LND-7330757468@CS Name : Unnamed Changed by : Marius

KISSsoft - Release 03-2011L File on: 09.11.2012 at: 22:55:27

Warning : Calculation not consistent. Results are probably not valid !

Important hint: At least one warning has occurred during the calculation: 1-> Contact interference! Notice: The length of the involute of gear 1 is too short. Some proposals: - Change tip form diameter of Gear 2 through Gear 2: Tip chamfer >= 0.0300 mm or Tip circle <= 164.7800 mm - Change reference profile of Gear 1 through: Smaller root radius or larger dedendum.

CALCULATION OF A HELICAL GEAR PAIR
Drawing or article number: Gear 1: 0.000.0 Gear 2: 0.000.0 Calculation method DIN 3990 Method B ------- GEAR 1 -------- GEAR 2 -Power (kW) Speed (1/min) Torque (Nm) Application factor Required service life Gear driving (+) / driven (-) 1. TOOTH GEOMETRY AND MATERIAL (Geometry calculation according ISO 21771) Center distance (mm) Centre distance tolerance Normal module (mm) Pressure angle at normal section (°) Helix angle at reference circle (°) Number of teeth Facewidth (mm) Hand of gear Accuracy grade Inner diameter (mm) Inner diameter of gear rim (mm) Material Gear 1: Gear 2: [a] [mn] [alfn] [beta] [z] [b] [Q-DIN3961] [di] [dbi] ------- GEAR 1 -------- GEAR 2 -112.000 ISO 286 Measure js7 2.7500 20.0000 12.0000 23 58 36.00 35.00 right left 8 8 0.00 0.00 0.00 0.00 steel, case-hardened core strength >=25HRC Jominy J=12mm<HRC28 steel, case-hardened core strength >=25HRC Jominy J=12mm<HRC28 ------- GEAR 1 -------- GEAR 2 -HRC 61 HRC 61 430.00 1500.00 1200.00 850.00 206000 0.300 0.00 4.80 20.00 430.00 1500.00 1200.00 850.00 206000 0.300 0.00 4.80 20.00 [P] [n] [T] [KA] [H] 725.0 38.2 + 2.900 1.25 800.00 287.5 96.3 -

18CrNiMo7-6, Case-carburized ISO 6336-5 Figure 9/10 (MQ), 18CrNiMo7-6, Case-carburized ISO 6336-5 Figure 9/10 (MQ),

Surface hardness Fatigue strength. tooth root stress (N/mm²) [sigFlim] Fatigue strength for Hertzian pressure (N/mm²) [sigHlim] Tensile strength (N/mm²) [Rm] Yield point (N/mm²) [Rp] Young's modulus (N/mm²) [E] Poisson's ratio [ny] Average roughness, Ra, tooth flank (µm) [RAH] Mean roughness height, Rz, flank (µm) [RZH] Mean roughness height, Rz, root (µm) [RZF]

