Transilvania University of Brasov

Program : MDESIGN User : TEDATA Customer: Test

Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
With the following program based on the standard calculations DIN 3960, the geometry of spur gears can be calculated.

This module has different operations and possibilities for calculation profile shift.
These possibilities are the following:
Automatic calculation and distribution of the total profile shift coefficient according to DIN 3992 (DIN 3993)
Input of centre distance
Input of total profile shift
Input of profile shift

With the following program the strength examination (pitting load capacity, root load capacity, corrosion load capacity) of spur gears will be
calculated. Therefore the calculation base DIN 3990 and also the international ISO 6336 can chose by the user.

With this program standard gauges for spur gears will be calculated.

The application of the number of teeth thickness, spherical dim.-roll diameter DM, deviations of center distance and deviations of teeth thickness
are optional.

Groundwork calculations

Geometry of the spur gear pair and the gear

The standard calculations for this module are described by DIN 3960, edition March 1987.

The following DIN specifications will also be utilized:

DIN 780 Module sequence for spur gears
DIN 867 edition February 1986 (basic profile)
DIN 3960 edition March 1987 (concept and dimension determination for spur gear pairs with involute gearing)
DIN 3960 supplement 1, edition July 1980
DIN 3992 edition March 1964 (profile displacement for spur gears with outer gearing)
DIN 3993 edition August 1981, part 1 - 4 (geometric design of cylindrical inner gear pairs).

Strength examination of spur gears

The standard calculations for this module are described by the following DIN specifications:

DIN 3990 Part 1 edition December 1987 (general influence factors)

DIN 3990 Part 2 edition December 1987 (calculation of the pitting load capacity)
DIN 3990 Part 3 edition December 1987 (calculation of the root load capacity)
DIN 3990 Part 4 edition December 1987 (calculation of the corrosion load capacity)
DIN 3990 Part 5 edition December 1987 (fatigue stress values and material qualities)
DIN 3990 Part 6 edition December 1994 (operational stability)
DIN 3990 Part 11 edition February 1989 (application standards for industrial gears)
DIN 3961 edition August 1961 (ground tolerances)
DIN 3962 Part 1 edition August 1978 (tolerances for deviation of individual determined dimensions)
DIN 3962 Part 2 edition August 1978 (tolerances for flank line deviations)
DIN 50 150, edition December 1976 1976 (conversion table for Vickers - Rockwell- Brinell hardness and ultimate strength)
ISO 6336 Part 1 edition September 2006 (Basic principles, influence factors)
ISO 6336 Part 2 edition September 2006 (Calculation of surface durability (pitting))
ISO 6336 Part 3 edition September 2006 (Calculation of tooth bending strength)
ISO 6336 Part 6 edition September 2006 (Calculation of service life under variable load)
ISO 6336-1 Technical Corrigendum 1
ISO 6336-2 Technical Corrigendum 1
ISO 6336-3 Technical Corrigendum 1
ISO 1328 Part 1 edition August 2005 (Definitions and allowable values of deviations)

Gauge Design for Spur Gears

The standard calculations for this program are described by DIN 3960, edition March 1987.

The following DIN specifications will also be utilized:

DIN 3961 edition August 1978 (tolerances for spur gearing)
DIN 3962 supplement 1 edition August 1978 (tolerances for deviation of individual determined dimensions)
DIN 3964 edition November 1980 (axis position and Axis position tolerances of housing for spur gears)
DIN 3967 edition August 1978 (flank play, tooth thickness dimension, tooth thickness tolerances)
DIN 3977 edition February 1981 (dimension diameter for the radial or diametric standard gauge of the tooth thickness of spur gears
(cylinder gears))

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Input data:

Spur Gear, Gear Rack

Calculation method Spur gear

Calculation variants Spur gear calculation,
strength
Calculation standard DIN 3990
Type of toothing External toothing

Spur gear geometry

Basic data
Normal modulus mn = 6 mm
Helical angle  : 16 °
Centre distance a: 0 mm

