ANST/AGMA 6010-F97 ANSI/AGMA 6010-F97 (Revision of ANSI/AGMA 6010-£88) AMERICAN NATIONAL STANDARD Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives (Yr AGMA STANDARDsi i Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives American ANsyaGMa 6010-F97 National [Revision of ANS/AGMA 6010-E8s} Standard Approval of an American National Standard requires verification by ANSI that the require- ments for due process, consensus and other criteria for approval have been met by the standards developer. Consensus is established when, in the judgment of the ANS! Board of Standards Review, substantial agreement has been reached by directly and materially affected interests. Substantial agreement means much more than a simple majority, but not necessarily Uunanimity. Consensus requires that all views and objections be considered, and that a concerted effort be made toward their resolution, - ‘The use of American National Standards is completely voluntary; their existonce does not in any respect preclude anyone, whether he has approved the standards or not, from. manufacturing, marketing, purchasing or using products, processes or procedures not conforming to the standards. ‘The American National Standards Institute does not develop standards and will in no circumstances give an interpretation of any American National Standard. Moreover, no person shall have the right or authority to issue an interpretation of an American National ‘Standardin the name of the American National Standards Insitute, Requests for interpre- tation of this standard should be addressed to the American Gear Manufacturers Association. CAUTION NOTICE: AGMA technical publications are subject to constant improvement, revision of withdrawal as dictated by experience. Any person who refers to any AGMA, technical publication should be sure that the publication is the atest available from the AS- sociation on the subject matter, [Tables or other self-supporting sections may be quoted or extracted. Credit ines should read: Extracted from ANSVAGMA 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives, with the permission of the publisher, the American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, Virginia 22314.) Approved October 2, 1997 ABSTRACT This standard includes design, rating, lubrication, testing and selection information for spur, helical, herring- bone and bevel gears when using enclosed speed reducers or increasers. Units covered include those with @ Pitch line velocity below 7000 feet per minute or rotational speeds no greater then 4500 rpm. Published by American Gear Manufacturers Association 1500 King Street, Suite 201, Alexandria, Virginia 22314 Copyright © 1997 by American Gear Manutacturers Association Alllrights reserved. 'No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher. Printed in the United States of America ISBN: 1-88589-690-1 ve» AMERICAN NATIONAL STANDARD ANSVAGMA 6010-F97 Contents Foreword 1 Scope - 2 Symbols, terminology and definitions . Applicaton end design considerations. 4 Unit rating . 5 6 7 8 Rating criteria. ‘Thermal power rating Component design Sorvice factors ......... 9 Lubrication and lubricants 10 Assembly and rotation ... 11 Ratios 12 Marking . 18 Storage ... 14 Installation Tables 1. Symbols used in equations . 2 2 Bearing coefficient of friction, f « Mt 3 Lubricant factor, C;, at 200°F sump temperature ..... tt 4 Heat transfer cosficient, for gear dtives without auxiary cooling . 14 5 Heat transfer coefficient, &, for gear drives with fan cooling . 4 6 Ambient temperature modifier, Bet s+ +s+eesee« Bo ce 4 7 Ambient air velocity modifier, By . ve 14 8 Attitude modifier, Bx 18 9 Maximum allowable oil sump temperature modifier, Br .. 15 10 Operation time modifier, Bp . 215 11 Nominal ratios .. Figures 1 Seal friction torque Shaft rotation 3 Parallel chatt spur, helical ard hertingbone gear drives, singe or multiple stage ... 4 Horizontal bevel gear drives, single stage; horizontal bevel-helical drives, multiple stage ..... 23. 5 Vertical bevel goar eres, ‘ge age vertical Bevel-helica drives, mute stage ee ecococsmon Annexes Service factors Keys and keyways for shaft extensions Ilustrative examples ......+..+++ Test and inspection procedures . ‘Owner responsibilities : ee Gear tooth mest losses for bevel goats sess esses. : 53 amoom> Bibliography - 55ANSIAGMA 6010-F97 AMERICAN NATIONAL STANDARD Foreword [The foreword, footnotes and annexes, if any, in this document are provided for informational purposes only and are not to be construed as a part of ANSVAGMA Standard 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives. ‘This standard presents general guidelines and practices for design, rating (including catalog rating) and lubrication of enciosed gear drives and is a revision to and supersedes ANSAGMA 6010-E88, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives. This standard was revised to include the latest data available using current gear technology and includes operational experience. Also, this revision conforms to the American Gear ‘Manufacturers Association style manual. This standard is written in conventional units while the parallel standard, ANS/AGMA 6110-F97, is available in hard metric. The allowable stress numbers used in this standard are derived from ANSYAGMA 2001-C95 and ANSVAGMA 2003-A86, and along with other rating factors, provide a rating basis for enclosed gear reducers and increasers. The rating formulas are based on many years of experience in the design and application of enclosed gear drives for industrial use. ‘The allowable stress numbers used by this standard are adjusted by the factors 2y and Yay {or the required number of cycles of operation. In previous versions of this standard, a C, and Kz value of unity has been allowed. Deviations from ANSVAGMA 2001-C95 or ANSI/AGMA 2003-A86 are not recommended unless they can be justified. The use of the stress cycle adjustment factor does not guarantee that a certain number of hours or revolutions of ite wil be obtained, but is a method of approximating gear life under different load and speed conditions. “The most significant changes in this standard include: information on obtaining ratings by direct reference to the empirical methods in ANSYAGMA 2001-C95 and ANSVAGMA 2003-A86; references to the necessary additional standards; a uniform selection method by specifying a nominal L life for the gearing of 10 000 hours; and a refinement of the thermal rating practice. ‘The competence to design enclosed gear drives, especially the knowledge and judgment required to properly evaluate the various rating factors, comes primatily from years of experience in designing, testing, manufacturing and operating similar gear drives. The proper application of the general rating formulas for enclosed gear drives is best accomplished by those experienced in the field. ‘There Is a need for a thorough knowledge and use of the safety, service and application factors. Application factors will represent actual loadings or will be replaced by a load spectrum analysis such as Miner's Rule. Work was started on this draft in December1991. This version was approved by the AGMA. membership in June 1997. It was approved as an American National Standard on October 2, 1997. ‘Suggestions for improvement ofthis standard will be welcome. They should be sent to the ‘American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, Virginia 22314.