1/7

895 70.700 / 17.e/i] [df.000 164.929 / 69.395 160.066 0.522 2.e/i] Working pressure angle at normal section (°) [alfwn] Helix angle at operating pitch circle (°) [betaw] Base helix angle (°) [betab] Reference centre distance (mm) [ad] Sum of profile shift coefficients [Summexi] Profile shift coefficient [x] Tooth thickness (Arc) (module) [sn*] Tip alteration (mm) Reference diameter (mm) Base diameter (mm) Tip diameter (mm) (mm) Tip diameter allowances (mm) Tip chamfer / tip rounding (mm) Tip form diameter (mm) (mm) Operating pitch diameter (mm) (mm) Root diameter (mm) Generating Profile shift coefficient Manufactured root diameter with xE (mm) Theoretical tip clearance (mm) Effective tip clearance (mm) [k*mn] [d] [db] [da] [da.909 / 0. profile (module) [rofP*] Addendum Reference profile (module) [haP*] Protuberance height (module) [hprP*] Protuberance angle (°) [alfprP] Buckling root flank height (module) [hFaP*] Buckling root flank angle (°) [alfKP] Data for Grinding / Honing: Depth of immersion (module) [hgrind*] Radius at cutter head (module) [rgrind*] Type of profile modification: Tip relief (µm) not topping 1.000 69.000 0.010 0.837 164.929 / 69. viscosity oil at 100 °C (mm²/s) FZG-Test A/8.861 / 0.435 / 152.837 / 164.595 57.826 164.000 0.370 152.0549 57.000 0.6350 0.100 none (only running-in) [Ca] -0.000 0.GEAR 1 -------.00 oil bath lubrication Oil: ISO-VG 220 Mineral-oil base [nu40] [nu100] [FZGtestA] [roOil] [TS] -0.00 Lubrication type Type of oil Lubricant base Kinem.3/90 (ISO 14635-1) Specific density at 15 °C (kg/dm³) Oil temperature (°C) Overall transmission ratio Gear ratio Transverse module (mm) Pressure angle at pitch circle (°) Working transverse pressure angle (°) 220.000 0.837 164.e/i] [hK] [dFa] [dFa.117 64.1085 -0.00 17.6350 1.250 0.38 / 1.000 0.066 0.603 69.000 1.929 69.117 163.25 / 0.e/i] [df] [xE.801 -0.000 0.410 17.420 / 160.809 11.605 63.000 2.919 0.615 / 63.380 1.811 20.7074 152.010 0.000 0.000 0.Tool or reference profile of gear 1 : Reference profile 1.GEAR 2 -0. viscosity oil at 40 °C (mm²/s) Kinem.250 0.837 / 164.000 1.827 0.788 -0.644 17.766 2/7 .e/i] [dw] [dw.000 1.486 0.663 60.000 0.000 0.320 11.000 1.672 17.5708 -0.919 63.929 69.063 152.2 Profil A Addendum coefficient [haP*] Dedendum coefficient [hfP*] Tip radius factor [rhoaP*] Root radius factor [rhofP*] Tip form height coefficient [hFaP*] Protuberance height factor [hprP*] Protuberance angle [alfprP] Ramp angle [alfKP] Summary of reference profile gears: Dedendum reference profile (module) [hfP*] Tooth root radius Refer.0 ISO 53.863 -0.000 / -0.297 0.000 0.380 0.827 160.000 1.0350 / -0.696 -0.596 / 57.25 / 0.380 1.250 0.2 Profil A Addendum coefficient [haP*] Dedendum coefficient [hfP*] Tip radius factor [rhoaP*] Root radius factor [rhofP*] Tip form height coefficient [hFaP*] Protuberance height factor [hprP*] Protuberance angle [alfprP] Ramp angle [alfKP] Tool or reference profile of gear 2 : Reference profile 1.380 0.000 0.000 0.250 0.000 [itot] [u] [mt] [alft] [alfwt] [alfwt.267 113.e/i] ------.0 ISO 53.0000 1.e/i] [c] [c.50 12 0.000 0.000 not topping 1.e/i] [Ada.6825 / -0.688 0.688 0.38 / 1.000 / -0.100 1.000 0.

