KISSsoft 03/2012 Tutorial 8

Verifying a cylindrical gear pair

KISSsoft AG
Uetzikon 4
8634 Hombrechtikon
Switzerland

Tel: +41 55 254 20 50
Fax: +41 55 254 20 51
info@KISSsoft.AG
www.KISSsoft.AG
27.03.2012 2 / 19
Contents
1 Task ......................................................................................................................................................... 3
1.1 Input data ........................................................................................................................................ 3
1.1.1 Power data ................................................................................................................................. 3
1.1.2 Geometry .................................................................................................................................... 3
1.1.3 Reference profile ........................................................................................................................ 3
1.1.4 Additional data ............................................................................................................................ 3
2 Solution .................................................................................................................................................... 5
2.1 Starting the software ....................................................................................................................... 5
2.2 Selecting a calculation .................................................................................................................... 5
2.3 Gear Pair Geometry ....................................................................................................................... 6
2.4 Defining the power data and calculation method ............................................................................ 7
2.5 Material and lubrication .................................................................................................................. 8
2.6 Reference profile ............................................................................................................................ 9
2.7 Tolerances ...................................................................................................................................... 9
2.8 Lubrication .................................................................................................................................... 10
2.9 Calculate ....................................................................................................................................... 11
2.10 Report ........................................................................................................................................... 12

























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1 Task
This tutorial explains how to input data you already know for cylindrical gear pairs in the KISSsoft system.

You must therefore perform the following steps for an existing cylindrical gear pair:

Input the necessary data in KISSsoft
Analyze it according to DIN 3990
Document the results

1.1 Input data
The method you use to input the following data is described at the end of section 0 in this tutorial:
1.1.1 Power data
Power [P] 3.5 kW
Speed [n] at drive 2500 1/min (Gear1 driving)
Application factor [K
A
] 1.35
Service life [H] 750 h
1.1.2 Geometry
Normal module [m
n
] 1.5 mm
Helix angle at reference circle [] 25
Pressure angle at normal section [
n
] 20
Number of teeth [z] Gear1/Gear2 16 / 43
Face width [b] Gear1/Gear2 14 / 14.5 mm
Center distance [a] 48.9 0.03 mm
Profile shift coefficient [x] Gear 1 (pinion) 0.3215
1.1.3 Reference profile
Dedendum coefficient [h*
FP
] Root radius coefficient [*
fP
] Addendum coefficient [h*
aP
]
Gear 1 (pinion) 1.25 0.3 1.0
Gear 2 1.25 0.3 1.0
1.1.4 Additional data
Material:

Material Hardness data Flim Hlim
Gear 1 (pinion) 15 CrNi 6 case-hardened HRC 60 430 N/mm
2
1500 N/mm
2

Gear 2 15 CrNi 6 case-hardened HRC 60 430 N/mm
2
1500 N/mm
2


Lubrication:

Grease lubrication Microlube GB 00 80 C




27.03.2012 4 / 19
Base tangent length allowances:

No. of teeth spanned [k] Max. base tangent length
[Wkmax]
Min. base tangent length [Wkmin]
Gear 1 (pinion) 3 11.782 mm 11.758 mm
Gear 2 6 25.214 mm 25.183 mm

Quality [Q] (DIN 3961) 8 / 8
Tooth trace modification End relief
Contact pattern not verified or inappropriate
Type of pinion shaft
ISO 6336 Figure 13a;l =53 mm; s =5.9 mm; dsh =14 mm


























Load case for the pinion shaft
27.03.2012 5 / 19
2 Solution
2.1 Starting the software
You can call KISSsoft as soon as the software has been installed and activated. Usually you start the
program by clicking "StartProgram FilesKISSsoft 03-2012KISSsoft". This opens the following
KISSsoft user interface:








Figure 1. Starting KISSsoft, initial window

2.2 Selecting a calculation
In the Modules tree window, select the " Modules" tab to call the calculation for cylindrical gear pairs:


Figure 2. Calling the cylindrical gear calculation










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The KISSsoft input window then opens:


Figure 3. KISSsoft Cylindrical gear calculation input window
The following sections describe how to input parameters for the gear pair.

2.3 Gear Pair Geometry
Input the normal module (1.5 mm), pressure angle (20), helix angle (25), center distance (48.9 mm),
number of teeth (16/43), tooth widths (14/14.5 mm), profile shift coefficient (0.3215/...) and the quality (8/8)
in the input window in the " Basic data" tab; "Geometry" group. You cannot input a value for the profile shift
of gear 2 directly because this value is calculated from the center distance and profile shift of the first gear.

However, you can click the Sizing button to size the value to match your requirements. You can set the
quality to suit you, no matter which calculation method is in use.



Figure 4. Module-specific settings. Quality does not depend on calculation method.
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Figure 5. Input window "Basic data" tab, "Geometry" group
Click the Convert button to the right of the input fields to enter additional data for each field, or to input
other data for these particular values. If you need to input an angle, right-click in the input field to open
another window in which you can enter the angle, minutes and seconds:


Figure 6. Additional entries, normal module, angle
2.4 Defining the power data and calculation method
Now, go to the input window in the " Rating" tab, group "Strength" and input the kinematics, the required
service life (750 h) and the application factor (1.35). In this example, the torque is defined by inputting the
power (3.5 kW) and speed (2500 1/min). However, in a different example, if you want to input the torque
and calculate the power, simply set the " Selection" button to the right of the input field from torque to
power. Under Details you can now input even more parameters about strength.

It is also important that you set the reference gear correctly (first gear - gear 1) for the load.
Input the calculation method in the drop-down list you see on the top left. In this case, you must also switch
to DIN 3990 method B.


Figure 7. Input window "Basic data" tab, group: Strength

In the input window in the " Factors" tab, group Face load factor/contact analysis, you can input face load
factor K
H
either directly (by setting the flag in the checkbox) or define it by clicking the Plus button next
to the input field.