* AMERICAN NATIONAL STANDARD ANSYAGMA 6010-F97 PERSONNEL of the AGMA Helical, Herringbone and/or Spiral Bevel Enclosed Drives and Standard Units Committee Chairman: WP. Crosher ....++.+++ Flendet Corporation Vice Chairman: G.A. DeLange Prager, Inc. ACTIVE MEMBERS RL. Cragg . Consultant R.G. Ferguson ‘Amatilo Gear Company RW. Holzman... Milwaukee Gear Company, inc. H.R. Johnson, Ill. «Lufkin Industries, Inc, LUoyd oe. eee. soeeeeseessess Lutkin Industries, Inc, DL Maret coven Consuttant D. McCarthy Dorris Company D.R.MeVittie .. Gear Engineers, Inc. AR. Perry 5 seeeseeees Dorris Company AE. Philips ........ +» Rockwell Automation/Dodge VEZ. Rychlinski 2... ee cseeeeeeeseeeee Brad Foote Gear Works, Inc. BW. Shirley Emerson Power Transmission Corp. RG. Smith... sseseseess Philadelphia Gear Corporation F.C. Unerek : seseses++ Flender Corporation ASSOCIATE MEMBERS JAF Alison, IHL esse oes .» Steward Machine Company, Inc. RG. Allenby . - Hamilton Gear AG. Becker... Nuttall Gear Corporation KA Beckman . Lufkin Industries, inc. AS. Cohen .. +» Engranes y Maquinaria Arco D. Fleischer - Hamilton Gear, inc. RA. Geary Ler, Ine. J. Gimper . B.Goebel Danieli United, Inc. ‘The Horsburgh & Scott Company V.Wvers . Xtek, Inc. D. King . - DLL. King & Associates CE. Long 2.2... Cummins Engine GMOCaIA ee eee ceeeteesenetene - Amarillo Gear Company JR. Partridge ..... é veces Boro Lutkin bv M.Peoulis ...... cesssseeseess The Horsburgh & Soot Company WE. Pizzichil 2.0. es ceeeessceeseseses++ Philadelphia Gear Corporation RK Polen ........ orn The Alliance Machine Company PIN. Salvucci .. : IMO Industries, nc. M.D. Schutte Lightnin ES. Scott The Alliance Machine Company J. Simpson, Jr. ceesseses++ Turner Uni-Drive Company L Spiers Emerson Power Transmission |. Wilson... WesTech Gear Corporation S. Yamada Sumitomo K Yasui oe : «+++ Seiki-Kogyosho, Ltd. (SKK)ANSVAGMA 6010-F97 AMERICAN NATIONAL STANDARD (This page is intentionally left blank.) vi‘AMERICAN NATIONAL STANDARD ‘ANSVAGMA 6010-F57 American National Standard - Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives 1 Scope ‘This standard is applicable to enclosed gear drives wherein the gear tooth designs include spur, helical, herringbone or double helical, or bevel, in single or multistage units. 4.1 Limitations ‘The rating methods and influences identified in this standard are limited to enclosed drives of single and: muttipie stage designs where the pitch line velocities. do not exceed 7000 feet per minute and pinion speeds do not exceed 4500 revolutions per minute. 1.2 Overlap ‘Thereisa speed and pitch line velocity overlap inthe scope of this standard and the scope of ANSVAGMA, 6011-G92. ANSAGMA6011-G92 permits designs, down to 6000 feet per minute and pinion speeds to ‘3600 revolutions per minute, Inthe area ofoveriap in the scope, the standard used is dependent on the application or unit designed. Al! parties should be aware of the standard used and should agree on the use of that standard. 1.3 Intended use ‘This standard is not intended to assure performance of assembied gear drive systems. It is intended for use by the experienced gear designer capable of selecting reasonable values forthe factors, based on his knowledge of performance of similar designs and the effects of such items as lubrication, deflection, manufacturing tolerances, metallurgy, residual stress and system dynamics. tis not intended for use by the engineering public at large. 1.4 Exceptions: This standard does not cover the design and application of epicycic drives or gear blank design. This standard does not cover the rating of gear drives due to wear or scoring (scuffing) cf gear teeth or components. This standard does not apply to gear drives that are covered by other specific AGMA application standards, 4.5 Annexes ‘The annexes are for reference only andare nota part ofthis standard. The annexes can be used to make a ‘more detailed analysis of certain rating factors, anda. guide to owner responsibilties. 2 Symbols, terminology and definitions ‘The symbols used in this standard are shown in table 1. NOTE: The symbols, terms and definitions contained in this document may vary from those used in other AGMA standards. Users of this standard should as- sure themselves tha they are using these symbols and definitions in the manner indicated herein. 24 Definitions The terms used, wherever applicable, conform to the following standards: ANSI Y10.3-1968, Letter Symbols for Quantities Used in Mechanics of Solids ANSVAGMA 1012-Fo0, Gear Nomenclature; Definitions of Terms with Symbols ANSVAGMA 9005-094, Industrial Gear Lubrication 2.2 Reference documents The following standards contain provisions which, through reference in this text, constitute provisions of this American National Standard. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this American National Standard are encouraged to Investigate the possibil- ity of applying the most recent editions of the standards indicated below.ANSI/AGMA 6010-F37 AGMA 299.01, Section Ill, Gear Sound Manual: Gear Noise Control AANSI/AGMA 1010-E95, Appearance of Gear Teeth = Terminology of Wear and Failure ANSVAGMA 1012-F90, Gear Nomenclature Definitions of Terms with Symbols ANSI/AGMA 2001-C95, Fundamental Rating Fac- tors and Calculation Methods for Involute Spur and Helical Gear Teeth ANSVAGMA 2003-A86, Rating the Pitting Resist ance and Bending Strength of Generated Straight Bevel, Zerol Bevel, and Spiral Bevel Gear Teeth ANSYAGMA 2008-890, Assembling Bevel Gears AMERICAN NATIONAL STANDARD ANSVAGMA — 6000-B96, Specification for ‘Measurement of Linear Vibration on Gear Units ANS/AGMA 6001-D97, Design and Selection of Components for Enclosed Gear Drives ANSIAGMA 6025-C90, Sound for Enclosed Helical, Herringbone, and Spiral Bevel Gear Drives ANSYAGMA 6011-G92, Specification for High Speed Helical Gear Units ANSIAGMA 9002-A88, Bores and Keyways for Flexible Couplings (Inch Series) ANSIAGMA, Lubrication 9005-D94, Industrial Gear Table 1 - Symbols used in equations First] Reference ‘Symbol Term Units | used | clause “A [Arrangement constant == JEqis [6514 Ae | Gear case surface area exposed to ambient air #@ |Eqso e.5.2 B-_| Length through bore of bearing in |Eq24 f65.1.5 By | Altitude correction factor Eq31 |e8 Bp | Operation cycle correction factor Eqa1 66 Bug | Ambient temperature correction factor Eqai 68 Br _ | Maximum allowable sump temperature correction factor Eqst |e6 By | Ambient ait velocity correction factor Egat [ee C, _ | External dynamic factor (bevel) -- 512 G, | Stress adjustment factor (bevel) 512 C; _| Surface condition factor (bevel) 54.4 G,__ | Life factor (bevel) 5124 Cy | Load distribution factor (bevel) - 512 na |Mesh alignment factor 5AA2 Cp | Lubricant absolute viscosity Eq23 6.5.14 C, | Size factor (beve) -- 512 Cr _ | Temperature factor (bevel) 5.1.2 C, | Dynamic factor (bevel) 512 Cy | Lubricant factor 65.121 Dz \Mean diameter of tapered roller in 65.15 D, | Shaft seal diameter in 65.13 4 | Bearing bore in 65.1.4 dy |Mean diameter of a tapered roller bearing in 65.15 4 | Bearing outside diameter in 6.5.1.1 4, | Operating pitch diameter of gear or pinion in 65.1.4 Ep _ | Electric power consumed bp 6.5.1.6 e __| Tapered bearing calculation factor -- 65.1.5 én | Electric motor efficiency % 65.1.6 & il pump efficiency % 65.1.6 (continued)AMERICAN NATIONAL STANDARD PP PSIF TTT ERAT PREAP AAAS EPS Sy External dynamic factor (bevel) Stress cycle factor (bevel) Load distribution factor (bevel) Overload factor Reliability factor Size factor (bevel) Shrink adjustment factor to compensate