589 5.0 0.000 Max.e/m/i] 1.783) Minimal length of contact line (mm) [Lmin] 59.593) Length T1-E (mm) [T1E.000 0.000 / 0.278 Transverse pitch on contact-path (mm) [pet] 8.0 0.load at p.657 Sliding factor on tip [Kga] 0.807 / 155.d.731 Reserve (dNf-dFf)/2 (mm) [cF.e/i] 2.311 / 2.438 5.167/ 9.654( 9.372 / 11.735) Diameter of single contact point D (mm) [d-D] 64.628 0.000 0. KHb or KHa are to high.986 / 32.982 155.081 Axial pitch (mm) [px] 41.345(24.342 0.832(24.148 Roll angle to dNa (°) [xsi_dNa.999 (33.GEAR 2 -0.383 Roll angle at dFa (°) [xsi_dFa.403 (mm) [san.722 2410. T2C] 9.842 2. T2E] 17.304/24.445/17.386) Length T1-D (mm) [T1D.e/i] 0.157) 24.335/11.633 0.287 -0.249) Length T1-A.0 0.Active root diameter (mm) [dNf] 60.347 Root form diameter (mm) [dFf] 60. force at pitch circle (N) ------.0 0.445(17.335 / 0.464) 22. (mm) [san] 2.000 0.900) Length T1-C (mm) [T1C.606/22.721 0.000 0.025 / 5.75 mm) [CR] Reference profile coefficient [CBS] Material coefficient [E/Est] Singular tooth stiffness (N/mm/µm) [c'] Meshing stiffness (N/mm/µm) [cg] The formula for c' and cg at w*KA < 25 is imprecise! Therefore the factors KV.986 / 32.624 0.671) 24.0 2. e/i] 14.931 -1.371 [dNf.705/64.826 0.941( 0.00000 0 0.0 0.c.000 0.400 / 156.694(160.e/i] 3.882 Dedendum (mm) [hf = mn * (hfP*-x)] 3.370 Roll angle at dFf (°) [xsi_dFf.270 Addendum (mm) [ha = mn * (haP*+x)] 2.184 (mm) [hf.per mm (N/mm) (N/mm) [w] Only as information: Forces at operating pitch circle: Nominal circumferential force (N) [Ftw] Axial force (N) [Faw] Radial force (N) [Frw] Circumferential speed pitch d.070 Virtual gear no.447 61.e/i] 60.158 / 23.938) 0.891 155.580 / 2.278 Lead height (mm) [pz] 955.0 0.795/ 0.148 Roll angle to dNf (°) [xsi_dNf.224 Tooth height (mm) [H] 6.115( 3..000 / 0.796) 159.923 156.497/16.366) Addendum contact ratio [eps] 0.000 0. (m/sec) [v] Running-in value (µm) [yp] Running-in value (µm) [yf] Correction coefficient [CM] Gear body coefficient (bs= 8.101 2. T2A] 3.435) 16.342 Pitch on reference circle (mm) [pt] 8.000 0.374/159.923 / 60.0 0.887 (mm) [ha.e/m/i] [eps_b] [eps_g] [eps_g.746 Specific sliding at the root [zetaf] -2.257 Normal spacewidth at root cylinder (mm) [efn] 0.000 (mm) [efn.000 0.775/24. T2-A (mm) [T1A.738 / 1. T2D] 11.553 Length of path of contact (mm) [ga.167( 9.316(63.e/i] 32.967 23. sliding velocity at tip (m/s) [vga] 0.746(64.393(11.006 0.0 0.0 0.649 Normal tooth thickness at tip cyl.832 Base pitch (mm) [pbt] 8.GEAR 1 -------.e/i] 6.938 / 60.e/i] 60.e/i] 32.00 0.310) 160.955 (mm) [dFf.464 / 12.606(22.638/ 9.889 / 5.573 2.287 Sliding factor on root [Kgf] -0.e/i] 0.731 1.982 (mm) Transverse contact ratio Transverse contact ratio with allowances Overlap ratio Total contact ratio Total contact ratio with allowances 2.000 3/7 . T2B] 9.942 / 34.633 / 2.316/63.887 / 0.555(16.158 / 23.534 / 3.884(30.057) Diameter of single contact point B (mm) [d-B] 63.e/i] 2.790( 0.186) 30.374(159.911 156.023 / -0.000 0.000 [eps_a] [eps_a.658/160. FACTORS OF GENERAL INFLUENCE Nominal circum. of teeth [zn] 24.45 0. Reduced mass (kg/mm) [mRed] Resonance speed (min-1) [nE1] Nominal speed (-) [N] Subcritical range Running-in value (µm) [ya] Bearing distance l of pinion shaft (mm) [l] Distance s of pinion shaft (mm) [s] Outside diameter of pinion shaft (mm) [dsh] 0.730 / 1.e/i] 5.071 6.000 0.591 11.057/ 3.031 / 1.572 / 2.884/30.622) Length T1-T2 (mm) [T1T2] 33.693 Specific sliding at the tip [zetaa] 0.387 / 14.781 12.983 2.967 23.564 [Ft] Axial force (N) [Fa] Radial force (N) [Fr] Normal force (N) [Fnorm] Tangent.330 (14.314 / 5.943/ 0.871) Length T1-B (mm) [T1B.

