the tooth thickness
measured over pins will not necessarily equate with tooth thickness at the reference circle.
The actual testing procedures to be adopted shall be the subject of agreement between purchaser and
manufacturer and requirements shall be stated clearly on drawings (see Section 5 and Figure 6) and on
purchase orders and contracts.
IMPORTANT NOTE. Generally, a pair of mating gears are of identical accuracy grade but, by agreement between purchaser and
manufacturer, finer or coarser grades may be adopted for the pinion or wheel, or for certain elements of a pinion or wheel.

3.2 Dual flank composite testing — test pressures and limits of tolerance
The product gear shall be rotated in close mesh with a calibrated master gear under just sufficient force to
ensure adequate contact whilst permitting free rotation. Forces appropriate to the pitch suitable for brass
and steel product gears are given in Table 4. The errors thus revealed shall not exceed the appropriate
limits of tolerance as prescribed in Table 5.
Table 4 — Forces appropriate to the pitch suitable for brass and
steel product gears
24 to 80 Pn over 80 to 160 Pn over 160 Pn

Master worm 8 ozf 4 ozf 2 ozf

Master wheel 16 ozf 8 ozf 4 ozf
NOTE These values may need to be reduced when checking product gears in soft materials such as
plastics or aluminium.

Table 5 — Limits of tolerance

Max. tooth to
tooth composite
10 to 19 teeth
20 to 29 teeth
Class A
in
0.0004
0.0003
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
Class B

0.0007
0.0006
in
Class C
in
0.0010
0.0009
Class D
in
0.0025
0.0023
error tolerance over 30 teeth 0.0002 0.0005 0.0009 0.0023
Max. total composite error tolerance 0.0006 0.0010 0.0016 0.0040
Max. departure from the centre
distance appropriate to this – 0.0003 – 0.0005 – 0.0005 – 0.0005
combination of master gear and
product gear when meshed with a – 0.0011 – 0.0019 – 0.0027 – 0.0060
theoretically correct master gear
Applicable to a pitch range ofa 24 to 200 Pn 24 to 160 Pn 24 to 80 Pn 24 to 40 Pn
NOTE Where for any reason it is desired to use a tooth thickness which is not that given for the Figure 1 basic rack,
the centre distance tolerance zones given above apply.
a
Finer pitches are permissible provided that the contact ratio of the gear pair is not less than 1.1.

14 © BSI 10-1999
 BS 978-1:1968

3.3 Limits of tolerance on blanks and gear elements

3.3.1 Gear blanks. Limits and tolerances on gear blanks shall be in accordance with Table 6. Where a
topping hob or cutter is used the limits on blank diameter may not apply.
Table 6 — Limits of tolerance on gear blanks
Item Class A Class B Class C Class D

Blank diameter when used

h7 of BS 1916a h7 of BS 1916a h8 of BS 1916a h9 of BS 1916a
for location
Radial runout of  in in in in
periphery (or reference 

surface) relative to datum 
when used for setting or 

measurement of teeth  0.000 2 0.000 2 0.000 3 0.000 1 da + 0.001
(FIMb) 

Axial runout at reference 

diameter (FIMb) 

Flatness of end faces
a
BS 1916, “Limits and fits for engineering”.
b
Full indicated movement.

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

Figure 5 — Tolerance zone for profile error

© BSI 10-1999 15
BS 978-1:1968

3.3.2 Profile. Limits of tolerance on tooth profile are given in Table 7. The limits given are in relation to
the design profile that coincides with the actual profile at mid working depth (see Figure 5).
Table 7 — Limits of tolerance on tooth profile
Limits of tolerance
Generally
Class Middle third of Outside middle applicable to a
third of pitch range of
working depth working depth

in in

A + 0.000 05 0 24 to 200 inc.