for less than 100 percent engagement Service factor Temperature factor Dynamic factor ‘Tapered beating dynamic load ratio factor ANSYAGMA 6010-F97 Table 1 (continued) First ‘Symbol Term Units | _used Face width in contact win mating Sloment in JEqta ‘Total face of gear oF pinion in |Eq19 Bearing coefficient of friction -- Table 2 Mesh coefficient of friction ~~ |Eqt2 ‘Siding ratio at start of approach -- |Eqts Sliding ratio at end of recess ~~ [Eq1s Contact load factor for pitting resistance Ijin? Eq 18 Heat transfer coefficient Mesh mechanical advantage Gear ratio Number of gear teeth Number of pinion teeth Shatt speed Pinion speed Bearing shaft speed Application power of the enclosed drive hp Allowable transmitted power for pitting resistance hp |-- ‘Allowable transmitted power for bending strength hp -- Bearing power losses hp jee P, | Load-dependent power losses hp |Eq3 Py | Gear mesh power losses hp |Eqe Pre | Minimum component power rating hp |Eq1 2px | Mean normal diametral pitch int eget Py _ | Non-load dependent power losses tp |Eq3 P, | Normal diametral pitch it legis 2» | Total oil pump power required (all pumps) hp |Eqo Pm | Motor driven oil pump losses hp |Eq27 Pp, | Shaft driven oil pump losses hp |Eq27 Pg | Heat dissipated hp JEq2 65 Ps | Oil seal power losses hp [ea 65.1 Pr — | Basic thermal rating of the drive hp leq7 65 Prim | Application thermal rating hp = |eqa1 jes Py |Heat generated (total power loss) hp Eq2 65 Pye_| Beating combined windage and churning power losses hp |ea9 654 (continued)ANSYAGMA 6010-F97 AMERICAN NATIONAL STANDARD Table 1 (concluded) First | Reference Calculated key compressive stress Symbol Term Units | used | clause Fwy | Gear combined windage and chuming power loss mp {Ea o51 p | Operating oi! pressure loin? Eq28 este Q — |Oilflow gpm Eq28 |e5.16 Q, | Transmission accuracy level number ~~ |-- BAA R, | Gear outside radius in JEqie = [651.24 R, | Gear operating pitch radius in JEqie § fesi21 im — |Mean reference radius in Jeq21 jests ro | Pinion outside radius in JEqi7— fes.t.24 rw | Pinion operating pitch radius in [Eg1a 65.1.2. Sy | Allowable contact stress number -- [ee BA22 So |Caloulated bending stress number excluding dynamic] -- — |-~ 5A22 effects Se | Safety factor for bending strength -- |-- 524 Su | Safety factor for pitting resistance -- 0 |-- 5.14 Sy _ | Allowable yield strength number Ijin? ~~ 44 ss _ | Adjusted compressive stress in? Jeqs2 |7.4.2 | Calculated key shear stress Ibfn? = | Eq33 742 Sq | Adjusted shear stress. win? |eqss |7.42 Zp __ | Design pinion torque bin |-- 51.23 Tp | Operating pinion torque Din |-- 5.123 J | Torque on the pinion Win JEqi2 |65.1.21 | Rolling bearing friction torque Win JEqio 65.11 17 __| Allowable percentage of torque capacity obtained due to % |eqs2 |742 interference ft % | Oilseal torque tbin JEqie § jes.1.3 y | Pitch line velocity fumin |Eqi3 65.1.2. W | Equivalent racial bearing load wm eqn jess Yy | Stress cycle factor for bending strength -- |e Zq | Stress cycle factor for piting resistance Sl 2 | Cup angle of the tapered roller bearing degrees |Eq24 4» | Operating transverse pressure angle degrees |Eq 15 y | Mean spiral angle degrees |Eq21 1, | Operating helix angle at operating pitch diameter degrees |Eq 12 Ar | Temperature differential °F |Eq30 1 __[ Overall unit efficiency % _|Eq6 Win? jEqs2 = [7.4.2 3 Application and design considerations Users of this standard are expected to have had experience in the field of gearing and mechanical drive systems. 3.1. Application limitations In this standard, the unit rating is defined as the mechanical capacity of the gear unit components determined with a unity service factor. Units rated to this standard can accommodate the following peak load conditions: = Each peak shall not exceed 200 percent of the unit rating (service factor, Ky = 1.0); - Allimited number of stress cycles, typically less than 10%, For applications exceeding these conditions an appropriate service factor should be selected.AMERICAN NATIONAL STANDARD WARNING: For momentary torques in excess of 200%, stall conditions and low number af stress cycles, the gear drive should be evaluated to assure the user ot this standard that these conditions do not exceed the yield strength of any component. Some applications may require selecting a gear drive with increased mechanical rating in order to accommodate adverse effects of environmental conditions, thermal capacity of the unit, extemal loading or any combination of these factors such as ‘overhung, transverse and thrust loads. 3.2 Rating factors The allowable stress numbers taken from ANSI’ AGMA 2001-C95 and ANSVAGMA 2003-A86 are maximum allowed values. Some latitude based upon experience is permissible in the selection of specific factors within this standard. Less conserva- tive values for rating factors in this standard shall not be used. Ratings shall be as outlined in clauses 4 and 5. 3.3 Cold temperature operation Ifunits are to be operated below -20°F, care must be given to select materials which have adequate impact properties at the operating temperature. Consideration should be given to: = low — temperature impact strength specification; fracture appearance transition or nil ductility temperature specification for impact testing; = reduce carbon content to less than 0.4 percent; = use of higher nickel alloy steels; ~ lubricant problems. 3.4 System analysis The system of connected rotating parts must be compatible, free from critical speeds, torsional or ‘other types of vibration, within the specified operat- ing speed range no matter how induced. The enclosed gear drive designer or manufacturer is not responsible for this analysis, unless agreed to inthe purchase contract. 4 Unit rating Historically, many terms have been used to denote conditions of operations - both calculated and ANSWAGMA 6010-FS7 actual. These terms have resutted in contusion as to the actual capability ofthe enclosed drive. Examples of terms previously used to denote some form of enclosed drive capacity are listed below: service rating; ~ nameplate rating; = equivalent rating; ~ catalog rating: = mechanical ratir = brake rating; = unity rating; transmitted horsepower, - calculated horsepower; ~ allowable horsepower, ~ application horsepower. For purposes of this standard, where component capacities are being determined, the calculations ate specifically related to the unit rating as defined below. 4.4 Unit rating definition ‘The unit rating is the overall mechanical power rating of all static and rotating elements within the enclosed drive. The minimum rated component (weakest ink, whether determined by gear teeth, shafts, bolting, housing, etc.) of the enclosed drive determines the unit rating. 