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Gear base pitch is the spacing of successive involute tooth profiles referred to the gear base circle. For base diameter $d_b$, tooth count $N$, gear module $m$ and reference gear pressure angle $\alpha$,It also gives the spacing between successive corresponding tooth contacts measured along the gear line of action. The gear circular pitch uses the reference circle instead, giving $p=\pi m$ and $p_b=p\cos \alpha$.^[ref]

For $m=2\mathrm{mm}$ and $\alpha =20{}^{\circ }$, $p=6.2832\mathrm{mm}$ but $p_b\approx 5.9043\mathrm{mm}$. A second gear with the same module but $25{}^{\circ }$ reference angle has $p_b\approx 5.6945\mathrm{mm}$. Matching reference tooth spacing alone therefore does not make these the same specified mating geometry.

Changing the mounting separation of a compatible involute pair does not change its cut profiles, base circles or gear base pitch. In operating-circle notation, $p_w=2\pi r_w/N$ changes with mounted radius, whilestays fixed. This links the mounted operating pressure angle to an invariant tooth-profile spacing.

For a tooth rotating at angular speed $\omega$, base-circle tangential speed is $r_b|\omega |$. Dividing by gear base pitch gives the gear mesh frequency,A 30-tooth gear at $600$ revolutions per minute gives $f_m=300\mathrm{Hz}$. Finally, the gear contact ratio divides usable gear path of contact length by this base pitch, so profile spacing and available contact length jointly determine overlap between successive tooth engagements.

Gear contact duration is the time for a specified tooth pair to traverse its active gear path of contact. For a fixed-axis external spur gear pair at constant speed, the contact location advances along the gear line of action at the common gear base-roll speedThis is the speed of the contact location along a geometric line, not the relative tooth-surface gear sliding velocity. The latter vanishes at the gear pitch point, while the contact location continues moving. For active path length $L$, duration is $T=L/u_b$. The geometry relates gear contact ratio to active path length divided by gear base pitch.^[ref]

The time between successive tooth-pair entries is $1/f_m$, with gear mesh frequency $f_m=N_1|{\omega }_1|/(2\pi )$. Since $r_{b1}=r_{w1}\cos {\alpha }_w$ for compatible operating geometry, the base-circle distance advanced per entry isConsequentlyA contact ratio above1 means one pair remains engaged after the next pair enters; it does not mean one pair contacts for an entire shaft revolution.

For the standard module2,20/40-tooth example with20degree reference angle, active length is9.65457mm and base pitch is5.90426mm. At driving angular velocity $50rad/s$, $u_b=0.93969m/s$, $f_m\approx 159.155\mathrm{Hz}$ and $T\approx 10.2742\mathrm{ms}$. The entry interval is6.28319ms, giving $T{f}_m\approx 1.63519$. Doubling both shaft speeds halves duration while preserving geometric gear contact ratio. Variable speed requires integrating the changing base-roll speed; a helical gear also needs a stated transverse slice or a whole-face contact convention.

Gear friction work per engagement is the mechanical energy dissipated by sliding during one tooth pair's active engagement. It is the time integral of that pair's gear sliding-friction loss:The result has units of joules, whereas instantaneous loss has units of watts. It excludes other gearbox losses such as support friction. Manufacturer efficiency guidance distinguishes meshing and support losses and emphasizes their dependence on operating conditions.^[ref]

For a fixed-axis external spur gear pair, let signed contact coordinate $s$ run from $-L_a$ to $L_r$ through the gear pitch point. Gear sliding velocity has magnitude $(|{\omega }_1|+|{\omega }_2|)|s|$. At constant shaft speeds, gear base-roll speed gives $ds/dt=u_b>0$ in this chosen direction. If $\mu$ and the force carried by this pair are constant,With hypothetical $\mu =0.05$, $F_n=100\mathrm{N}$, angular-speed sum75rad/s, $L_a=5.0586\mathrm{mm}$, $L_r=4.5960\mathrm{mm}$ and $u_b=0.93969m/s$, this gives about9.32mJ. Doubling both shaft speeds doubles instantaneous power but halves gear contact duration, leaving this idealized work per engagement unchanged. Real friction and load can themselves change with speed.

Gear tooth load sharing is essential when several pairs engage simultaneously. A constant total mesh load is not a constant full load on each active pair. If identical pair events recur at gear mesh frequency $f_m$, averaging their correctly modeled losses over many events gives $\overline{P}=f_m{E}_f$. The event's force history must already include load sharing; assigning the whole mesh load independently to every overlapping pair would overcount transmitted load and loss.