– 0.000 10 – 0.000 1
B + 0.000 05 0 24 to 160 inc.
– 0.000 20 – 0.000 2
C + 0.000 10 0 24 to 80 inc.
– 0.000 30 – 0.000 3
D + 0.000 10 0 24 to 40 inc.
– 0.000 70 – 0.000 7

3.3.3 Pitch. Limits of tolerance on pitch (adjacent and cumulative) are given in Table 8.
Table 8 — Limits of tolerance on pitch
Generally applicable
Class Limits of tolerance
to a pitch range of
in

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
A 0.000 2 l + 0.000 1 24 to 200 inc.
B 0.000 32 l + 0.000 16 24 to 160 inc.
C 0.000 5 l + 0.000 25 24 to 80 inc.
D 0.000 8 l + 0.000 4 24 to 40 inc.
where l = any selected length of arc, including an arc length of one pitch, but
;d .
not greater than -------
2
NOTE Limits of pitch tolerance are given with reference to the axis of
rotation.

3.3.4 Tooth alignment. The tolerances are listed in Table 9.

Table 9 — Limits of tolerance on tooth alignment
Face width
up to Class A Class B Class C Class D
Over
and inc.
in in in in in in
0.5 0.000 16 0.000 25 0.000 4 0.000 6
0.5 1 0.000 2 0.000 32 0.000 5 0.000 8
1 2 0.000 25 0.000 4 0.000 6 0.001 0
2 4 0.000 32 0.000 5 0.000 8 0.001 3

16 © BSI 10-1999
 BS 978-1:1968

3.3.5 Radial run-out of teeth. Tolerances are given in Table 10.

Table 10 — Limits of tolerance on radial run-out of teeth
Class A Class B Class C Class D

Pitch range 24 to 100 Pn over 100 24 to 100 over 100 24 to 80 24 to 40

generally inc. to 200 Pn Pn inc. to 160 Pn Pn inc. Pn inc.
applicable inc. inc.

in in in in in in

Tolerance 0.000 3 0.000 2 0.000 4 0.000 3 0.000 6 0.001 6

NOTE Where backlash is allowable the limit for radial run-out does not apply provided the pitch tolerances
are within the limits specified in 3.3.3.

3.3.6 Tooth thickness. Limits of tolerance for tooth thickness are given in Table 11.
Table 11 — Limits of tolerance on tooth thickness
Limits of tolerance Generally
Class applicable to a
Figure 1 gears Figure 2 gears pitch range of

A – 0.000 3 ± 0.000 25 24 to 200 inc.

– 0.000 6
B – 0.000 6 ± 0.000 4 24 to 160 inc.
– 0.001 0
C – 0.000 9 ± 0.000 8 24 to 80 inc.
– 0.001 6
D – 0.001 6 ± 0.001 6 24 to 40 inc.
– 0.003 0

dual flank method of composite testing is employed. ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

NOTE 1 The above tolerances should be related to those of Table 5 when the

NOTE 2 Measuring pin diameters for external and internal spur gears are
given in Appendix E.

4 Limits and tolerances of assembly

4.1 Centre distance
Limits of tolerance for centre distance of mounting shall be as given in Table 12.
Table 12 — Limits of tolerance on centre
distance of mounting
Generally
Class Limits of tolerance applicable to a
pitch range of
in in
A ± (0.000 08 a + 0.000 08) 24 to 200 inc.
B ± (0.000 16 a + 0.000 16) 24 to 160 inc.
C ± (0.000 32 a + 0.000 32) 24 to 80 inc.
D ± (0.000 6 a + 0.000 6) 24 to 40 inc.
where a is the centre distance in inches.

© BSI 10-1999 17
BS 978-1:1968

4.2 Depth of engagement

It may be found necessary, in the finer pitches of gears, to resort to graded inspection and selective
assembly in order to maintain a satisfactory minimum depth of engagement and a suitable contact ratio.
Table 13 and Table 14 give recommended minimum values for working depth, based on contact ratios not
less than 1.0 where the teeth have rounded tips or approximately 1.2 where the rounding is absent.
The larger of the two values obtained from the tables should be taken.
These data are applicable to spur gears. They will be applicable to helical or crossed helical gears if the
number of teeth in each gear is multiplied by sec3 ".
It should be noted that backlash is increased when the working depth is less than nominal, and in
circumstances in which backlash has to be limited, tolerances affecting depth of engagement are
governed by consideration of the backlash rather than by contact ratio.
Table 13 — Minimum depth of engagement for spur
gear pairs with 28 to 33 teeth (z2 + z1)
No. of teeth Sum of number
Minimum depth Minimum depth
in pinion of teeth
of engagement of engagement
(z1) (z2 + z1)
10–12 1.85/Pn 28–29 1.80/Pn
13–14 1.80/Pn 30–32 1.75/Pn
15–16 1.70/Pn 33 1.7/Pn
Table 14 — Minimum depth of engagement for
spur gear pairs with more than 33 teeth (z2 + z1)