42 Unit rating requirements ‘The unit rating implies that all items within the gear drive have been designed to meet or exceed the unit rating. Gear and pinion ratings are to be in accordance with the bending strength and pitting resistance ratings as outlined in this standard. Shaft stresses, key stresses and fastener stresses are tobe within he limits set by this standard, Rolling ‘jerment bearing or sleeve bearing designs are to be within limits set by ANSVAGNA 6001-D97. Where user requirements or specifications dictate different design criteria, such as higher bearing life, this must be by contractual agreement, Unit ratings may also inciude allowable overhung load values which are usually designated to act at a distance of one shaft diameter from the face of the housing or enclosure component. Stresses in related parts resulting from these overhung loads must also be within limits set by this standard. Refer to clause 7 for further information.ANSVAGMA 6010-F97 43 Application of unit rating ‘The required unit rating of an enclosed drive is a function of the application and assessment of variable factors that affect the overall rating. These factors include environmental conditions, severity of service and life. Refer to clause 8 for further explanation. ‘The application of the enclosed drive requires that its capacity as defined by its unit rating; ie., its minimum rated component power, Prac, be related to the actual service conditions. Pre Py s Re (1) Ky where is the application power of enclosed drive, hp; Pre isthe minimum component power rating, hp; Ky__is the service factor. For cases where the gear mesh has been deter- mined to be the minimum rated component, the lesser of Pye Of Pai, a8 defined in this standard, becomes Pre in equation 1 (see 5.1 and 5.2). 4A Momentary overloads ‘When the enclosed drive is subjected to infrequent momentary overloads, stall conditions and low- cycle fatigue (less than 100 cycles), the conditions should be evaluated to assure that the yield strength of any component is not exceeded (se8 8.3.1). With respect to the gear bending strength for momentary overloads, the maximum allowable stress is determined by the allowable yield proper- ties rather than the bending fatigue strength of the material. This stress is designated as sy; its determination is shown in ANSVAGMA 2001-C95. Shaft, bearing and housing deflections have a significant effect on gear mesh alignment during momentary overloads. The enclosed drive must be evaluated to assure that the reactions to momentary overloads do not result in excessive misalignment causing ‘localized high stress concentrations or permanent deformation or both. In addition, the effects of external loads such as overhung, trans- verse and thrust loads must be evaluated. 45 Efficiency estimate ‘There are certain applications where the efficiency of an enclosed drive must be estimated and its thermal rating determined, AMERICAN NATIONAL STANDARD. The determination of efficiency is dependent on many complex characteristics and relationships. There are many factors which affect efficiency values. Some factors are: ~ operating temperature; ~ _ambierit temperature; - toad and speed; = gear geometry; ~ lubricant and lubrication system; = housing characteristics; = aligninent and deflection; ~ bearing type and assembly; ~ seals; ~ shaft driven accessories such as fans and pumps. ‘The heat dissipation characteristics and interaction of these factors are complex. The conditions of this standard prevail where rolling element bearings and hydrodynamic tip seals are used and a nominal gear efficiency value of 98 percent per mesh may be assumed. When other components (and their associated setups) are required, such as bearing reloads, face seals, high oil levels, special gear ‘geometry, joumal bearings and shifting mecha- nisms, a detailed analysis is necessary. Itis beyond the scope of this standard to present a detailed analysis of efficiency. ‘An estimate of the efficiency of an enclosed drive may be made by using the thermal capacity calculated in clause 6, but such an estimate will be ‘only an approximation of efficiency under test. The ‘temperature sensitive portions of power loss may be different rom those calculated according to clause 6, unless the operating sump temperature is nearly 20°F. Unless specifically agreed to between the user and manufacturer, items such as the prime mover, couplings, external driven ioads, attaching devices and motor diven accessories, are not included in the enclosed drive efficiency estimate, 5 Rating criteria ‘The pitting resistance rower rating and the bending ‘strength power rating for each mesh in the unit must be calculated and the lowest value obtained shall be used as the power rating of the gearset. It is Permissible to use more conservative values.AMERICAN NATIONAL STANDARD. 5.1 Pitting resistance power rating, Pac The pitting of gear teeth is considered to be a Hertzian contact fatigue phenomenon. Initial pitting and destructive pitting are illustrated and discussed in ANSVAGMA 1010-E95, Appearance of Gear Teeth - Terminology of Wear and Fallure. ‘The purpose of the pitting resistance formula is to determine a oad rating at which destructive pitting of the teeth does not occur during their design life. The ratings for pitting resistance are based on the formulas developed by Hertz for contact pressure betweentwo curved surfaces, modified for the effect of load sharing between adjacent tecth. 5.1.1 Pitting resistance of spur and helical gears The pitting resistance power rating shall be per the rating procedures and formulas of ANSYAGMA 2001-C95. The following factors for enclosed drives: shall be used: Ky = 1.0, temperature factor, G_ =1.0, surface condition factor; Ky = 1.0, reliability factor; Sin = 1.0, safety factor, is the dynamic factor (see 5.1.1.1); is the load distribution factor (see 6.1.1.2); = 1.0, overload factor, Is the stress cyole factor (see 5. Dynamic factor, K, K, is to be determined by clause 8 of ANSV/AGMA 2001-C95, with the exception that values of K, shall not be based on a transmission accuracy number greater than Q, = 11. 1.3), e BOQ ARR ‘Transmission accuracy number (0,) shall be based upon the quality level of the gearing produced. Inthe absence of a known specific quailty level, the curve for Q, = 6 shall be used. Figure 1 of ANSI/AGMA 2001-C95 limits values for the dynamic factor as a function of pitch line velocity. ‘These curves cannot be extrapolated to obtain values beyond the limits given. 5.1.1.2 Load distribution factor, Kor The empirical method of ANSVAGMA 2001-C95 shall be used in determining the load distribution factor. For typical enclosed drives, the mesh alignment factor, Cua, Shall be obtained fram curve 3 of figure 7 in ANSVAGMA 2001-CS5. A more ANSYAGMA 6010-F97 conservative approach such as curves 1 of 2 is allowed. If assembled quality level is unknown, curve 1 should be used 5.1.1.3 Stress cycle factor, 257 This factor adjusts the rating of individual gear elements based on the relatve number of subjected ‘stress cycles. This does not in anyway imply a fixed life. ttadjusts each gear element rating based on the relative number of cycles. The number of cycles ‘corresponding to 10 000 hours should be used to determine the Zy factor. In figure 17 of ANSVAGMA 2001-C85, for stress ‘cycle factors above 1 x 107 cycles, use the upper ‘curve for piting 5.1.2 Pitting resistance of bevel gears ‘The pitting resistance power rating for bevel gears shall be per the rating procedures and formulas of ANSVAGMA 2003-A86. The following factors for ‘enclosed drives shall be used: G = 1.0, size factor; G = 1.0, surface condition factor; = 1.0, external dynamic factor; Cy = 0.785, stress adjustment factor; = 1.0, le adjustment factor; Gis the dynamic factor (see 5.1.2.2); Gu is the load distribution factor (see 5.1.2.9); Cr =1.0, temperature factor. 