Gear mesh frequency is the rate at which successive teeth pass through a mesh. For a fixed-axis gear with $N$ teeth rotating at $f_{\mathrm{rot}}$ revolutions per second,where $n$ is speed in revolutions per minute and $\omega$ is angular velocity in radians per second. The formula follows by counting $N$ tooth passages per complete turn. Both gears of one steady compatible mesh give the same result because their tooth-passage rates agree.^[ref]

For an original example, a24-tooth input rotating at1500 revolutions per minute gives $f_m=600\mathrm{Hz}$. Its60-tooth mate turns at600 revolutions per minute, also giving $60(600)/60=600\mathrm{Hz}$. The shaft rotation frequencies differ even though the mesh frequency agrees.

A compound gear train can have different mesh frequencies at successive stages. If that60-tooth gear is rigidly joined to a20-tooth gear driving an80-tooth output, the second mesh frequency is $20(600)/60=200\mathrm{Hz}$. The final output turns at150 revolutions per minute. By contrast, every mesh of an ideal fixed-axis simple gear train shares the same tooth-passage frequency: its intermediate gear engages both neighbors with the same tooth count and rotation rate.

A gear vibration spectrum may contain components at the mesh frequency and its integer multiples, together with other mechanical excitations. Measuring rotation with a rotary encoder lets a test compare observed frequency components with tooth-passage predictions. A spectral peak near $f_m$ does not by itself establish a structural natural frequency or identify a particular defect; the forcing and the system's frequency response both shape measured vibration.^[ref] For trains with moving gear axes, the simple fixed-axis formula requires the appropriate relative rotational rate rather than an unqualified absolute shaft speed.

Gear surface pitting is local loss of tooth-flank material associated with repeated contact loading and mechanical fatigue. The pits alter the surface geometry and can produce debris in the lubricant. This failure mode concerns the loaded flank; it must be distinguished from a tooth breaking through its section. Hertzian contact provides a basic elastic contact-stress model, while actual fatigue depends on the material, lubrication, load history and surface condition.^[ref]

A practical inspection can record a gear pitting area fraction $\varphi =A_{\mathrm{pit}}/A_{\mathrm{inspected}}$, provided the inspected flank region and image scale are fixed. An original example with0.80mm² of projected pit area in a40mm² inspected region gives $\varphi =0.02$, or2%. The same fraction in a smaller region need not represent the same damaged volume or depth. Consistent illumination and a stated area convention are needed before comparing successive inspections.

A2009 NASA study provides a motivating experiment. It analyzed24 sets of tapered involute spur pinions meshing with face gears in an endurance program. Vibration measurements were compared with an in-line oil-debris sensor whose coils detected passing metallic particles. Repeated inspections connected the signals to actual tooth-surface damage. The paper found debris responses for the pitting failures, while vibration indicators differed in their ability to detect different damage patterns.^[ref]

The experiment illustrates why one spectral amplitude is insufficient to identify pitting. The damaged geometry, its position among the teeth and the transmission path all affect a gear vibration spectrum. Combining repeated surface inspection with vibration and debris measurements tests a damage interpretation more directly than labeling every rise at gear mesh frequency as a pitting event.

Gear vibration order expresses the frequency of a measured vibration component relative to a specified shaft's rotation rate:Here $f$ is frequency in hertz and $n$ is shaft speed in revolutions per minute. The dimensionless order is cycles per shaft revolution. It must name the reference shaft: the same gear mesh frequency has different orders relative to the two gears in one mesh. Order tracking follows such rotation-related components as speed changes.^[ref]

For a24-tooth input at1500 revolutions per minute, $f_r=25\mathrm{Hz}$ and mesh frequency is600Hz, so mesh order is24. Its60-tooth mate turns at10Hz, giving mesh order60 relative to that shaft. If the input rises to1800 revolutions per minute, mesh frequency becomes720Hz but input-relative mesh order remains24. An unrelated structural natural frequency at600Hz would instead move from order24 to order20 as reference speed increases.

Angular resampling makes the distinction explicit. Let $\theta (t)=2\pi {\int }_0^t{f}_r(u)du$ be shaft angle. A tooth-periodic illustrative signal $a(t)=A\cos [N\theta (t)]$ can spread across many fixed-frequency bins during acceleration, while as a function of angle it remains $a(\theta )=A\cos (N\theta )$, with order $N$. Enough angle samples are needed to resolve the desired tooth-related oscillations. This derivation describes the resampling approach; not every order tracking algorithm uses that implementation.