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
No. of teeth in Sum of number
Minimum depth of teeth Minimum depth
pinion
of engagement (z2 + z1) of engagement
(z1)
8 1.8/Pn 34–59 1.70/Pn
9 1.75/Pn 40–49 1.65/Pn
10–11 1.70/Pn 50 and above 1.60/Pn
12–16 1.65/Pn
17 and above 1.60/Pn

5 Information to be given on drawings

In accordance with the requirements of BS 3084) the following is recommended as a standard form showing
essential information required on drawings for workshops and office reference (see Figure 6 which is for
illustration purposes only).
All manufacturing dimensions should be shown in the body of the drawing except those relating to gear
cutting which should be shown in a table, either at the right hand side or bottom of the drawing.
The following information should be given in the table:
Type of gear
Number of teeth
Normal diametral pitch
Basic rack tooth form
Class of gear
Reference circle diameter
Whole depth of tooth
Tooth thickness on reference circle
Hand
Lead

4)
BS 308, “Engineering drawing practice”.

18 © BSI 10-1999
 BS 978-1:1968

Helix angle at reference cylinder

Centre distance with mating gear (optional)
Drawing No. of mating gear (optional).
A table concerning inspection data and auxiliary information may also be included. When inserting
information in this table care must be exercised to avoid conflict between requirements for accuracy of
individual elements and dual flank testing requirements.

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

© BSI 10-1999 19
BS 978-1:1968

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

Figure 6 — Example of information to be given on drawings

20 © BSI 10-1999
 BS 978-1:1968

Appendix A Centre distance and addendum modification

A.1 Introduction
The centre distance of a pair of gears may have any value within certain limits since two gears generated
by similar tools with equal base pitch will mesh correctly. The working pressure angle, the pitch diameters
and the backlash will vary with change in centre distance.
By taking advantage of these features in the design and manufacture of involute gears, the pitches listed
in Table 1 will be adequate for most purposes. Gear diameters and centre distances may be varied by the
choice of a suitable value for the addendum coefficients x1 and x2 within the upper and lower limits laid
down by Figure 3.
The case where there is no addendum modification is dealt with in 2.1. In other cases the rules given apply
to gears generated from the Figure 1 basic rack tooth shape. They apply substantially to the Figure 2 basic
rack tooth shape also except where reference is made to close mesh and minimum backlash.
The chart given in Figure 3 has been prepared with the following points in mind:
1) Upper limits of addendum modification coefficient.
Too large a value will lead to an undesirably narrow crest width which should be not less
than 0.3/Pn.
If small wheels and pinions with excessively enlarged addenda are meshed together, the contact
ratio becomes too low.
2) Lower limits of addendum modification coefficient.
Where x has a smaller value than the following the gears become undercut by generation:
2
z sin !
For Figure 1 type gears x = 1.14 – ----------------------t
2 cos"

z sin !
2
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
Figure 2 type gears x = 1.066 – ----------------------t
2 cos"
The root fillets of gears extend a minimum distance from the root circle when x is slightly greater than + 1.
As x varies from this value the root fillets extend progressively further up the teeth. A limiting negative
value of x is reached when the root fillets are just clear of the path of contact during engagement.
A.2 Addendum modification coefficient x1 and x2
A.2.1 Gears at predetermined centre distance
When the centre distance is predetermined the addendum modification coefficient x1 and x2 may have any
value permitted by Figure 3 provided that x1 is within the limits imposed by equations (30) and (31).
Nominal tip diameters and tooth thicknesses are then obtained from:

(15)

(16)

Figure 1 type gears, (17)

(18)

Figure 2 type gears, (19)

© BSI 10-1999 21
BS 978-1:1968

(20)

If the centre distance modification coefficient is equal to the sum of the addendum modification coefficients
of pinion and wheel then:
d 1 + d 2
y = x1 + x2 =  a – ------------------- P (21)
 2  n

and y has a positive or negative value other than zero;

Figure 1 type external gears have backlash at nominal dimensions
Figure 1 type internal gears have interference at nominal dimensions
Figure 1 type crossed helical gears have zero backlash at nominal dimensions.
The normal backlash (or interference) obtained is given by

(22)

where j* is obtained from Figure 7.