e) Tooth form factor [YF] 0.00 0.000 0.000 0.00 Working angle (°) [alfen] 0.000 0.00 0.000 0 0.8 (0:6.Scuffing Helix angle coefficient scuffing Number of load cycles (in mio.00 0. 4:6.) 3.000/0. 2:6.000 0.00 0.000 0.000 0.000 0.000 0.Load according DIN 3990/1 Figure 6.000 0. TOOTH ROOT STRENGTH ------.00 Tooth thickness at root (mm) [sFn] 0.00 0.00 1.00 0. SAFETY AGAINST PITTING (TOOTH FLANK) Zone factor [ZH] Elasticity coefficient (N^.000 dsFn = 0.00 0.00/ 0.00 0.00 (hF* = 0.GEAR 1 -------.000 0.00 0.ZD] Flank pressure (N/mm²) [sigH] Lubrication factor Speed factor Roughness factor Material mating factor Finite life factor [ZL] [ZV] [ZR] [ZW] [ZNT] [ZL*ZV*ZR*ZNT] Small amount of pitting permissible (0=no.00 1.000 36.000 0.8d.GEAR 2 -0.00 0.000 0.000 0.000 35.000 4 0.40 0.00 0.000 0. xE.00 Stress correction factor [YS] 0.00/ 0.00 0.40 0. 3:6.00 0.8b.000 0.000 0. 1:6.GEAR 1 -------.00 0.00 35.000 0.00 0.000 0.000/0. 1=yes) ------.000 0.000 Transverse load factor .00 alfsFn = 0.000 1.00 4/7 .8a.000 0.00 0.000 0.00 0.000 1.00 0.00 0.5/mm) [ZE] Contact ratio factor [Zeps] Helix angle factor [Zbet] Effective facewidth (mm) [beff] Nominal flank pressure (N/mm²) [sigH0] Surface pressure at operating pitch circle (N/mm²) [sigHw] Single tooth contact factor [ZB.000 1.8c.8e) Without support effect Tooth trace deviation (active) (µm) from deformation of shaft (µm) Tooth without tooth trace modification Position of Contact pattern: favorable from production tolerances (µm) Tooth trace deviation.000 roF* = 0.00 Bending lever arm (mm) [hF] 0.000 0.Tooth root .000 0.flank . theoretical (µm) Running-in value (µm) Dynamic factor Face load factor flank Tooth root Scuffing [-] [Fby] [fsh*B1] [fma*B2] [Fbx] [yb] [KV] [KHb] [KFb] [KBb] [KHa] [KFa] [KBa] [Kbg] [NL] 0.00 0.GEAR 2 -Calculation of Tooth form coefficients according method: B (Calculate tooth form factor YF with manufacturing addendum mod.00 0.000 0.00 Tooth root radius (mm) [roF] 0.00 0.00 0.000 0.00 0.000 0 0.00 0.000 0.00 0.000 0.000 0.000 0.000 0.000 0.00 0.000/0.0 1.00 0.00) Contact ratio factor [Yeps] Helical load factor [Ybet] Effective facewidth (mm) [beff] Nominal shear stress at tooth root (N/mm²) [sigF0] Tooth root stress (N/mm²) [sigF] Permissible bending stress at root of Test-gear Support factor [YdrelT] Surface factor [YRrelT] Size coefficient (Tooth root) [YX] Finite life factor [YNT] [YdrelT*YRrelT*YX*YNT] Alternating bending coefficient [YM] Stress correction factor [Yst] Limit strength tooth root (N/mm²) [sigFG] Permissible tooth root stress (N/mm²) [sigFP=sigFG/SFmin] Required safety [SFmin] Safety for Tooth root stress [SF=sigFG/sigF] Transmittable power (kW) [kWRating] 4.000 sFn* = 0.