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Figure 8. Define the face load factor
To calculate the load coefficients, you must enter:
The tooth trace modification (in this case Figure 9).
Possible shaft configurations. To do this, click the Info button to the right of the " Type of pinion shaft"
field in the " Info window". See the selection on the right-hand side of the next figure. This example
corresponds to Figure A in Figure 9. You can then input the distances l and s as soon as the flag is set in
the checkbox to the right of the corresponding input fields.

You must also select the Position of contact pattern, which is not verified, from the appropriate drop-down
list.


Figure 9. Define face load factor

Note:
You need the shaft configuration to calculate face load factor K
H
. ISO 6336 (or DIN 3990) provides 5
different configurations from which you can select the one you require. These examples are listed A to E in
the figure at the top, on the right.
Face load factor K
H
shows the non-linear distribution of the load across the face width. You can request
special instructions from KISSsoft AG about this: see document: "KISSSOFT-anl-072-e.-Contact analysis-
Cylindrical gear calculation.pdf".
2.5 Material and lubrication
In the " Basic data" tab, "Material and lubrication" group input window you select the gear materials from a
drop-down list. 15 Cr Ni 6, case-carburized steel is used in this example.
You can also select the lubrication as well as the lubrication type.


Figure 10. Input window "Basic data" tab, "Material and Lubrication" group
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Click the Plus button on the far bottom right to define the lubricant temperature.



2.6 Reference profile
In the " Reference profile" tab you can now input further data, such as the reference profile, the dedendum
coefficient, the root radius factor and the addendum coefficient for Gear 1 and Gear 2.


Figure 11. Input window "Reference profile" tab
2.7 Tolerances
You define the tooth thickness deviation in the " Tolerances" tab. In a verification example, it is often the
case that only the effective tolerances of base tangent length and the number of teeth spanned are
specified. If you input these values, the KISSsoft system will then calculate the correct tooth thickness
tolerances for the tooth form.

In this case, you can also input the center distance tolerances either by selecting them from the drop-down
list or by inputting your own values as shown in the example.


Figure 12. Input window "Tolerances" tab
To input the base tangent lengths, click the " Tolerances" tab, "Deviation" group, and then click the Sizing
button next to the tooth thickness deviation input window (middle markings).
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Figure 13. Calculating the base tangent lengths
You can now input the number of teeth spanned and the base tangent length (min/max). Then click
Calculate . Then click " Accept" to transfer the values to the main screen.

Attention: You cannot input a deviation until profile shifts have been specified for both gears. Otherwise you
will receive incorrect values and you must repeat the sizing process.

Note: You can change the number of teeth spanned between steps 2 and 3. To do this, set the flag in the
checkbox next to the "Number of teeth spanned" field in the input window in the "Settings" group in the
" Tolerances" tab and then change the Number of teeth spanned either in the "Settings" group or in the
calculation screen.


Figure 14. Input window "Tolerances" tab, "Settings" group

2.8 Lubrication
The input window in the "Material and lubrication" group in the " Basic data" tab is only designed to hold the
input value for lubricant temperature for the various types of lubricant that can be used. You can select
other lubrication types and grease types in the appropriate drop-down list when you input the temperature
as a numerical value.

The " Lubricant temperature" input field for oil or grease lubrication defines the basic temperature of the
gear body. For this reason, the " Lubricant temperature" is also important for calculating the effective
lubricant viscosity. The " Ambient temperature" does not affect the calculation (see also 2.5 Material and
lubrication).

The " Ambient temperature" field only defines the base temperature during a dry run. In this case, the
temperature of the gear body does influence the calculation.

Exceptions:
Worm gears: the " Ambient temperature" is an input value used to calculate the temperature
safety coefficient.
Plastic gears: as the strength values of plastic gears depend greatly on the temperature of the gear
body you must input the corresponding temperatures here.
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Figure 15. Inputting the temperature for a dry run


Figure 16. Inputting the temperature for grease lubrication

2.9 Calculate
Click in the tool bar or press "F5" to calculate the strength results. As the proof of the contact pattern is
missing, this message appears to tell you the K
H
value is too high.


Figure 17. Information window after "Calculation"

This means that the calculation for the value K
H
was performed with an unrealistic contact pattern. When
you test the contact pattern in the workshop, you can see whether this assumption was conservative or
realistic.

If you have worked through this tutorial correctly, the highlighted strength values should match Figure 18:

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Figure 18. End result of tutorial

2.10 Report


________________________________KI SSsof t - Rel ease 03- 2012_____________________________
KI SSsof t Cal cul at i on pr ogr ams f or machi ne desi gn

_________________________________________Dat ei ________________________________________
Name : Tut or i al - 008
Descr i pt i on: KI SSsof t Tut or i al
Changed by : sms on: 22. 02. 2012 at : 16: 31: 15


Important hint: At least one warning has occurred during the calculation:
1- > I ndi cat i on:
Wi t h t he set t i ng ' Posi t i on of t he cont act pat t er n: unf avor abl e'
unr eal i st i c hi gh f ace l oad coef f i ci ent KHb i s gi ven f or gear s wi t h t oot h t r ace modi f i cat i ons.