For helical gears the normal backlash is obtained by using av in place of a in formula (22) and Figure 7,
where
av = a/cos2" (23)

NOTE For internal gears the values of a, z2 and d2 are to be regarded as negative, and x2 as negative when its sense is to enlarge
the wheel. All formulae are then applicable.
If it is desired to reduce (or increase) backlash it will be necessary to increase (or decrease) tooth thickness
by a secondary addendum modification %x1 for the pinion and %x2 for the wheel.
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
% x1 + % x 2 desired reduction in normal backlash
-------------------------- = ------------------------------------------------------------------------------------------------------- (24)
Pn 0.6840

%x1 and %x2 are then added to the initial values of x1 and x2 obtained by equations (21), (30), (31) and used
in equations (15) – (20).
In following this procedure it is necessary, if x1 + x2 have values toward the upper limits of Figure 3, to
examine the root clearance and if insufficient, to modify the outside diameter of one or both gears by
amounts;
2 %x 2 %x
---------------1 and --------------2-
Pn Pn
A.2.2 Gears having zero backlash requirement
Calculation of values of x1 + x2 (or a) for gears (other than crossed helical gears) which require zero backlash
at nominal dimensions.
Given a, to find (x1 + x2).

(25)

(26)

tan!
where tan! t = ------------- (27)
cos "

22 © BSI 10-1999
 BS 978-1:1968

Given (x1 + x2), to find a.

(28)

(29)

NOTE inv!t and inv!tw may be obtained from tables of involute functions. An involute function of an angle is the small difference
between the tangent of the angle and the value of the angle in radians.
A.3 Limiting values of x1 and x2
Where x1 and x2 have been fixed by the foregoing formulae, x1 should lie between the following values:
z1
- ( x + x2 )
Minimum x1 = ----------------- (30)
z2 + z 1 1

z1
- ( x + x 2 ) + 0.4
Maximum x1 = ----------------- (31)
z2 + z1 1

In general, most favourable action is obtained when a high value of x1 is used with the pinion driving the
wheel and a low value of x1 with the wheel driving the pinion.
Where a negative value of the sum (x1 + x2) arises the value of x2 may be below the relevant line, XX or YY,
of Figure 3 provided that the sum of minimum values of (x1 + x2) allowed by the graph is more negative
than the sum required.

Appendix B Examples of calculations ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

Example 1. External spur gears at predetermined centre distance which differs from half the sum of the
reference circles and a normal amount of backlash is permissible.
Given Required
z2 = 63 x1 and x2
z1 = 20 da2 and da1
Pn = 24
a = 1.8 in
Pinion driving
Figure 1 gears.

( 63 + 20 )
From formula (21), x1 + x2 = ( 1.8 × 24 ) – ------------------------
2
= 1.7
20
From formula (30), x1 min. = ------ × 1.7
83
= 0.41
20
From formula (31), x1 max.= ------ × 1.7 + 0.4
83
= 0.81

© BSI 10-1999 23
BS 978-1:1968

From Figure 3, x1 must not exceed 0.75. Selecting this value of 0.75 for x1 then x2 = 1.7 – 0.75

= 0.95
63 2 ( 1 + 0.95 )
From formula (16), da2 = ------ + ------------------------------
24 24
= 2.788 inches
20 2 ( 1 + 0.75 )
From formula (15), da1 = ------ + -----------------------------
24 24
= 0.979 inch
Ans: da1 = 0.979 da2 = 2.788 x1 = 0.75 x2 = 0.95