Driving element Pinion

Input of geometry z1, z2
Number of teeth (pinion) z1 = 24
Number of teeth (wheel) z2 = 72
Translation ratio i= 3
Pinion Wheel
Tooth width b = 112 110 mm

Input method for tooth-tip height modification No input

Addendum modification according to DIN 3992/3993

Input methode profile shift coefficients No input
Optimization for profile shift coefficient Special case (very high
strength capacity)

Basic gear rack Pinion Wheel

Tip clearance factor cP* = 0,2 0,2
Root fillet radius factor f P* = 0,4 0,4
Pressure angle p = 20 °
Tooth-tip thickness factor san* = 0,4
Pinion Wheel
Tooth-tip height factor haP* = 1 1
Residual fillet undercut spr : 0 0 mm

Cutter data Pinion Wheel

Number of cutter teeth z0 : 0 0
Basic gear rack profile shift coefficient x0 : 0 0

Spur Gear Calculation - Strength

Drive data
Load case Nominal load
Pinion Wheel
Number of meshed teeth nZE = 1 1
Application factor KA = 1,25
Dynamic factor Kv : 0
Performance P= 20,6 kW
Rotation speed (pinion) n1 = 27,3 1/min
Required lifetime Lh = 10000 h

Lubrication
Viscosity class for 40° oil = 220 cSt
Viscosity class for 100° oil = 4 cSt
Density for 15°C oil = 800 kg/m³
Oil temperature oil = 40 °C

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Force level (according to FZG-test) 3
Type of oil distribution Splash lubrication

Material selection
Pinion - materials (strength values) according to MDESIGN database
International materials no

Material designation 18CrNiMo7-6

Material number 1.6587
Material group Casehardening steel
Heat treatment / State trial hardened
Standard dimension dNm = 16 mm
Standard dimension dNp = 16 mm
Ultimate strength for dNm RmN = 1200 N/mm²
Yield point for dNp RpN = 850 N/mm²
Tooth root strength Flim = 430 N/mm²
Surface durability (pitting) Hlim = 1500 N/mm²
Type of Material 7
Modulus of elasticity E = 210000 N/mm²
Poisson's ratio  = 0,3
Hardness scale HB
Hardness =0
Density  = 7850 kg/m³
Linear expansion factor  = 12 10^-6/K

Temperature T= 0 °C
Enable pitting ? no

Wheel - materials (strength values) according to MDESIGN database

International materials no

Material designation 18CrNiMo7-6

Material number 1.6587
Material group Casehardening steel
Heat treatment / State trial hardened
Standard dimension dNm = 16 mm
Standard dimension dNp = 16 mm
Ultimate strength for dNm RmN = 1200 N/mm²
Yield point for dNp RpN = 850 N/mm²
Tooth root strength Flim = 430 N/mm²
Surface durability (pitting) Hlim = 1500 N/mm²
Type of Material 7
Modulus of elasticity E = 210000 N/mm²
Poisson's ratio  = 0,3
Hardness scale HB
Hardness =0
Density  = 7850 kg/m³
Linear expansion factor  = 12 10^-6/K

Temperature T= 0 °C
Enable pitting ? yes

Spur gear calculation material Pinion Wheel

Structure factor XW = 1 1
Thermal conductivity  = 50 50 N/(s*K)
Heat capacity cM = 485 485 N*m/(k
g*K)
Root roughness Rz = 3,2 3,2 µm
Tooth flank roughness Rz = 1,6 1,6 µm

Data width load factor

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Tooth modification No
Face load factor (root stress) KF : 0
Face load factor (contact stress) KH : 0
Face load factor (scuffing load) KB : 0
Bearing span l = 120 mm
Eccentricity (pinion) s: 0 mm
Shaft diameter at pinion dsh = 50 mm
Factor K' = 1.33
Type of helical toothing Simple

Transverse load factors

Transverse load factor (root stress) KF : 0
Transverse load factor (contact stress) KH : 0
Transverse load factor (scuffing load) KB : 0