5.1.2.4 Life factor (stress cycle factor), C, This factor adjusts the rating of individual gear elements based on the relative number of load cycles. The number of cycles corresponding to 10 000 hours should be used to determine C,. See figure 1 in ANSVAGMA 2003-A86. The upper curve should be used. 5.1.2.2 Dynamic factor, C,, Ky G and k, are to be determined by clause 8.5 in ANSVAGMA 2003-A86, with the exception that values of G, and K, shall not be based on a transmission accuracy number greater than Q,= 11. Sos setto the smalier of the gear or pinion allowable stress numbers, Se, 5.1.2.3 Load distribution factor, Cy, Km Cn and Ky ate to be determined by 10.1 of ANSVAGMA 2003-A86 by setting design pinion torque, Tp, equal to operating pinion torque, Tp.ANSVAGMA 6010-F97 5.2 Bending strength power rating, Par Bending strength of gear teeth is a measure of the resistance to fatigue cracking at the tooth root filet ‘Typical cracks and fractures are illustrated in ANSI AGMA 1010-E95. The intent of the AGMA strength rating formula is to determine the load which can be transmitted for the design life of the teeth without causing root fillet cracking or failure. Occasionally manufacturing tool marks, wear, surface fatigue or plastic flow may timit bending strength due to stress concentration around large, sharp comered pits or wear steps on the tooth surface. 5.2.1 Bending strength of spur and helical gears ‘The bending strength rating for gearing within the scope of this standard shall be determined by the rating methods and procedures of ANSVAGMA 2001-C95. The following factors for enclosed drives shall be used: = 1.0, temperature factor, = 1.0, reliability factor; = 1.0, safety factor; Is the dynamic factor (see 5.1.1.1); is the load distribution factor (see 5.1.1.2); = 1.0, overload factor, is the stress cycle factor (see 5.2.1.1). 5.2.1.1 Stress cycle factor, Yy This factor adjusts the rating of individual gear elements based on the relative number of subjected stress cycles. This does not in anyway imply a fixed life, Itadjusts each gear element rating based on the relative number of cycles. The number of cycles corresponding to 10 000 hours should be used to determine the Yy factor. In figure 18 of ANSYAGMA 2001-C35, for stress cycle factors above 3 x 10® cycles, use the upper curve for bending 5.2.2 Bending strength of bevel gears ‘The bending strength rating of bevel gears shall be determined by the rating methods and procedures of ANSVAGMA 2003-A86. The following factors for enclosed drives shall be used: K, = 1.0, extemal dynamic factor; K, = (@8-P/y1.2, size factor, BARRE RR AMERICAN NATIONAL STANDARD K, _ is the dynamic factor (see 5.1.2.2); Kr =1.0, temperature factor; Ki, isthe stress cycle factor (see 5.2.2.1); Ky is the load distrbution factor (see 5.1.2.9). 5.2.2.1 Life factor (stress cycle factor), Kr, This factor adjusts the rating of individual gear elements based on the relative number of load cycles. The number of cycles corresponding to 10 000 hours should be used to determine K,. See figure 2 in ANSVAGMA 2003-A86, The lower curve shall be used. 5.2.22 Momentary starting loads. Since the bending strength rating practice for bevel gears of ANSJAGMA 2003-A86 does not account for momentary peak loads as encountered during starting, a load spectrum analysis, such as with Miner's Rule, is required to account for the permissible starting and operating peak load cycles. 5.3 Allowable stress numbers for pitting resistance and bending strength AAs defined in the gear tooth rating standards, the allowable stress numbers for gear materials vary with composition, cleanliness, quality, heat treat- ment and processing practices. Unless justified by testing, do not use the allowable stress numbers for Grade 9 material. Use the allowable stress numbers for Grades 1 or 2 in accordance with ANSVAGMA 2001-C95, clause 16, or ANSAGMA 2003-A86, clause 20. 6 Thermal power rating ‘The following thermal model has been established using empirical factors. Itis based on the experience of several gear manufacturers, The model has been validated by extensive testing of concentric shaft, base mounted reducers with shafts mounted in a horizontal orientation. Limited testing of some parallel shaft gear units has also been performed to ‘spot check the adequacy (validity) of the model. Values of some variables such as arrangement constant, heat transfer coefficient and coefficient of friction may not adequately address other enclosed drive configurations and operating conditions. ‘These configurations or conditions may necessitate modifications of these variables. Changing any variable requires care and testing to insure that the principles of the heat balance formulation are not violated.AMERICAN NATIONAL STANDARD Maintaining an acceptable temperature in the oil sump of a gear drive is critical to its life. Therefore, the selection of a gear drive must consider not only ‘the mechanical rating but also the thermal rating. ‘Thermal rating is defined as the maximum power that can be continuously transmitted through a gear drive without exceeding a spocified oll sump temperature. The thermal rating must equal or exceed the transmitted power. Service factors are ot used when determining thermal requirements. ‘The thermal rating depends upon the specifics of the drive, operating conditions, the maximum allowable sump temperature, as well as the type of cooling employed. 6.1 Rating criteria ‘The primary thermal rating criterion is the maximum. allowable oll sump temperature. Unacceptably high oll sump temperatures influence gear drive operation by increasing the oxidation rate of the oil and decreasing its viscosity. Reduced viscosity transiates into reduced ollflm thickness on the gear teeth and bearing contacting surfaces which may resutt in reducing the fife of these elements. To achieve the requited life and performance of a gear drive, the operating oll sump temperatures must be evaluated and limited. ‘Thermal ratings of gear drives rated by this standard ‘are limited to a maximum allowable oll sump temperature of 200° F. However, based on the gear manufacturer's experience or application require- ments, selection can be made for oil sump temperatures above or below 200°F (see 6.6). ‘Additional criteria that must be applied in establish- ing the thermal rating for a specific gear drive with a given type of cooling are related to the operating conditions of the drive. The basic thermal rating, Py, is established by test (Method A) or by calculation (Method 8) under the following conditions: = oil sump temperature at 200°F; - ambient air temperature of 75°F; = ambient air velocity of =275 fpm in a large indoor space; = air density at sea level; and ~ continuous operation Modifying factors for deviation from these criteria are given in66. ANSVAGMA 6010-FS7 6.2 Service conditions 6.2.1 Intermittent service For intermittent servioe, the input power may exceed: ‘the manufacturer's thermal power rating provided the oil sump temperature does not exceed 200° F. 6.22 Adverse conditions ‘The ability of a gear drive to operate within its thermal power rating may be reduced when adverse condi- tions exist. Some examples of adverse environmental conditions are: = anenclosed space; = buildup of material that may cover the gear drive and reduce heat dissipation; = _ahhigh ambient temperature, such as boiler, ‘machinery or turbine rooms, or in conjunetion with hot processing equipment = high altitudes; ~ the presence of solar energy or radiant heat. 6.2.3 Favorable conditions The thermal power rating may be enhanced when operating conditions indude increased air ‘movement or a low ambient temperature. 