CALCULATION OF A HELICAL GEAR PAIR

Dr awi ng or ar t i cl e number :
Gear 1: 0. 000. 0
Gear 2: 0. 000. 0

Cal cul at i on met hod DI N 3990: 1987 Met hod B

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -

Power ( kW) [ P] 3. 500
Speed ( 1/ mi n) [ n] 2500. 0 930. 2
Tor que ( Nm) [ T] 13. 4 35. 9
Appl i cat i on f act or [ KA] 1. 35
Power di st r i but i on f act or [ Kgam] 1. 00
Requi r ed ser vi ce l i f e [ H] 750. 00
Gear dr i vi ng ( +) / dr i ven ( - ) + -





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1. TOOTH GEOMETRY AND MATERIAL

( geomet r y cal cul at i on accor di ng t o
I SO 21771: 2007)
- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Cent er di st ance ( mm) [ a] 48. 900
Cent r e di st ance al l owances ( mm) [ Aa. e/ i ] 0. 030 / - 0. 030
Nor mal modul e ( mm) [ mn] 1. 5000
Pr essur e angl e at nor mal sect i on ( ) [ al f n] 20. 0000
Hel i x angl e at r ef er ence ci r cl e ( ) [ bet a] 25. 0000
Number of t eet h [ z] 16 43
Facewi dt h ( mm) [ b] 14. 00 14. 50
Hand of gear r i ght l ef t
Accur acy gr ade [ Q- DI N 3961: 1978] 8 8
I nner di amet er ( mm) [ di ] 0. 00 0. 00
I nner di amet er of gear r i m( mm) [ dbi ] 0. 00 0. 00

Mat er i al
Gear 1: 15 Cr Ni 6, Case- car bur i zed st eel , case- har dened
I SO 6336- 5 Fi gur e 9/ 10 ( MQ) , cor e st r engt h >=25HRC J omi ny
J =12mm<HRC28
Gear 2: 15 Cr Ni 6, Case- car bur i zed st eel , case- har dened
I SO 6336- 5 Fi gur e 9/ 10 ( MQ) , cor e st r engt h >=25HRC J omi ny
J =12mm<HRC28

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Sur f ace har dness HRC 60 HRC 60
Fat i gue st r engt h. t oot h r oot st r ess ( N/ mm )
[ si gFl i m] 430. 00 430. 00
Fat i gue st r engt h f or Her t zi an pr essur e ( N/ mm )
[ si gHl i m] 1500. 00 1500. 00
Tensi l e st r engt h ( N/ mm ) [ Rm] 1000. 00 1000. 00
Yi el d poi nt ( N/ mm ) [ Rp] 685. 00 685. 00
Young' s modul us ( N/ mm ) [ E] 206000 206000
Poi sson' s r at i o [ ny] 0. 300 0. 300
Mean r oughness, Ra, t oot h f l ank ( m) [ RAH] 0. 60 0. 60
Mean r oughness hei ght , Rz, f l ank ( m) [ RZH] 4. 80 4. 80
Mean r oughness hei ght , Rz, r oot ( m) [ RZF] 20. 00 20. 00

Tool or r ef er ence pr of i l e of gear 1 :
Ref er ence pr of i l e 1. 25 / 0. 30 / 1. 0 I SO 53. 2: 1997 Pr of i l B
Addendumcoef f i ci ent [ haP*] 1. 000
Dedendumcoef f i ci ent [ hf P*] 1. 250
Ti p r adi us f act or [ r hoaP*] 0. 000
Root r adi us f act or [ r hof P*] 0. 300
Ti p f or mhei ght coef f i ci ent [ hFaP*] 0. 000
Pr ot uber ance hei ght f act or [ hpr P*] 0. 000
Pr ot uber ance angl e [ al f pr P] 0. 000
Ramp angl e [ al f KP] 0. 000
not t oppi ng

Tool or r ef er ence pr of i l e of gear 2 :
Ref er ence pr of i l e 1. 25 / 0. 30 / 1. 0 I SO 53. 2: 1997 Pr of i l B
Addendumcoef f i ci ent [ haP*] 1. 000
Dedendumcoef f i ci ent [ hf P*] 1. 250
Ti p r adi us f act or [ r hoaP*] 0. 000
Root r adi us f act or [ r hof P*] 0. 300
Ti p f or mhei ght coef f i ci ent [ hFaP*] 0. 000
Pr ot uber ance hei ght f act or [ hpr P*] 0. 000
Pr ot uber ance angl e [ al f pr P] 0. 000
Ramp angl e [ al f KP] 0. 000
not t oppi ng

Summar y of r ef er ence pr of i l e gear s:
Dedendumr ef er ence pr of i l e ( modul e) [ hf P*] 1. 250 1. 250
Toot h r oot r adi us Ref er . pr of i l e ( modul e)
[ r of P*] 0. 300 0. 300
AddendumRef er ence pr of i l e ( modul e) [ haP*] 1. 000 1. 000
Pr ot uber ance hei ght f act or ( modul e) [ hpr P*] 0. 000 0. 000
Pr ot uber ance angl e ( ) [ al f pr P] 0. 000 0. 000
Ti p f or mhei ght coef f i ci ent ( modul e) [ hFaP*] 0. 000 0. 000
Ramp angl e ( ) [ al f KP] 0. 000 0. 000
Dat a f or Gr i ndi ng / Honi ng:
Dept h of i mmer si on ( modul e) [ hgr i nd*] 1. 118 1. 118
Radi us at cut t er head ( modul e) [ r gr i nd*] 0. 100 0. 100


27.03.2012 14 / 19
Type of pr of i l e modi f i cat i on:
none ( onl y r unni ng- i n)
Ti p r el i ef ( m) [ Ca] 2. 0 2. 0

Lubr i cat i on t ype Gr ease l ubr i cat i on
Type of gr ease Gr ease: Mi cr ol ube GB 00
Lubr i cant base Mi ner al - oi l base
Ki nem. vi scosi t y base oi l at 40 C ( mm / s) [ nu40] 700. 00
Ki nem. vi scosi t y base oi l at 100 C ( mm / s) [ nu100] 35. 00
FZG- Test A/ 8. 3/ 90 st ep [ FZGt est A] 12
Speci f i c densi t y at 15 C ( kg/ dm ) [ r oOi l ] 0. 900
Gr ease t emper at ur e ( C) [ TS] 80. 000