General input Pinion Wheel

Gearing quality 1 1
Design Disk Disk
Inner diameter of rim di : 0 0 mm
Tooth modification, base relief Ca : 0 0 µm
Loading type Pulsating Pulsating
Stress ratio = 0 0

Minimal root safety SFmin = 1,3

Minimal flank safety SHmin = 1,3
Minimal scuffing load safety SBmin = 1

Standard gauge spur gear

General data Pinion Wheel
Deviation of teeth thickness (DIN 3967) f f
Tolerances of teeth thickness (DIN 3967) 25 25

Free input deviations Pinion Wheel

Upper deviation of teeth thickness Asne : 0 0 µm
Lower deviation of teeth thickness Asni : 0 0 µm

Machining allowance q: 0 mm

Results:

General data
Effective number of teeth ratio u = 3
Effective translation ratio i = 3
Transverse pressure angle t = 20,739 °
Pressure angle at pitch cylinder wt = 23,912 °
Ground lead b = 15,012 °
Zero centre distance ad = 299,606 mm
Centre distance a = 306,5 mm
Profile shift coefficient (pinion) x1 = 0,5849
Profile shift coefficient (wheel) x2 = 0,65
Sum profile shift coefficient xs = 1,2349

Length of path of contact g = 20,074 mm

Length of recess path ga = 12,882 mm
Length of approach path gf = 7,192 mm
Transverse contact ratio  = 1,095
Overlap ratio  = 1,609
Total contact ratio  = 2,703

Number of teeth z = 24 72

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Virtual number of teeth of helical gear zn = 26,763 80,288

Geometrical data
Reference diameter d = 149,803 449,409 mm
Base diameter db = 140,097 420,29 mm
Pitch diameter dw = 153,25 459,75 mm
Root diameter df = 142,422 442,809 mm
V-circle diameter dv = 156,822 457,209 mm
Tip diameter da = 165,378 465,766 mm
Theoretical tip diameter da th = 168,822 469,209 mm
Root form circle diameter dFf = 145,896 445,892 mm
Root form diameter dNf = 148,005 449,924 mm

Specific sliding at point A A = -0,402 0,287

Specific sliding at point E E = 0,391 -0,642

Tooth thickness on the tip cylinder san = 5,176 5,82 mm

Tooth depth h = 11,478 11,478 mm
Addendum ha = 7,788 8,178 mm
Dedendum hf = 3,691 3,3 mm

Theoretical bottom clearance c = 1,2 1,2 mm

Actual topland play ctat = 2,496 2,476 mm
Tooth – tip height modification k = -1,7217 -1,7217 mm

Normal base pitch pen = 17,713 mm

Transverse base pitch pet = 18,339 mm
Normal pitch on base cylinder pbn = 17,713 mm
Transverse pitch on base cylinder pbt = 18,339 mm

Cutter data of gear rack

Cutter data pinion type cutter
Number of teeth z0 = 0 0
Profile shift coefficient x0 = 0 0
Topland height factor haP0* = 1,2 1,2
Root height factor hfP0* = 1 1
Reference diameter d0 = 0 0 mm
Base diameter db0 = 0 0 mm
Tip diameter da0 = 14,4 14,4 mm
Deddendum diameter (generation) dfE = 142,281 442,631 mm
Centre distance a0 = 77,955 228,322 mm
Zere centre distance ad0 = 74,902 224,705 mm
Pressure angle at pitch cylinder wt0 = 26,029 23,017 °

Results of calculation strength

Forces, moment, speed
Transverse tangential load Ft = 96202,22 N
at reference cylinder
Transverse tangential load Ftw = 94038,451 N
at pitch cylinder
Radial load at pitch cylinder Frw = 41695,05 N
Axial load at pitch cylinder Faw = 27585,543 N
Tooth load at pitch cylinder Fw = 106501,97 N
Moment (pinion) T1 = 7205,696 N*m
Moment (wheel) T2 = 21617,089 N*m
Line load = 1093,207 N/mm
Peripheral speed at reference cylinder v = 0,214 m/s
Peripheral speed at pitch cylinder vw = 0,219 m/s
Rotation speed (pinion) n1 = 27,3 1/min
Rotation speed (wheel) n2 = 9,1 1/min
Number of loading cycle (pinion) NL1 = 16380000