Rotation-synchronous amplitude modulation can produce neighboring modulation sidebands: a24th-order component modulated once per input revolution has orders23 and25. Modulation associated with another shaft need not give integer spacing in the chosen reference. Orders identify kinematic relationships, while amplitudes still depend on loads, mounting and frequency response. A high mesh order or a sideband is therefore not itself a diagnosis of damaged teeth.^[ref]

A gear vibration spectrum describes how a measured gearbox motion signal is distributed over frequency. An accelerometer on a housing supplies a response spectrum; a rotary encoder supplies a rotation reference. Gear mesh frequency predicts tooth-passage components, but their observed amplitudes also depend on applied loads, sensor direction and the mechanical frequency response. A response peak alone therefore does not identify a structural natural frequency.^[ref]

For an original example, a24-tooth gear at1500 revolutions per minute rotates at $f_r=25\mathrm{Hz}$ and has mesh frequency $f_m=600\mathrm{Hz}$. Consider an illustrative acceleration signal with amplitude modulation:The product-to-sum identity gives a600Hz component of amplitude $A$ and modulation sidebands at575 and625Hz, each of amplitude $\mu A/2$. For $A=1m/{\mathrm{s}}^2$ and $\mu =0.20$, each sideband has peak amplitude $0.10m/{\mathrm{s}}^2$. Gear vibration order expresses these frequencies relative to the chosen shaft: the central order is24 and the neighboring orders23 and25. These positions follow from the constructed signal, without requiring a damaged tooth.

A primary apparatus example makes that ambiguity concrete. NASA's2015 transmission experiment compared rotating accelerometers on a pinion shaft with stationary housing sensors. The rotating radial channel showed sidebands at1854 and2060Hz around a1957Hz mesh frequency, spaced by the103Hz shaft rate. The report derives this shift from the rotating measurement direction and discusses sums and differences of tangential channels. A measurement-frame effect can therefore create sidebands as well as a mechanical defect.^[ref]

A useful test records speed, load, mounting and sensor orientation with each spectrum. If speed changes appreciably within one record, fixed-frequency lines can spread; comparisons should then account for the changing rotation rate. Record duration also controls Fourier frequency resolution. Sideband changes are evidence to interpret alongside a baseline and the test conditions, rather than a unique diagnosis from one spectral peak.

A rotational order expresses a signal’s frequency relative to a specified reference shaft’s rotational frequency:Thus $q=1$ means one oscillation per reference revolution and $q=1/2$ means one oscillation per two reference revolutions. A rotational order is dimensionless and need not be an integer. It is especially useful when a machine changes speed: a shaft-synchronous feature can keep the same rotational order while moving through many frequencies in an ordinary frequency spectrum.^[ref]

The reference is essential. Suppose shaft A turns at $600\mathrm{rpm}=10\mathrm{Hz}$ and shaft B at $1500\mathrm{rpm}=25\mathrm{Hz}$. The same $100\mathrm{Hz}$ signal has rotational order $10$ relative to A and $4$ relative to B. Changing the reference has changed the dimensionless label, not the measured vibration. Likewise, a 24-tooth gear turning at $900\mathrm{rpm}$ has a gear mesh frequency of $24\times 15=360\mathrm{Hz}$. Its mating 8-tooth gear turns at $2700\mathrm{rpm}$, giving the same gear mesh frequency but rotational orders $24$ and $8$ relative to the two shafts.

For a component with unwrapped phase $\varphi (t)$ and reference angle $\theta (t)$, the instantaneous version iswhere the reference angular velocity is nonzero and both angles use the same units. A constant rotational order gives $\varphi (t)=q\theta (t)+{\varphi }_0$. This explains why angular resampling makes a speed-following component periodic as a function of shaft angle. A vibration fixed at $100\mathrm{Hz}$ instead changes from rotational order $10$ to $5$ when the reference shaft accelerates from $600$ to $1200\mathrm{rpm}$.

An order tracking measurement therefore pairs a vibration sensor, such as an accelerometer, with a shaft-angle or speed reference, such as a tachometer. An order peak identifies a speed relationship; it does not by itself establish which part is damaged. A resonance can greatly change the amplitude as speed changes even when the excitation’s rotational order stays fixed.