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Over al l t r ansmi ssi on r at i o [ i t ot ] - 2. 688
Gear r at i o [ u] 2. 688
Tr ansver se modul e ( mm) [ mt ] 1. 655
Pr essur e angl e at pi t ch ci r cl e ( ) [ al f t ] 21. 880
Wor ki ng t r ansver se pr essur e angl e ( ) [ al f wt ] 22. 100
[ al f wt . e/ i ] 22. 186 / 22. 013
Wor ki ng pr essur e angl e at nor mal sect i on ( ) [ al f wn] 20. 199
Hel i x angl e at oper at i ng pi t ch ci r cl e ( )
[ bet aw] 25. 034
Base hel i x angl e ( ) [ bet ab] 23. 399
Ref er ence cent r e di st ance ( mm) [ ad] 48. 824
Sumof pr of i l e shi f t coef f i ci ent s [ Summexi ] 0. 0506
Pr of i l e shi f t coef f i ci ent [ x] 0. 3215 - 0. 2709
Toot h t hi ckness ( Ar c) ( modul e) [ sn*] 1. 8048 1. 3736

Ti p al t er at i on ( mm) [ k*mn] 0. 000 0. 000
Ref er ence di amet er ( mm) [ d] 26. 481 71. 168
Base di amet er ( mm) [ db] 24. 573 66. 041
Ti p di amet er ( mm) [ da] 30. 446 73. 355
( mm) [ da. e/ i ] 30. 446 / 30. 436 73. 355 / 73. 345
Ti p di amet er al l owances ( mm) [ Ada. e/ i ] 0. 000 / - 0. 010 0. 000 / - 0. 010
Ti p chamf er / t i p r oundi ng ( mm) [ hK] 0. 000 0. 000
Ti p f or mdi amet er ( mm) [ dFa] 30. 446 73. 355
( mm) [ dFa. e/ i ] 30. 446 / 30. 436 73. 355 / 73. 345
Act i ve t i p di amet er ( mm) [ dNa. e/ i ] 30. 446 / 30. 436 73. 355 / 73. 345
Oper at i ng pi t ch di amet er ( mm) [ dw] 26. 522 71. 278
( mm) [ dw. e/ i ] 26. 538 / 26. 506 71. 322 / 71. 234
Root di amet er ( mm) [ df ] 23. 696 66. 605
Gener at i ng Pr of i l e shi f t coef f i ci ent [ xE. e/ i ] 0. 2601 / 0. 2367 - 0. 3275 / - 0. 3577
Manuf act ur ed r oot di amet er wi t h xE ( mm) [ df . e/ i ] 23. 511 / 23. 441 66. 436 / 66. 345
Theor et i cal t i p cl ear ance ( mm) [ c] 0. 375 0. 375
Ef f ect i ve t i p cl ear ance ( mm) [ c. e/ i ] 0. 540 / 0. 429 0. 537 / 0. 437
Act i ve r oot di amet er ( mm) [ dNf ] 25. 050 68. 670
( mm) [ dNf . e/ i ] 25. 086 / 25. 020 68. 719 / 68. 627
Root f or mdi amet er ( mm) [ dFf ] 24. 894 67. 921
( mm) [ dFf . e/ i ] 24. 820 / 24. 794 67. 816 / 67. 761
Reser ve ( dNf - dFf ) / 2 ( mm) [ cF. e/ i ] 0. 146 / 0. 100 0. 479 / 0. 405
Addendum( mm) [ ha = mn * ( haP*+x) ] 1. 982 1. 094
( mm) [ ha. e/ i ] 1. 982 / 1. 977 1. 094 / 1. 089
Dedendum( mm) [ hf = mn * ( hf P*- x) ] 1. 393 2. 281
( mm) [ hf . e/ i ] 1. 485 / 1. 520 2. 366 / 2. 411
Rol l angl e at dFa ( ) [ xsi _dFa. e/ i ] 41. 909 / 41. 870 27. 702 / 27. 682
Rol l angl e t o dNa ( ) [ xsi _dNa. e/ i ] 41. 909 / 41. 870 27. 702 / 27. 682
Rol l angl e t o dNf ( ) [ xsi _dNf . e/ i ] 11. 766 / 10. 969 16. 480 / 16. 189
Rol l angl e at dFf ( ) [ xsi _dFf . e/ i ] 8. 135 / 7. 696 13. 371 / 13. 160
Toot h hei ght ( mm) [ H] 3. 375 3. 375
Vi r t ual gear no. of t eet h [ zn] 20. 960 56. 329
Nor mal t oot h t hi ckness at t i p cyl . ( mm) [ san] 0. 874 1. 225
( mm) [ san. e/ i ] 0. 806 / 0. 771 1. 166 / 1. 127
Nor mal spacewi dt h at r oot cyl i nder ( mm) [ ef n] 0. 000 1. 352
( mm) [ ef n. e/ i ] 0. 000 / 0. 000 1. 388 / 1. 409
Max. sl i di ng vel oci t y at t i p ( m/ s) [ vga] 1. 436 0. 919
Speci f i c sl i di ng at t he t i p [ zet aa] 0. 610 0. 591
Speci f i c sl i di ng at t he r oot [ zet af ] - 1. 443 - 1. 567
Sl i di ng f act or on t i p [ Kga] 0. 414 0. 265
Sl i di ng f act or on r oot [ Kgf ] - 0. 265 - 0. 414
Pi t ch on r ef er ence ci r cl e ( mm) [ pt ] 5. 200
Base pi t ch ( mm) [ pbt ] 4. 825
Tr ansver se pi t ch on cont act - pat h ( mm) [ pet ] 4. 825
Lead hei ght ( mm) [ pz] 178. 408 479. 470
Axi al pi t ch ( mm) [ px] 11. 150
Lengt h of pat h of cont act ( mm) [ ga, e/ i ] 6. 555 ( 6. 635 / 6. 456)
Lengt h T1- A, T2- A ( mm) [ T1A, T2A] 2. 432( 2. 352/ 2. 523) 15. 965( 15. 965/ 15. 954)
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Lengt h T1- B ( mm) [ T1B, T2B] 4. 162( 4. 162/ 4. 154) 14. 235( 14. 155/ 14. 323)
Lengt h T1- C ( mm) [ T1C, T2C] 4. 989( 4. 967/ 5. 011) 13. 408( 13. 350/ 13. 466)
Lengt h T1- D ( mm) [ T1D, T2D] 7. 257( 7. 177/ 7. 348) 11. 140( 11. 140/ 11. 129)
Lengt h T1- E ( mm) [ T1E, T2E] 8. 987( 8. 987/ 8. 979) 9. 410( 9. 330/ 9. 498)
Lengt h T1- T2 ( mm) [ T1T2] 18. 397 ( 18. 317 / 18. 477)
Di amet er of si ngl e cont act poi nt B ( mm)
[ d- B] 25. 945( 25. 945/ 25. 940) 71. 916( 71. 853/ 71. 986)
Di amet er of si ngl e cont act poi nt D ( mm)
[ d- D] 28. 540( 28. 459/ 28. 633) 69. 698( 69. 698/ 69. 691)
Addendumcont act r at i o [ eps] 0. 829( 0. 833/ 0. 822) 0. 530( 0. 542/ 0. 516)
Mi ni mal l engt h of cont act l i ne ( mm) [ Lmi n] 19. 611