ANGRENAJ CILINDRIC.mdp 11/03/2019 07:57:33 Page 5/17

 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Number of loading cycle (wheel) NL2 = 5460000

General factors
Hekix slope deviation fH = 3 3 µm
Transverse pitch deviation fpe = 1,5 2 µm
Profile form deviation ff = 2 2 µm
Effective meshing slope deviation fpe eff = 1,519 µm
Effective profile form deviation ff eff = 1,45 µm
Flank line deviation fx = 21,04 µm
Manufacturing - flank line deviation fma = 3 µm
Flank line deviation through pinion def. fsh = 13,564 µm
Reduced mass / tooth width mred = 0,079 kg/mm
Individual spring rigidity c' = 15,58 N/(mm*µm)
Meshing spring rigidity c = 15,017 N/(mm*µm)
Resonance velocity (pinion) nE1 = 5475,442 1/min
Resonance velocity (gear) nE2 = 1825,147 1/min
Basic velocity NR = 0,005
Dynamic factor Kv = 1
Face load factor (root stress) KF = 1,058
Face load factor (contact stress) KH = 1,065
Face load factor (scuffing load) KB = 1,065
Transverse load factor (root stress) KF = 1
Transverse load factor (contact stress) KH = 1
Transverse load factor (scuffing load) KB = 1
Helix angle factor KB = 1,254

Pitting load capacity

Zone factor ZH = 2,232
Elasticity factor ZE = 191,646
Contact ratio factor Z = 0,956
Helix angle factor Z = 0,98
Work hardening factor ZW = 1

Lubricant factor ZL = 1,016 -

Velocity factor Zv = 0,952 -
Roughness factor ZR = 1,068 -
Life factor for contact stress ZNT = 1,088 1,354
Size factor ZX = 1 1
Single pair tooth contact factor ZB = 1 ZD = 1,000
Pitting stress limit HG = 1685,976 2059,616 N/mm²
Allowable flank pressure HP = 1296,904 1584,32 N/mm²
Contact stress H = 1290,648 1290,648 N/mm²
Safety factor for pitting SH = 1,306 1,596
Attainable lifetime Lh = fat. strength fat. strength

Root load capacity

Overlapping factor (root stress) Y = 0,914
Helix angle factor Y = 0,867
Deep tooth factor YDT = -
Rim thickness factor YB = - -
Tooth form factor YF = 1,385 1,42
Stress correction factor YS = 2,153 2,183
Relativ notch sensitivity factor YrelT = 1,007 1,011
Relativ survace factor YRrelT = 1,042 1,042
Size factor YX = 0,994 0,994
Life factor for tooth root stress YNT = 1 1
Mean stress influence factor YM = 1 1
Tooth root stress limit FG = 896,777 900,365 N/mm²
Allowable root stress FP = 689,828 692,588 N/mm²
Tooth root stress F = 498,51 518,204 N/mm²
Safety factor for tooth breakage SF = 1,799 1,737
Attainable lifetime Lh = fat. strength fat. strength

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Scuffing load capacity

Angle factor X = 1,026
Lubricant factor XS = 1

Flash temperature calculation way

Load distribution factor X = 0,667
Flash factor XM = 50,235
Geometry factor XB = 0,169
Tangential line force at weigth wBt = 1460,877 N/mm
Scuffing temperature  = 95,857 °C
Corrosion safety factor SB = 2,178

Integral calculation way

Flash factor XM = 50,235
Geometry factor (pinion tip) XBE = 0,193
Pitch factor XQ = 1
Tip relief factor XCa = 1
Contact ratio factor X = 0,369
Mass temperature M = 46,679 °C
Integral temperature int = 60,99 °C
Scuffing integral temperature intS = 95,857 °C
Corrosion safety factor SintS = 1,572
Scuffing load safety factor SSL = 2,661