Example 2. External spur gears at predetermined centre distance and minimum backlash.
Given Required
Pn = 36 z1, z2, x1, x2
a = 2.55 s1 and s2
Ratio = 4 : 1
Pinion driving
Figure 1 gears.
Two different solutions, A and B, are given. A is derived by involute functions and B by the method
of Figure 7.
Solution A. By examination, tooth numbers which give a near approach to the required centre distance
are 36 and 144. With these tooth numbers and unmodified gears the centre distance would be:

2.5
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
From (25) cos!w = ----------- × 0.939 69 = 0.921 265
2.55
Whence !w = 22.89° and inv!w = 0.022 70 inv! = 0.014 904 and 0.022 700 — 0.014 904 = 0.007 796
0.007 796 × 180
From (26) x1 + x2 = ------------------------------------------- = 1.928
2 × 0.363 97
36
From (30) x1 (min.) = ---------- × 1.928 = 0.3856
180
36
From (31) (x1 max.) = ---------- × 1.928 + 0.4 = 0.7856, say 0.78
180
As the pinion is driving the maximum value of x1 may be taken and from Figure 3, x1 can be 0.78.
Therefore x2 = 1.928 – 0.78 = 1.148
From (17 and 18)
1.5708 + 0.7279 ( 0.78 )
s 1 = -------------------------------------------------------------- = 0.0594 inch
36
1.5708 + 0.7279 ( 1.148 )
s 2 = ----------------------------------------------------------------- = 0.0668 inch
36
Note that s2 cannot be gauged at the reference diameter, but can be used for calculation of diameter over
gauge pins.
Ans. z1 = 36, z2 = 144, x1 = 0.78, x2 = 1.148, s1 = 0.0594 in, s2 = 0.0668 inch.
Solution B. Taking alternative tooth numbers, z1 = 37 and z2 = 148, the centre distance of unmodified
z1 + z2 185
gears would be: -----------------
- = ---------- = 2.569 45 inches
2P n 72

24 © BSI 10-1999
 BS 978-1:1968

From (21) x1 + x2 = (2.55 – 2.569 45) 36 = – 0.700

From A.3, this value may be used without restriction,
37
whence from (31), x max. = ---------- ( – 0.7 ) + 0.4 = 0.26 and x2 = – 0.700 – 0.260 = – 0.960.
185
To check the amount of backlash obtained, using Figure 7
y – 0.700
------- = -------------------- = – 0.019 45
Pn 36

--------- = –
y 0.019 45
-------------------------
- = – 0.0076 whence j* = 2.63
aP n 2.55

2.63
From (22) j n = ----------- (0.019 452 ) = 0.000 39 inch.
2.55
This is an acceptably small amount and no increase in x1 or x2 is justified.
From (17) and (18)
1.5708 + 0.7279 × 0.26
s 1 = ------------------------------------------------------------- = 0.048 86 inch
36
1.5708 – 0.7279 × 0.96
s 2 = -------------------------------------------------------------- = 0.024 22 inch
36
Note that the reference circle is near the tip of the wheel and it will not be practicable to gauge s2, except
by gauge pin measurement.

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
Ans. z1 = 37, z2 = 148, x1 = 0.26, x2 = – 0.96, s1 = 0.048 86 inch, s2 = 0.024 22 inch.
Example 3. External spur gears with no limitations other than avoidance of undercutting and
backlash. (2.2.2.)
Given Required
z1 = 10 x1 and x2
z2 = 60 s1 and s2
Pn = 36 da1 and da2
a
Two solutions are available, A) and B):
A) From Table 2, x1 = 0.4151, x2 = 0,

B) x1 = 0.4150, x2 = – 0.4150
whence da1 and s1 are as obtained for solution A).

© BSI 10-1999 25
BS 978-1:1968

Ans. (A and B): x1 = 0.4150, s1 = 0.0520 inch, da1 = 0.3564 inch.