Tr ansver se cont act r at i o [ eps_a] 1. 359
Tr ansver se cont act r at i o wi t h al l owances [ eps_a. e/ m/ i ] 1. 375 / 1. 357 / 1. 338
Over l ap r at i o [ eps_b] 1. 256
Tot al cont act r at i o [ eps_g] 2. 614
Tot al cont act r at i o wi t h al l owances [ eps_g. e/ m/ i ] 2. 631 / 2. 612 / 2. 594


2. FACTORS OF GENERAL INFLUENCE

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Nomi nal ci r cum. f or ce at pi t ch ci r cl e ( N)
[ Ft ] 1009. 7
Axi al f or ce ( N) [ Fa] 470. 8
Radi al f or ce ( N) [ Fr ] 405. 5
Nor mal f or ce ( N) [ Fnor m] 1185. 6
Tangent . l oad at p. c. d. per mm( N/ mm) ( N/ mm)
[ w] 72. 12
Onl y as i nf or mat i on: For ces at oper at i ng pi t ch ci r cl e:
Nomi nal ci r cumf er ent i al f or ce ( N) [ Ft w] 1008. 1
Axi al f or ce ( N) [ Faw] 470. 8
Radi al f or ce ( N) [ Fr w] 409. 4
Ci r cumf er ent i al speed pi t ch d. . ( m/ sec) [ v] 3. 47

Runni ng- i n val ue ( m) [ yp] 1. 1
Runni ng- i n val ue ( m) [ yf ] 0. 9
Cor r ect i on coef f i ci ent [ CM] 0. 800
Gear body coef f i ci ent [ CR] 1. 000
Ref er ence pr of i l e coef f i ci ent [ CBS] 0. 975
Mat er i al coef f i ci ent [ E/ Est ] 1. 000
Si ngul ar t oot h st i f f ness ( N/ mm/ m) [ c' ] 11. 915
Meshi ng st i f f ness ( N/ mm/ m) [ cg] 15. 120
Reduced mass ( kg/ mm) [ mRed] 0. 00235
Resonance speed ( mi n- 1) [ nE1] 47834
Runni ng- i n val ue ( m) [ ya] 1. 1
Bear i ng di st ance l of pi ni on shaf t ( mm) [ l ] 53. 000
Di st ance s of pi ni on shaf t ( mm) [ s] 5. 900
Out si de di amet er of pi ni on shaf t ( mm) [ dsh] 14. 000
Load accor di ng t o
DI N 3990- 1: 1987 Bi l d 6. 8 [ - ] 0
( 0: 6. 8a, 1: 6. 8b, 2: 6. 8c, 3: 6. 8d, 4: 6. 8e)
Fact or K' f ol l owi ng
DI N 3990- 1: 1987 Bi l d 6. 8 [ K' ] 0. 80
Wi t hout suppor t ef f ect
Toot h t r ace devi at i on ( act i ve) ( m) [ Fby] 12. 41
f r omdef or mat i on of shaf t ( m) [ f sh*B1] 2. 56
Toot h t r ace: wi t h end r el i ef
Posi t i on of Cont act pat t er n: not ver i f i ed or i nappr opr i at e
f r ompr oduct i on t ol er ances ( m) [ f ma*B2] 11. 20
Toot h t r ace devi at i on, t heor et i cal ( m) [ Fbx] 14. 60
Runni ng- i n val ue ( m) [ yb] 2. 2

Dynami c f act or [ KV] 1. 049

Face l oad f act or - f l ank [ KHb] 1. 919
- Toot h r oot [ KFb] 1. 644
- Scuf f i ng [ KBb] 1. 919

Tr ansver se l oad f act or - f l ank [ KHa] 1. 344
- Toot h r oot [ KFa] 1. 344
- Scuf f i ng [ KBa] 1. 344