6.2.4 Auxiliary cooling ‘Auxiliary cooling should be used when the thermal rating Is insufficient for operating conditions. The oil may be cooled by a number of means, some of which, are: - Fan cooling. The fan shall maintain the fan cooled thermal power rating: = Heat exchanger. The heat exchanger used shall be capable of absorting generated heat that cannot be dissipated by the gear drive by convection and radiation. : 6.3 Methods for determi g the thermal rating ‘Thermal rating may be determined by one of two methods: Method A - test, or Method B = calculation. 63.1 Method A: Test Test of full scale gear drives at operating conditions fs the most accurate method for establishing the thermal rating of the gear drive. See 6.4. 632 Method B: Heat balance catcutation The thermal rating of a gear drive can be calculated using the heat balance equation which equates heat generated with heat dissipated. The method forANSVAGMA 6010-F97 calculating the thermal rating is given in 6.5. The method for calculating heat generation is discussed in 6.5.1 and for heat dissipation in 6.5.2. 6.4 Method A - Test Atest of a specific gear drive at its design operating conditions is the most reliable means to establish the thermal rating. Thermal testing involves measuring the steady state bulk oil sump temperature of the goar drive operating atts rated speed at no load and at least one or two increments of load. Preferably cone test should be at 200°F sump temperature. While no load testing cannot yield a thermal rating, it may be used to approximate the heat transfer coefficient for comparison purposes, if the power required to operate the drive at no load is measured. ‘Some guidelines for acceptable thermal testing are as follows: - The ambient air temperature and velocity must be stabilized and measured for the duration of the test; = Thetime required for the gear drive to reacha steady state sump temperature depends upon the drive size and the type of cooling; ~ Steady state conditions can be approximated ‘when the change in oilsump temperature is 2°F or less per hour. ‘The oil temperature in the sump at various locations can vary as much as 27°F. The location of the temperature measurement should represent the bulk oil temperature. Outer surface temperatures ‘can vary substantially from the sump temperature. ‘The opposite direction of rotation can create a different sump temperature. During thermal testing the housing outer surface temperature can be surveyed if detailed analysis of the heat transfer coefficient and effective housing surface areais desired. Also, with fan cooling, the air velocity distribution over the housing surface can be measured. 6.5 Method B - Calculations for determining the thermal power rating, Py The calculation of thermal rating is an iterative process due to the load dependency of the coeffi- Cient of friction for the gear mesh and the bearing power loss. 10 AMERICAN NATIONAL STANDARD. The basis of the therrral rating is when the losses, Py. at R, are equal to the heat dissipation, Pp, of the gear drive. Po =Py (2) When this is satisfied under the conditions of 6.1, input power, fis equal tothe thermal power rating, Pr. ‘The heat generation in a gear drive comes from both load dependent, Fy, and non-load dependent losses, Py. Py =P. + Py (3) , is a function of the input power, Py, Py, = (PA) (4) Using equation 2 and rearranging terms, we can write the basic heat balance equation as follows: Pq ~ Py ~ fa) = 6) To determine the basic thermal rating, Pr vary Py until equation 5 is satsfed. This can be done by recalculating the load dependent losses, Fi), at different input powers, Fs. IfPo = Py, the gear drive does not have adequate thermal capacity. The design must be changed to increase Po or auxiliary cooling methods must be used. When equation 5 Is satisfied, the overall unit efficiency, n, is calculated as follows: Plt Py Pa ‘The thermal rating of the gear drive can be related to efficiency as follows: = 100- x 100 (6) oul) 6.5.1 Heat generation ‘The heat generated ina gear drive comes from both load dependent, P,, and non-load dependent losses, Py. ‘The load dependent losses are comprised of the bearing losses, Pa, and the gear mesh losses, Py: P= Seat Sly (8) ‘The non-load dependent losses consist of the oil seal losses, Ps, the internal windage and oll churning losses, Pyy and Pp, and the oil pump power, Pa, consumed. Py = SPs + Pw t DP ww + DP pl) ‘These losses must be summed for each occurrence Inthe gear drive.AMERICAN NATIONAL STANDARD 6.5.1.1 Bearing power loss, Ps Rolling contact bearing power loss, Pa, may be estimated by using equations 10 and 11. Values for the bearing coefficient of friction, f, may be approximated using the values from table 2 [1]. ‘When more exact values are known, they should be used. For more detailed information see [1]. [2, (3) and [4] To P= BOS (10) where Ty _ isthe rolling beaxing tition torque, Ib in; (do + di) 1 fame. + 4) (1) 1% is bearing shaft speed, rpm; fy Is bearing coefficient of friction (table 2}; W is bearing load, tb; & is bearing outside diameter, in; Is bearing bore, in. Table 2 - Bearing coefficient of friction, f, ANSUAGMA 6010-F57 churning effects have often been combined with the assumed friction values. Ideally, the coefficient of friction depends on the lubricant properties, surface conditions and sliding velocity. It also changes with contact load factor, K. 6.5.1.2.1 Mesh power loss, Py, spur and helical gears For spur and helical gears, the following equation can be used to estimate the gear tooth mesh losses 11], (5). [6] and [7]: Py = Pelee Ne (12) 63: 025M where J isthe mesh coefficient of friction at mesh oil temperature; Ifthe pitch line velocity, x, s 400 < v < $000 fpm and the contact load factor, K, 100 < K < 2000 tbyin? and1SOVGis between 46 and 460, then fa canbe estimated by equation 13. Outside these limits the mesh coefficient should be determined experimentally 1 KO35 CoB (18) Sin Coefficient oo ‘Type of bearing of friction, f Tp _is the torque on the pinion, i Fadil ball bearing — (Gingle-row deep graave) 0.0015, tp isthe mpm of the pinion; SSetf-aligning ball bearing 6.0010 ‘be is the operating helix angle at operating ‘Angular-contact ball bearing 0.0013 bitch diameter, deg; “Thrust ball bearing 0.0018 ‘M__ isthe mesh mechanical advantage; Cylindrical roller bearing 0.0011 Cy is lubricant factor (see table 8); Spherical roller bearing?) 0.0018 1» ispitch ine velocity, fpm. “Tapered roller bearing?) o.0018 NOTE: ‘Table 3 - Lubricant factor, Cj, at 200°F sump 1) Variation in depends on speed and load, temperature’) 2) ls greater on tapered and spherical roller bearings due fo rubbing on the roller ends, AGMA TSOVG G 7 76 i018 6.5.1.2 Mesh power loss, Py 2 68 953 4 150 B46 Mosh losses are a function of the mechanics of tooth . Ban a action and the coefficient of friction. Tooth action : 6 320 763 involves fore sliding with the meshing teeth ‘ sco ae separated by an oil film, roe ‘Themesheficiencyisexpressedasatunctionctthe |") These values can, be approximated by| specific sliding velocities and the coeficient of | L1= 17285 x GSOVG) friction. The coefficient of friction is difficult to assess. Reliable published data is rather limited, especially at high pitch line velocities. In the past, windage and kis gven by he equation Tp We N Tale Mal os 2F (rn) Ng "ANSVAGMA 6010-F97 where Np _ is the number of pinion teeth; Ng is the number of gear teeth; F ig the face width In contact with mating element, in; ty is the pinion operating pitch radius, in ‘The equation for the mesh mechanical advantage is: 208 bw (Hs + Ft) HE +B Mg ‘be is the operating