000 0.000 0.00 0.000 0.00 0.00 0. Diameter of ball/pin (mm) [DMeff] 0.00 1.e/i] 0.A]= -0.m] [theM-C] [theflaint] [theSint] [Xeps] [etaOil] [mym] [XBE] [XQ] [XCa] [theint] [SSmin] [SSint] [SSL] ------.00 0.941) [Xalfbet] Flash temperature-criteria Tooth mass temperature (°C) [theM-B] theM-B = theoil + XS*0.807 Highest contact temp.00 0. eps2: 0.000 0.e/i] [dMWk.000 13.795 0.000 0.095 / -0.000 0.00 0.70*theflaint Integral scuffing temperature (°C) Contact ratio factor Dynamic viscosity (mPa*s) Averaged coefficient of friction Geometry factor Meshing factor Tip relief factor Integral tooth flank temperature (°C) Required safety Safety factor for scuffing (intg.795 0. STRENGTH AGAINST SCUFFING Calculation method according DIN3990 0.000 0.00 0.000 Theoretical diameter of ball/pin (mm) [DM] 0.5*mm) [XM] Pressure angle factor (eps1: 0.000 / 0.000.000 0.47*theflamax [theflamax] Scuffing temperature (°C) [theS] Coordinate gamma (point of highest temp.00 Calculation did not run.-temp.000 0.000 0.000 / 0.00 0.75*s^.00 1.000 0.000 13.677 [Gamma.000 Actual dimension centre to ball (mm) [MrK. MICROPITTING ACCORDING TO ISO/TR 15144-1:2010 0.000 0.000 -0.GEAR 2 -DIN3967 cd25 DIN3967 cd25 -0.000 0.000 0.00 0.000 0.00 Lubrication coefficient (for lubrication type) [XS] Relative structure coefficient (Scuffing) [XWrelT] Thermal contact factor (N/mm/s^.000 0.) [Gamma] [Gamma.000 2.000 0.00 0.070 / -0. centre to ball (mm) [MrK] 0.000 0.000 0.m] 0. MEASUREMENTS FOR TOOTH THICKNESS Tooth thickness deviation Tooth thickness allowance (normal section) (mm) [As.00 0.00 1.000 0.000 0.00 0.00 0.) Safety referring to transferred torque 6.000 Eff.110 0.00 0.000 / 0.5*m^-.000 Theor.000 0.000 / 0.800 0.000 Diameter of contact point (mm) [dMMr. dim.145 0.000 0.000 0.00 0.000 0.000 0.000 0.00 0.e/i] Number of teeth spanned Base tangent length (no backlash) (mm) Actual base tangent length ('span') (mm) Diameter of contact point (mm) [k] [Wk] [Wk.00 0.00 0.GEAR 1 -------.000 Diametral measurement over two balls without clearance (mm) 5/7 . (°C) [theB] Geometry factor [XB] Load sharing factor [XGam] Dynamic viscosity (mPa*s) [etaM] Coefficient of friction [mym] Required safety [SBmin] Safety factor for scuffing (flash-temp) [SB] Integral temperature-criteria Tooth mass temperature (°C) theM-C = theoil + XS*0.00 35.Size coefficient (flank) [ZX] Limit strength pitting (N/mm²) [sigHG] Permissible surface pressure (N/mm²) [sigHP=sigHG/SHmin] Safety for surface pressure at operating pitch circle [SHw] Required safety [SHmin] Transmittable power (kW) [kWRating] Safety for stress at single tooth contact [SHBD=sigHG/sigH] (Safety regarding nominal torque) [(SHBD)^2] 4b.00 0.00 1.5/K) [BM] Relevant tip relief (µm) [Ca] Optimal tip relief (µm) [Ceff] Effective facewidth (mm) [beff] Applicable circumferential force/facewidth (N/mm) [wBt] Flash factor (°K*N^-.790 0.000 0.00 0.E]= 0. (Lubricant: Load stage micropitting test is unknown 5.