Hel i cal l oad f act or scuf f i ng [ Kbg] 1. 242

Number of l oad cycl es ( i n mi o. ) [ NL] 112. 500 41. 860

27.03.2012 16 / 19
3. TOOTH ROOT STRENGTH

Cal cul at i on of Toot h f or mcoef f i ci ent s accor di ng met hod: B
( Cal cul at e t oot h f or mf act or YF wi t h manuf act ur i ng addendummod. xE. e)
- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Toot h f or mf act or [ YF] 1. 37 1. 67
St r ess cor r ect i on f act or [ YS] 2. 15 1. 84
Wor ki ng angl e ( ) [ al f en] 21. 64 18. 97
Bendi ng l ever ar m( mm) [ hF] 1. 52 1. 84
Toot h t hi ckness at r oot ( mm) [ sFn] 3. 14 3. 15
Toot h r oot r adi us ( mm) [ r oF] 0. 65 0. 82
( hF* = 1. 012/ 1. 225 sFn* = 2. 093/ 2. 102 r oF* = 0. 431/ 0. 545 dsFn = 24. 00/ 67. 03 al f sFn =
30. 00/ 30. 00)

Cont act r at i o f act or [ Yeps] 1. 000
Hel i cal l oad f act or [ Ybet ] 0. 792
Ef f ect i ve f acewi dt h ( mm) [ bef f ] 14. 00 14. 50
Nomi nal shear st r ess at t oot h r oot ( N/ mm )
[ si gF0] 112. 30 113. 33
Toot h r oot st r ess ( N/ mm ) [ si gF] 351. 41 354. 63

Per mi ssi bl e bendi ng st r ess at r oot of Test - gear
Suppor t f act or [ Ydr el T] 0. 999 0. 994
Sur f ace f act or [ YRr el T] 0. 957 0. 957
Si ze coef f i ci ent ( Toot h r oot ) [ YX] 1. 000 1. 000
Fi ni t e l i f e f act or [ YNT] 1. 000 1. 000
[ Ydr el T*YRr el T*YX*YNT] 0. 956 0. 951
Al t er nat i ng bendi ng coef f i ci ent [ YM] 1. 000 1. 000
St r ess cor r ect i on f act or [ Yst ] 2. 00
Li mi t st r engt h t oot h r oot ( N/ mm ) [ si gFG] 822. 21 818. 14
Per mi ssi bl e t oot h r oot st r ess ( N/ mm )
[ si gFP=si gFG/ SFmi n] 632. 47 629. 34
Requi r ed saf et y [ SFmi n] 1. 30 1. 30
Saf et y f or Toot h r oot st r ess [ SF=si gFG/ si gF] 2. 34 2. 31
Tr ansmi t t abl e power ( kW) [ kWRat i ng] 6. 30 6. 21



4. SAFETY AGAINST PITTING (TOOTH FLANK)

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Zone f act or [ ZH] 2. 291
El ast i ci t y coef f i ci ent ( N^. 5/ mm) [ ZE] 189. 812
Cont act r at i o f act or [ Zeps] 0. 858
Hel i x angl e f act or [ Zbet ] 0. 952
Ef f ect i ve f acewi dt h ( mm) [ bef f ] 14. 00
Nomi nal f l ank pr essur e ( N/ mm ) [ si gH0] 686. 65
Sur f ace pr essur e at oper at i ng pi t ch ci r cl e ( N/ mm )
[ si gHw] 1312. 18
Si ngl e t oot h cont act f act or [ ZB, ZD] 1. 00 1. 00
Fl ank pr essur e ( N/ mm ) [ si gH] 1312. 18 1312. 18

Lubr i cat i on f act or [ ZL] 1. 096 1. 093
Speed f act or [ ZV] 0. 974 0. 975
Roughness f act or [ ZR] 0. 945 0. 946
Mat er i al mat i ng f act or [ ZW] 1. 000 1. 000
Fi ni t e l i f e f act or [ ZNT] 1. 000 1. 014
[ ZL*ZV*ZR*ZNT] 1. 009 1. 022
Smal l amount of pi t t i ng per mi ssi bl e ( 0=no, 1=yes) 0 0
Si ze coef f i ci ent ( f l ank) [ ZX] 1. 000 1. 000
Li mi t st r engt h pi t t i ng ( N/ mm ) [ si gHG] 1513. 28 1533. 36
Per mi ssi bl e sur f ace pr essur e ( N/ mm ) [ si gHP=si gHG/ SHmi n] 1592. 92 1614. 07

Saf et y f or sur f ace pr essur e at oper at i ng pi t ch ci r cl e
[ SHw] 1. 15 1. 17
Requi r ed saf et y [ SHmi n] 0. 95 0. 95
Tr ansmi t t abl e power ( kW) [ kWRat i ng] 5. 16 5. 30
Saf et y f or st r ess at si ngl e t oot h cont act
[ SHBD=si gHG/ si gH] 1. 15 1. 17
( Saf et y r egar di ng nomi nal t or que) [ ( SHBD) ^2] 1. 33 1. 37


4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Cal cul at i on di d not r un. ( Lubr i cant : Load st age mi cr opi t t i ng t est i s unknown


27.03.2012 17 / 19
5. STRENGTH AGAINST SCUFFING

Cal cul at i on met hod accor di ng t o
DI N 3990: 1987

The cal cul at i on of l oad capaci t y f or scuf f i ng does not cover gr ease.
The FZG- Test st age [ FZGt est A] i s onl y est i mat ed f or gr ease.
The cal cul at i on can onl y ser ve as a r ough gui de. !

