Analysis on inverse method for design parameters of involute spur gears with unilateral tooth profile wear
LI Xueyi
WU Zongkun
NIU Xingwang
ZHANG Zhenhang
YANG Tong
Abstract：[Objective]The failure of transmission gears in imported and aged equipment due to tooth flank wear often leads to premature scrapping of the entire machine,as original design data is frequently unavailable for repair or replacement.To address this issue,a method for reverse-engineering the design parameters of involute spur gears with unilateral tooth flank wear based on visual inspection was proposed.[Methods]Firstly,a high-precision visual inspection system was used to obtain the end face tooth profile images of the gear.Based on the principle of the gear structure,the tooth profile feature point sequences were effectively extracted and segmented.Then,the geometric characteristics of the involute tooth flank were utilized to accurately identify the worn tooth flank,which was then reconstructed using the standard tooth flank from the unworn side to obtain the original design tooth flank.Finally,the design parameters of the gear were solved by using the structural dimensions of the reconstructed involute spur gear tooth profile.[Results]The test results show that the gear modulus and pressure angle obtained by the proposed method are consistent with the theoretical values,and the absolute errors of the profile shift coefficient and other basic parameters are all less than 0.035 mm,meeting the requirements of manufacturing precision.In addition,the proposed method has the advantages of non-contact,simple operation,stable detection results,and being less affected by the degree of gear wear.
Keywords：Worn gearFeature extractionTooth flank reconstructionParameter inversion
Publication Date：2026-03-15
Online Publishing Date：2026-09-12(First online date of this platform, not the publication date of the document)
Pages：8( 53-60 )