transverse pressure angle, deg; H, is the sliding ratio at start of approach; H, isthe sliding ratio at end of recess. ‘The values for H, and H, are: Hy = (mg + il(E-~+)-o] sn(t8) where mg is the gear ratio, NeINp: R,_ isthe gear outside radius, in; Ry _ is the gear operating pitch radius, in; 7% Is the pinion outside radius, in. 6.5.1.2.2 Mesh power loss, Py, bevel gears ‘A method for determining bevel gear mesh power loss is shown in annex F. 6.5.1.3 Oil seal power loss, Ps Contact tip oil seal losses are a function of shaft speed, shaftsize, oll sump temperature, oll viscosity, depth of submersion of the oil seal in the oil and oil seal design. Oil seal power losses can be estimated from equation 18. Figure 1 can be used to estimate il seal frictional torque as a function of shaft diameter for oll seals typically used in gear drives, see [8]. Isn = it (t Ps 63025 (18) 12 AMERICAN NATIONAL STANDARD where Ts__ is the oll seal torque, ib in (figure 1); nis the shaft speed, 1pm. 7 T Ss 4 is 2 7208172, > wal a ® g ae s T, = 0.536 Dy 51 Zo 04 5 68 7 Pans Shaft diameter, D,, in Figure 1 - Seal friction torque 6.5.1.4 Gear windage and churning power loss, Pw For gear drives covered by this standard, windage and churning losses are generally combined into a single loss. This loss, Py, for each gear and pinion canbe estimated from equation 19 and 20 for spur or helical gears, and equations 21 and 22 for bevel gears. ‘The empirical arrangement constant, A, varies with the arrangement of the gears in the gear drive, the degree of contact with the oil and the oil viscosity. The same arrangement constant can be used for gears, pinions and bearings. For gear drives covered by this standard, the arrangement constant is given by equation 23. Gr F, cs? Ww 2 ne 3 ee Pap = OEE 9 ty where Parc. is the windage loss for gear; Pup is the windage loss for pinion; 4y is the operating pitch diameter of gear or pinion, in; nis the shaft speed (gear or pinion), rpm; F, _ is the total face width of gear or pinion, in; isthe mean spiral angle, degrees; tm _ is the mean reference radius,AMERICAN NATIONAL STANDARD P, isthe normal diametral pitch, in Pra is the mean normal diametral pitch, in-’; A isthe arrangement constant. 22.440 A= (23) where Cp is the absolute oil viscosity at sump temperature, cP. 65.1.5 Bearing windage and churning power loss, Pun For gear drives covered by this standard, windage land churning losses are generally combined into & single loss. For bearings other than tapered roller bearings, the windage and churning losses are included in Ps. This is a simplified approach ‘combining no load and load dependent losses. For tapered roller bearings, this loss, Pig, can be ‘estimated for each bearing from equation 24. For tapered roller bearings only: pg, = Gt B cos? ay Dy wa = “136000 « (O.78VA where dq 8 mean bearing diameter (1/2 (bearing cup outer diameter + bearing cone bore diameter)), of the tapered roller bearing, in; nis shaft speed (each bearing), rpm; Bis length thru bore of bearing, Dz _ is the mean roller diameter, in; is cup angle of a tapered roller bearing, (24) oy = tan(;85) ~-(25) ‘The value of e is determined from the bearing manufacturer for the specific bearing number, or when ¢ is not provided, wo) where (26) Ks__is the ratio of basic dynamic radial load rating to basic dynamic thrust load rating, The value of Ks is available from the bearing manufacturer for the specific bearing number. 6.5.1.6 Oil pump power loss, Fp ‘The required power and capacity of most lubrication oll pumps vary directly with the speed. Thus, the ANSVAGMA 6010-F97 required power is a function of the cil flow and cil pressure at a given pump speed. Pp = Post Pom (27) For an oll pump driven by one of the reducer shatts, the oll pump loss, Pp,, can be estimated by equation 28. Op Pes Ts 6 (28) where 2 iscilfiow, gal/min; PIs operating oil pressure, Ibjin?; 4 _ iscil pump efficienoy, usually around 85%. For an oil pump driven by an electric motor, the oil pump losses, Pry, can be estimated using equation 29, which considers the electric power consumed ‘and the efficiencies of both theelectric motor andthe oil pump. (29) where Ep _ is electric power consumed, hp; ém iS electric motor efficiency, %. Pm, Should be included in the thermal calculations, but should not be included in the enclosed gear unit, efficiency. See 4.5. 6.5.2 Heat dissipation, Po ‘The heat dissipated from a gear drive is influenced by the surface area of the gear drive, the air velocity across the surface, the temperature differential, AT, between the oll sump and the ambient air, the heat transfer rate from the oil to the gear case and the heat transfer rate’ from the gear case and the ambient air. The heat dissipation is given by ‘equation 30. , Po =AckAT (80) where ‘Ac isthe gear case surface area, 2; k isthe heat transfer coefficient, np/t2°F (see table 4 oF 6); AT is the temperature differential, “F. NOTE: A. isthe gearcase suriace area exposed toam- bent air, not including fins, bolts, bosses or mounting surfaces. CAUTION: The tubricant must be eelected to accom- modate the extreme conditions of the temperature differential, See clause 9. ‘The heat transter coefficient, kis defined as the average value aver the entire gear drive outer 13ANSVAGMA 6010-F97 surface. The heat transter coctticient will vary depending upon the material of the gear case, the dleanliness of the extemal surface, the extent of wetting of the internal surfaces by the hot oil, the configuration of the gear drive and the air velocity across the external surface. For gear drives covered by this standard, typical values for & can be found in table 4. See [9]. ‘Table 4 - Heat transfer coefficient, k, for gear drives without auxiliary cooling Air Feat transier velocity, | coefficient, ?> Condition fom hp/t? °F Small confined <275 [0.0007 - 0.0010 ‘space Large indoor 2275 0.0011 - 0.0014 ‘space Large indoor 275 /0.0012- 0.0015, ‘space Outdoors 2725 |0.0014- 0.0017 NOTE: 1) The choloe of k values within each range is atfected| by the items listed in 6.5.2. Use of the high values in| each range should be justified by test. ‘The heat transfer coefficient for a shaft fan cooled gear drive is a function of fan design, shroud design. and fan speed. It will vary substantially depending upon the effectiveness of the fan and the proportion ofthe exterior surface cooled by the resulting airflow. The air velocity is defined to be the average ait velocity over 60% of the surface area, A., of the gear drive. The effect of using multiple fans on a gear rive could increase the average air velocity, thereby resulting in a higher heat transfer coafficient. Table 5 provides values for k for fan cooled gear drives. Table 5 - Heat transfer coefficient, k, for gear drives with fan cooling ‘Air velocity | Heat transfer coefficient, k pm. hpi °F ‘500 0.0010 1000 0.0017 2000 0.0029 3000 0.0040 14 AMERICAN NATIONAL STANDARD 66 Corrections for non-standard operating conditions When the actual operatng conditions for a specific application are differentiromtthe standard conditions, defined in 6.1, and the thermal rating is calculated for the conditions of 6.1, the thermal rating may be ‘modified for the application as follows: Pram = Pr Bo By Ba Br By (1) Brg and By may be applied to natural or shaft fan cooling. By may be applied only to natural cooling, The gear drive manufacturer should be consulted ‘when the conditions exosed the limits given in tables 6 thru 10 or when correction factors are required for any type of cooling other than natural or shaft fan. ‘When the ambient air temperature is below 75°F. Brey allows an increase inthe thermal rating. Conversely, with an ambient air temperature above 75°F, the thermal rating is reduced. See table 6. Table 6 - Ambient temperature modifier, Bry ‘Ambient temperature, Brey 30 Tis 65, 1.07 7% 7.00 85 0.93 100 083 110 0.75 120 067 When the surrounding air has a steady velocity in excess of 275 fpm due to natural or operational wind fields, the increased convection heat transfer allows the thermal rating to be increased by applying By. Conversely, with an ambient air velocity of <100 ‘pm, the thermal rating is reduced. See table 7. Table 7 - Ambient air velocity modifier, By ‘Ambient air velocity, fpm- By = 100 O75 > 100 «275 1.00 > 275 < 725 1.40 2725 1.90 ‘At high altitudes the decrease in air density results in the derating factor, By. See table 8.