Lubr i cat i on coef f i ci ent ( f or l ubr i cat i on t ype)
[ XS] 1. 200
Rel at i ve st r uct ur e coef f i ci ent ( Scuf f i ng)
[ XWr el T] 1. 000
Ther mal cont act f act or ( N/ mm/ s^. 5/ K) [ BM] 13. 780 13. 780
Rel evant t i p r el i ef ( m) [ Ca] 2. 00 2. 00
Opt i mal t i p r el i ef ( m) [ Cef f ] 6. 44
Ef f ect i ve f acewi dt h ( mm) [ bef f ] 14. 000
Appl i cabl e ci r cumf er ent i al f or ce/ f acewi dt h ( N/ mm)
[ wBt ] 327. 144
Pr essur e angl e f act or ( eps1:
0. 829, eps2: 0. 530) [ Xal f bet ] 0. 990

Fl ash t emper at ur e- cr i t er i a
Toot h mass t emper at ur e ( C) [ t heM- B] 116. 53
t heM- B = t heoi l + XS*0. 47*t hef l amax [ t hef l amax] 64. 76
Scuf f i ng t emper at ur e ( C) [ t heS] 398. 47
Coor di nat e gamma ( poi nt of hi ghest t emp. ) [ Gamma] 0. 455
[ Gamma. A] = - 0. 513 [ Gamma. E] = 0. 801
Hi ghest cont act t emp. ( C) [ t heB] 181. 29
Fl ash f act or ( K*N^- . 75*s^. 5*m^- . 5*mm) [ XM] 50. 058
Geomet r y f act or [ XB] 0. 215
Load shar i ng f act or [ XGam] 1. 000
Dynami c vi scosi t y ( mPa*s) [ et aM] 17. 93
Coef f i ci ent of f r i ct i on [ mym] 0. 112
Requi r ed saf et y [ SBmi n] 2. 000
Saf et y f act or f or scuf f i ng ( f l ash- t emp) [ SB] 3. 144

I nt egr al t emper at ur e- cr i t er i a
Toot h mass t emper at ur e ( C) [ t heM- C] 100. 52
t heM- C = t heoi l + XS*0. 70*t hef l ai nt [ t hef l ai nt ] 24. 42
I nt egr al scuf f i ng t emper at ur e ( C) [ t heSi nt ] 398. 47
Fl ash f act or ( K*N^- . 75*s^. 5*m^- . 5*mm) [ XM] 50. 058
Cont act r at i o f act or [ Xeps] 0. 282
Dynami c vi scosi t y ( mPa*s) [ et aOi l ] 63. 62
Aver aged coef f i ci ent of f r i ct i on [ mym] 0. 089
Geomet r y f act or [ XBE] 0. 364
Meshi ng f act or [ XQ] 1. 000
Ti p r el i ef f act or [ XCa] 1. 000
I nt egr al t oot h f l ank t emper at ur e ( C) [ t hei nt ] 137. 15
Requi r ed saf et y [ SSmi n] 1. 800
Saf et y f act or f or scuf f i ng ( i nt g. - t emp. ) [ SSi nt ] 2. 905
Saf et y r ef er r i ng t o t r ansf er r ed t or que [ SSL] 5. 573


6. MEASUREMENTS FOR TOOTH THICKNESS

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Toot h t hi ckness devi at i on Own I nput Own I nput
Toot h t hi ckness al l owance ( nor mal sect i on) ( mm)
[ As. e/ i ] - 0. 067 / - 0. 093 - 0. 062 / - 0. 095

Number of t eet h spanned [ k] 3. 000 6. 000
Base t angent l engt h ( no backl ash) ( mm) [ Wk] 11. 845 25. 272
Act ual base t angent l engt h ( ' span' ) ( mm) [ Wk. e/ i ] 11. 782 / 11. 758 25. 214 / 25. 183
Di amet er of cont act poi nt ( mm) [ dMWk. m] 26. 843 69. 973

Theor et i cal di amet er of bal l / pi n ( mm) [ DM] 2. 789 2. 496
Ef f . Di amet er of bal l / pi n ( mm) [ DMef f ] 3. 000 2. 500
Theor . di m. cent r e t o bal l ( mm) [ Mr K] 16. 053 36. 846
Act ual di mensi on cent r e t o bal l ( mm) [ Mr K. e/ i ] 15. 989 / 15. 964 36. 760 / 36. 714
Di amet er of cont act poi nt ( mm) [ dMMr . m] 27. 596 70. 166
Di amet r al measur ement over t wo bal l s wi t hout cl ear ance ( mm)
[ MdK] 32. 107 73. 644
Act ual di mensi on over bal l s ( mm) [ MdK. e/ i ] 31. 978 / 31. 929 73. 473 / 73. 381
Di amet r al measur ement over r ol l s wi t hout cl ear ance ( mm)
[ MdR] 32. 107 73. 691
Act ual di mensi on over r ol l s ( mm) [ MdR. e/ i ] 31. 978 / 31. 929 73. 520 / 73. 428
27.03.2012 18 / 19
Di mensi ons over 3 r ol l s wi t hout cl ear ance ( mm)
[ Md3R] 0. 000 73. 691
Act ual di mensi ons over 3 r ol l s ( mm) [ Md3R. e/ i ] 0. 000 / 0. 000 73. 520 / 73. 428

Chor dal t oot h t hi ckness ( no backl ash) ( mm)
[ ' sn] 2. 704 2. 060
Act ual chor dal t oot h t hi ckness ( mm) [ ' sn. e/ i ] 2. 637 / 2. 611 1. 998 / 1. 965
Ref er ence chor dal hei ght f r omda. m( mm) [ ha] 2. 037 1. 103
Toot h t hi ckness ( Ar c) ( mm) [ sn] 2. 707 2. 060
( mm) [ sn. e/ i ] 2. 640 / 2. 615 1. 999 / 1. 966

Backl ash f r ee cent er di st ance ( mm) [ aCont r ol . e/ i ] 48. 723 / 48. 641
Backl ash f r ee cent er di st ance, al l owances ( mm)
[ j t a] - 0. 177 / - 0. 259
Cent r e di st ance al l owances ( mm) [ Aa. e/ i ] 0. 030 / - 0. 030
Ci r cumf er ent i al backl ash f r omAa ( mm) [ j t _Aa. e/ i ] 0. 024 / - 0. 024
Radi al cl ear ance ( mm) [ j r ] 0. 289 / 0. 147
Ci r cumf er ent i al backl ash ( t r ansver se sect i on) ( mm)
[ j t ] 0. 231 / 0. 118
Tor si onal angl e f or f i xed gear 1 ( ) 0. 3725 / 0. 1899
Nor mal backl ash ( mm) [ j n] 0. 197 / 0. 100