018 -0.di) (kgm²) [TraeghMom] System ((da+df)/2.018 / / / / 0.di) (kgm²) [TraeghMom] 9. ISO/TR 10064.000 0.GEAR 1 -------.000 / 0.07 8.000 0.00 39.000 / 0.00 25.00 18.000 0.00 50.018 0.011 -0.e/i] 0.000 / 0.953 / 2.00 8 16.00 0 0.0 0. GEAR ACCURACY According DIN 3961: Accuracy grade Profile form deviation (µm) Profile slope deviation (µm) Total profile deviation (µm) Helix form deviation (µm) Helix slope deviation (µm) Total helix deviation (µm) Normal base pitch deviation (µm) Single pitch deviation (µm) Difference between adjacent pitches (µm) Total cumulative pitch deviation (µm) Cumulative circular pitch deviation over 0.00 20.00 19.000 / 0. ADDITIONAL DATA Maximal possible centre distance (eps_a=1.000 / 0. Niemann) [mum] Wear sliding coef.000 3.00 20.0000 /0.00 37.320 4. allowances (mm) [jta] Centre distance allowances (mm) [Aa.00 25.00 43.00 [Q-DIN3961] [ff] [fHa] [Ff] [ffb] [fHb] [Fb] [fpe] [fp] [fu] [Fp] z/8 pitches (µm) [Fpz/8] Concentricity deviation (µm) [Fr] Tooth Thickness Variation (µm) [Rs] Total radial composite deviation (µm) [Fi"] Radial tooth-to-tooth composite deviation (µm) [fi"] Total tangential composite deviation (µm) [Fi'] Tangential tooth-to-tooth composite deviation (µm) [fi'] According DIN 58405 (Precision Mechanics): Tooth-to-tooth composite error (µm) [fi"] Composite error (µm) [Fi"] Axis alignment error (µm) [fp] Flank direction error (µm) [fbeta] Concentricity deviation (µm) [Trk.00 18.00 66.00 16.36 12.000 0.e/i] Backlash free center distance. dimension over two pins (mm) Actual dimension over rolls (mm) [MdK] [MdK.e/i] [MdR] [MdR.calculated with da (g) [Mass] Moment of inertia (System referenced to wheel 1): calculation without consideration of the exact tooth shape single gears ((da+df)/2.00 31.000 0.m (mm) [ha] Tooth thickness (Arc) (mm) [sn] (mm) [sn. DETERMINATION OF TOOTHFORM Data for the tooth form calculation : Calculation of Gear 1 113.000 / 0.903 /112.00 33.00 20.000 0.e/i] Reference chordal height from da.e/i] Backlash free center distance (mm) [aControl.e/i] Radial clearance (mm) [jr] Circumferential backlash (transverse section) (mm) [jt] Torsional angle for fixed gear 1 (°) Normal backlash (mm) [jn] 7.24 65.00 15.03 Maximum value for inclination error of axes (µm) [fSigdel] 52. Quality 8) Maximum value for deviation error of axis (µm) [fSigbet] 26.011 0.250 / 4.000 0.00 25.000 0.000 0.000 0.000 0.000 ------.00 20.00 53.00 12.00 22.00 11.000 0.00 62.000 0.000 -0.00 12.00 31.00 58.00 17..e/i] Circumferential backlash from Aa (mm) [jt_Aa.018 Chordal tooth thickness (no backlash) (mm) ['sn] Actual chordal tooth thickness (mm) ['sn.000 0..0000 0.90 72.000 / 0.00 20.GEAR 2 -8 16.0) [aMAX] Torsional stiffness (MNm/rad) [cr] Mean coeff.00 16. of friction (acc.048 2.983 0.000 0.00 15.00 17. Fr] Tolerance for alignment of axes (recommendation acc.00 22..000 / 0.00 51.000 4.0 0.00 0 0 6/7 . by Niemann [zetw] Power loss from gear load (kW) [PVZ] Weight .36 11.00 20.00 44.000 0.000 0.210 112.00 56..00 11.000 0.000 0.Actual dimension over balls (mm) Theor.

380 REMARKS: .e/i] imply: Maximum [e] and Minimal value [i] with consideration of all tolerances Specifications with [.m] imply: Mean value within tolerance .For the backlash tolerance. Shown is the maximal and the minimal backlash corresponding the largest resp.Tooth form. Gear 2. Step 1: automatic (final treatment) haP*= 1.002.Details of calculation method: cg according to method B KV according to method B KHb. hfP*= 1. the center distance tolerances and the tooth thickness deviation are taken into account.. rofP*= 0. Gear 1. hfP*= 1. rofP*= 0. KFa according to method B End report lines: 495 7/7 . KFb according method C KHa.250.250.Specifications with [. Step 1: automatic (final treatment) haP*= 1.016.380 Calculation of Gear 2 Tooth form. . the smallest allowances The calculation is done for the Operating pitch circle.