A; x2 = 0, s2 = 0.043 63 inch, da1 = 1.7222 inch, a = 0.9833 inch.
B; x2 = – 0.4150, s2 = 0.035 24 inch, da2 = 1.699 17 inch, a = 0.9722 inch.
Example 4. Helical gears at predetermined centre distance and minimum backlash.
Given Required
z1 = 22 da1
z2 = 67 da2
Pn = 40 x1
" = 18° x2
a = 1.1562
Pinion driving
Figure 1 type gears.
(Solution using involute functions)

Obtain, sec" = 1.051 46

sec3" = 1.162
tan! = 0.363 97
cos! = 0.939 69

From (1) and (2) × 1.051 46- = 0.5783

d 1 = 22
-----------------------------------
40
67 × 1.051 46

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
d 2 = ----------------------------------- = 1.7612
40

From (27) Tan!t = 0.363 97 × 1.051 46 = 0.3827

whence !t = 20.942°
cos!t = 0.933 94
inv!t = 0.017 196
From (25)
( 1.7612 + 0.5783 ) 0.933 94
Cos!tw = ------------------------------------------------------------------------- = 0.944 84
2 × 1.1562
!tw= 19.119°
inv!tw= 0.012 963
( 0.012 963 – 0.017 196 ) ( 67 + 22 )
From (26) x1 + x2 = ------------------------------------------------------------------------------------------- = – 0.517 54
2 × 0.363 97
From (30)
22
x1 (min.) = -------------------- ( – 0.517 54 ) = – 0.1279
22 + 67
x2 (max.) = – 0.517 54 + 0.1279 = – 0.3896
From (31)
x1 (max.) = – 0.1279 + 0.4 = 0.2721
x2 (min.) = – 0.517 54 – 0.2721 = – 0.789 64
To find the range of values of x1 and x2 which are permissible find zv1 and zv2, i.e. from (7)
zv1 = 22 × 1.162 = 25.6
zv2 = 67 × 1.162 = 78
From Figure 3 we chose the value – 0.48 for x2 leaving x1 = – 0.517 54 + 0.48 = – 0.0375.
From (15) and (16)

26 © BSI 10-1999
 BS 978-1:1968

2 ( 1 – 0.0375 )
da1 = 0.5783 + -------------------------------------- = 0.6264 inch
40
2 ( 1 – 0.48 )
da2 = 1.7612 + ------------------------------- = 1.7872 inch.
40
Ans. x1 = – 0.0375, x2 = – 0.48, da1 = 0.6264 inch, da2 = 1.7872 inches.

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ

© BSI 10-1999 27
28

BS 978-1:1968
ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
© BSI 10-1999

Figure 7 — Chart for normal backlash when x1 + x2 = y

 BS 978-1:1968

Appendix C Comparable diametral pitches and metric modules

Diametral pitch Module

in mm

24 1.058
28 0.907
32 0.794

36 0.706
40 0.635
48 0.529
64 0.397
80 0.318
100 0.254

120 0.212
140 0.181
160 0.159

180 0.141
200 0.127

Appendix D Single flank composite testing: limits of tolerance

ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ
When single flank testing is applied, the limits of tolerance are derived as follows:
1) Tooth-to-tooth composite error. For all grades, the tolerance is derived from: single pitch tolerance +
tooth profile tolerance.
2) Total composite error. For all grades, the tolerance is derived from: maximum cumulative pitch
tolerance + tooth profile tolerance; where the maximum cumulative pitch tolerance is derived from the
value of l = ;d/2.
The values derived represent errors in angular transmission when a product gear is rotated in mesh with
a calibrated master gear under similar conditions to those prescribed in 3.1.

Appendix E Calculation of measuring pin dimensions for external and internal

spur gears
In order to overcome the difficulty of resetting on the gear-cutting machine gears which are found to be
outside dual flank tolerances in respect of size, it is necessary either to carry out dual flank testing on the
machine or to adopt other methods of test at that stage of manufacture. The former method is used only in
exceptional cases, whilst the practice of measurement over pins is a practical method for this purpose
although insufficient in itself to dispose of the final dual flank test.
For external and internal spur gears the measuring pin diameter dR should be calculated from the
following formulae. Further information on measurement of pins is given in B.R.6001 (1) “Precision
gearing for control systems and armaments”*.
For external gears of 7 to 17 teeth with positive addendum modification:
1.92
d R = -----------
Pn

1.728
For external gears: d R = ------------
Pn
-

1.44
For internal gears: d R = ---------
Pn
-

© BSI 10-1999 29
BS 978-1:1968

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