7. GEAR ACCURACY

- - - - - - - GEAR 1 - - - - - - - - GEAR 2 - -
Accor di ng t o
DI N 3961: 1978:
Accur acy gr ade [ Q- DI N3961] 8 8
Pr of i l e f or mdevi at i on ( m) [ f f ] 12. 00 12. 00
Pr of i l e sl ope devi at i on ( m) [ f Ha] 10. 00 10. 00
Tot al pr of i l e devi at i on ( m) [ Ff ] 16. 00 16. 00
Hel i x f or mdevi at i on ( m) [ f f b] 8. 00 8. 00
Hel i x sl ope devi at i on ( m) [ f Hb] 16. 00 16. 00
Tot al hel i x devi at i on ( m) [ Fb] 18. 00 18. 00
Nor mal base pi t ch devi at i on ( m) [ f pe] 13. 00 14. 00
Si ngl e pi t ch devi at i on ( m) [ f p] 13. 00 14. 00
Di f f er ence bet ween adj acent pi t ches ( m) [ f u] 17. 00 18. 00
Tot al cumul at i ve pi t ch devi at i on ( m) [ Fp] 38. 00 49. 00
Cumul at i ve ci r cul ar pi t ch devi at i on over z/ 8 pi t ches ( m)
[ Fpz/ 8] 24. 00 31. 00
Concent r i ci t y devi at i on ( m) [ Fr ] 27. 00 32. 00
Toot h Thi ckness Var i at i on ( m) [ Rs] 15. 00 19. 00
Tot al r adi al composi t e devi at i on ( m) [ Fi " ] 33. 00 40. 00
Radi al t oot h- t o- t oot h composi t e devi at i on ( m)
[ f i " ] 13. 00 16. 00
Tot al t angent i al composi t e devi at i on ( m)
[ Fi ' ] 44. 00 52. 00
Tangent i al t oot h- t o- t oot h composi t e devi at i on ( m)
[ f i ' ] 21. 00 21. 00

Accor di ng t o
DI N 58405: 1972 ( Fei nwer kt echni k) :
Toot h- t o- t oot h composi t e er r or ( m) [ f i " ] 14. 00 16. 00
Composi t e er r or ( m) [ Fi " ] 40. 00 45. 00
Axi s al i gnment er r or ( m) [ f p] 13. 69 13. 69
Fl ank di r ect i on er r or ( m) [ f bet a] 9. 00 9. 00
Concent r i ci t y devi at i on ( m) [ Tr k, Fr ] 56. 00 65. 00

Axi s al i gnment t ol er ances ( r ecommendat i on acc. I SO TR 10064: 1992, Qual i t y
8)
Maxi mumval ue f or devi at i on er r or of axi s ( m)
[ f Si gbet ] 39. 75 ( Fb=21. 00)
Maxi mumval ue f or i ncl i nat i on er r or of axes ( m)
[ f Si gdel ] 79. 50


8. ADDITIONAL DATA

Maxi mal possi bl e cent r e di st ance ( eps_a=1. 0)
[ aMAX] 49. 577
Tor si onal st i f f ness ( MNm/ r ad) [ cr ] 0. 0 0. 2
Mean coef f . of f r i ct i on ( acc. Ni emann) [ mum] 0. 098
Wear sl i di ng coef . by Ni emann [ zet w] 0. 819
Power l oss f r omgear l oad ( kW) [ PVZ] 0. 061
( Meshi ng ef f i ci ency ( %) [ et az] 98. 253)
Wei ght - cal cul at ed wi t h da ( g) [ Mass] 79. 80 479. 82
27.03.2012 19 / 19
Tot al wei ght ( g) [ Mass] 559. 63
Moment of i ner t i a ( Syst emr ef er enced t o wheel 1) :
cal cul at i on wi t hout consi der at i on of t he exact t oot h shape
si ngl e gear s ( ( da+df ) / 2. . . di ) ( kg*m ) ( kg*m )
[ Tr aeghMom] 5. 684e- 006 0. 0002656
Syst em ( ( da+df ) / 2. . . di ) ( kg*m ) ( kg*m )
[ Tr aeghMom] 4. 246e- 005

I ndi cat i ons f or t he manuf act ur i ng by wi r e cut t i ng:
Devi at i on f r omt heor et i cal t oot h t r ace ( m) [ Wi r eEr r ] 400. 3 149. 6
Per mi ssi bl e devi at i on ( m) [ Fb/ 2] 9. 0 9. 0


9. DETERMINATION OF TOOTHFORM

Dat a f or t he t oot h f or mcal cul at i on :
Dat a not avai l abl e.



REMARKS:
- Speci f i cat i ons wi t h [ . e/ i ] i mpl y: Maxi mum[ e] and Mi ni mal val ue [ i ] wi t h
consi der at i on of al l t ol er ances
Speci f i cat i ons wi t h [ . m] i mpl y: Mean val ue wi t hi n t ol er ance
- For t he backl ash t ol er ance, t he cent er di st ance t ol er ances and t he t oot h t hi ckness
devi at i on ar e t aken i nt o account . Shown i s t he maxi mal and t he mi ni mal backl ash cor r espondi ng
t he l ar gest r esp. t he smal l est al l owances
The cal cul at i on i s done f or t he Oper at i ng pi t ch ci r cl e. .
- Det ai l s of cal cul at i on met hod:
cg accor di ng t o met hod B
KV accor di ng t o met hod B
KHb, KFb accor di ng met hod C
KHa, KFa accor di ng t o met hod B

End r epor t l i nes: 516