‘AMERICAN NATIONAL STANDARD Table 8 - Altitude modifier, By ‘Anitade, tt Ba 0- Sea level T.00 2500 0.95 5000 0.0 7500 0.85 +9000 ot 12.500 076 1.000 o72 17.500 0.68 ‘The standard maximum allowable oll sump tempera- ture is 200°F, A lower sump temperature requires a reduction inthe thermal rating using By. See table 9. ‘Amaximum allowable sump temperature in excess of 200°F will increase the thermal rating and can provide acceptable gear drive performance in some applications. However, it must be recognized thet operating above 200°F may reduce lubricant and contact seal life and increase the surface deteriora- tion on the gears and bearings with a subsequent increase in the frequency of maintenance. The gear manufacturer should be consulted when a maximum allowable oil sump temperature in excess of 200°F Is. being considered, Table § - Maximum allowable oil sump temperature modifier, Br imam oir sump temperature, | By Tes oat 200 1.00 220 1.43 When a gear drive sees less than continuous operation with periods of zero speed, the resulting “cool-off” time allows the thermal rating to be increased by Bp. See table 10. Table 10 - Operation time modifier, Bp ‘Operation time per Bo each hour TOO% (continuous) 7.00 80% 1.05 60% 115 40% 1.35 20% 1.80 ANSVAGMA 6010-F57 7 Component design ‘The components at a gear rive must be designed ‘with consideration for ail loads likely to be encoun tered during operation. These include the torque loads imposed on the components through the (gearing, and the external loads, such as overhung loads, external thrust loads and dynamic loads. Components must also be designed to withstand any assembly forces which might exceed the operating loads. During the design process, the operating loads must be considered to occur in the worst possible direction and loading combinations. ‘All components shall allow for peak loads of 200 percent of the unit rating, considering both internal and external loads, in accordance with 3.1. User requirements or specifications dictating different design criteria must be by contractual agreement. 7.1 Housing Refer to clause 7 of ANS/AGMA 6001-D97 ‘or design guidance. 7.2 Bearings Shafis may be mounted in sleeve or roling element bearings, of a size, type and capacity to carry the radial and thrust loads that would ocour under maximum operating conditions. For additional in- formation, consutt clause 6 of ANSVAGMA 6001-D97. 7.2.1 Sleeve bearings Sleeve bearings shall be designed for maximum bearing pressures of 750 Ib/in? on projected area. Journal velocities shall not exceed the values given below. = 1500 fpm with lubricant supplied not under pressure; 7200 fpm with lubricant supplied under grav- ity with the oil inlet fully flooded. 7.2.2 Roller and ball bearings Roller and ball bearings shall be selected to provide ‘@ minimum Lyo bearing life of 5000 hours based on unit rating @s calculated by the methods of the bearing manufacturers, with considerations given to lubrication, temperature, load zone, alignment and bearing material. 7.3 Shatting Shafting should be designed in accordance with clause 4 of ANSVAGMA 6001-D97.ANSVAGMA 6010-F97 7.4 Keys Refer to clause 5 of ANSYAGMA 6001-D97. See annex B, 7.4.1 External keyways Keyways in external shaft extensions on the gear rive should conform to ANS! 817 “commercial class" or ISO 773-1969 (E) “tree fit. 7.4.2 Allowance for interference fit The allowable stresses provided in annex A of ANSI/AGMA 6001-097 are based on the assump- tion that an interference fi is not used and that the key carries the entire torque load. When an interfer- ence fitis used in conjunction with a key, the actual compressive or shear stress may be reduced by the effect of the interference fit at maximum operating ‘temperature as follows: (1001, Ke) 0 = 5 Xe (82) (400-7, x Ke) Sap = yy x DT Ae (83) where So is the adjusted compressive stress, Ib/in’; S» is the adjusted shear stress, Ib/in?; & Is the calculated key compressive stress, Ibfin?; sxe is the calculated key shear stress, Ibfin Jy _ isthe allowable percentage of torque capac- ity obtained due to the interference fit (by calculation or test); Kjq_is the shrink adjustment faotor to compen- sate for less than 100 percent engagement (determined by test or experience). ‘The product of J} Ksz < 100. 7.5 Threaded fasteners Refer to clause 8 of ANSYAGMA 6001-097. 7.6 Backstops Backstops are designed to prevent reverse rotation of driven equipment that is intended for uni- directional rotation only. They allow free, unimpeded rotation in one direction, while preventing rotation in the opposite direction. Specified torque limit and rotational speed will vary depending upon the manufacturer. 16 AMERICAN NATIONAL STANDARD 7.6. Types Backstops are a variety of clutch, This discussion is, limited to cam or *sprag” type clutches. However, other types may be. used. Cam clutches are generally used for three distinct operational modes: overrunning, indexing and backstopping. This dis- cussion is further limited to the backstopping mode of operation. 7.6.2 Selection and application Backstopping load is permitted to pass through all components between the load and the backstop, ‘This may render the backstop function ineffective in case of component failure between the backstop and the driven load. The maximum allowable overrunning backstop speed must be greater than the maximum shaft speed attainable in all operating conditions. The backstop should be selected based upon the number of backstopping cycles and the applied torque. 7.6.3 Installation ‘A backstop is installed with the outer race of the backstop anchoredto astationary member while the inner members can overrun freely in one direction of rotation. Abackstop wih a separate inner race must have the race secured to the rotating shaft. 7.6.3.1 Installation of built in types ‘A backstop can be buit into the gear drive and the inner race eliminated by having the cams engaging directly on the supporting shaft. In this case, the Inner race surface must be capable of sustaining a Hertzian contact stress as required by the backstop design. ‘The following items concerning the shaft must also be addressed: - surface hardness; = case depth; = taper of the supporting cam contact area; = concentricity with backstop outer race. ‘The shaft that the backstop is mounted on must be supported by bearings. The backstop is not intended to withstand reaction loads imposed by gears or other sources. 7.6.3.2 Source of installat ‘Some manufacturers choose to ship gear drives with ackstops intemal to the gear drive while others