Ultimate strength for pinion Rm = 1200 N/mm² (for deff = 140,1 mm )

Ultimate strength for gear Rm = 1200 N/mm² (for deff = 420,29 mm )
Yielding point for pinion Re = 850 N/mm² (for deff = 140,1 mm )
Yielding point for gear Re = 850 N/mm² (for deff = 420,29 mm )

Specific sliding accord. to DIN 3960

Kg  External toothing
x1 = 0,585
x2 = 0,650
4,3 xs = 1,235

1,621
3,2 ga = 12,882
gf = 7,192
Kg1
2,1 g = 20,074
A E Kga1 = 0,224
0,540 1,1 Kga2 = 0,125
C
0,224 Kgf1 = 0,125
0,125
0 Kgf2 = 0,224
-0,125
-0,224
spec. sliding: pinion
-1,1
-0,540
A = -0,402
1 E = 0,391
-2,1
2 Kg2
spec. sliding: gear
-3,2
-1,621 A = 0,287
-4,3 E = -0,642

0 12,423 37,270 62,117 86,963 111,810 [mm]

Meshing Line

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Tooth profile (evolvent) pinion

da1

dw 1

d1

df1

Tooth profile (evolvent) gear

da2

dw 2

d2

df2

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Gap of tooth (envelope curv e, ev olv ent) pinion

da1

dw 1
d1

df1

Gap of tooth (envelope curv e, evolvent) gear

da2

dw 2

d2

df2

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Side view pinion

df1 d1 da1

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Side view gear

df2 d2 da2

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Front view pinion

df1 d1da1

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Front view gear

df2 d2 da2

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Gear wheel (evolvent) pinion

ANGRENAJ CILINDRIC.mdp 11/03/2019 07:57:33 Page 14/17

 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack

Gear wheel (evolvent) gear

Pinion, Pitting Bearing Capacity Diagram

HG material : 18CrNiMo7-6 load cycle [-] lifetime [h]

[N /mm²]
2
10 0,06
3000 3
10 0,61
4
10 6,11
static
5
10 61,05
2400 6
10 610,50
7
10 6105,01
time strength
8
10 61050,06
1800

fatigue strength
1200

600

0
2 3 4 5 6 7 8
10 10 10 10 10 10 10 load cy cle

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 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Gear, Pitting Bearing Capacity Diagram

HG material : 18CrNiMo7-6 load cycle [-] lifetime [h]

[N /mm²]
2
10 0,18
3000 3
10 1,83
4
10 18,32
static
5
10 183,15
2400 6
10 1831,50
7
10 18315,02
time strength
8
10 183150,18
1800
9
10 1831501,83
10
fatigue strength 10 18315018,32

1200

600

0
2 3 4 5 6 7 8 9 10
10 10 10 10 10 10 10 10 10 load cy cle

Pinion, Root Bearing Capacity Diagram

FG material : 18CrNiMo7-6 load cycle [-] lifetime [h]

[N /mm²]
2
10 0,06
3000 3
10 0,61
4
10 6,11
5
10 61,05
2400 static
6
10 610,50
7
10 6105,01
8
10 61050,06
1800

time strength

1200

fatigue strength
600

0
2 3 4 5 6 7 8
10 10 10 10 10 10 10 load cy cle

ANGRENAJ CILINDRIC.mdp 11/03/2019 07:57:33 Page 16/17

 Transilvania University of Brasov
Program : MDESIGN User : TEDATA Customer: Test
Module version: 15.0 Date : 21.06.2019 Project: 11
Spur Gear, Gear Rack
Gear, Root Bearing Capacity Diagram

FG material : 18CrNiMo7-6 load cycle [-] lifetime [h]

[N /mm²]
2
10 0,18
3000 3
10 1,83
4
10 18,32
5
10 183,15
2400 static
6
10 1831,50
7
10 18315,02
8
10 183150,18
1800

time strength

1200

fatigue strength
600

0
2 3 4 5 6 7 8
10 10 10 10 10 10 10 load cy cle

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