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AMERICAN NATIONAL STANDARD. make them external. in either case, special care must be taken to identify the proper direction of rotation, Manufacturers usually identify the backstop housing with a marking to indicate the appropriate shaft rotation to prevent damage to the backstop. ‘The installation should take the added precaution of manually rotating the input shaft with the motor installed to insure the proper operation of the clutch. 7.6.4 Lubrication ‘The backstop, much like other elements of the gear drive, must have proper lubrication that is free of contaminants, and the lubricant should be drained, flushed, and changed on @ regular maintenance schedule as recommended by the gear drive manufacturer. ‘The backstop may be lubricated by grease or oll that is appropriately selected for the application considering the environment in which it will operate. WARNING: Do notuse extreme pressure lubricants or \ubricants with formulations including sulphur, chlorine, lead and phosphorous derivatives, as well as graphite and molybdenum cisulide in gear drives equipped with an intemal backstop unless approved by the gear drive manufacturer or the backstop manufacturer. WARNING: Some synthetic gear lubricants adversely affect the operation of internal backstops. Special au- thorization is required tom the gear crive manufacturer before using @ synthetic lubricant in a gear drive cequippeg with an intemal backstop. 7.7 Balancing ‘The purpose of balancing is to minimize or eliminate vibration in a rotating element due to unbalance. The importance of proper balancing increases directly in proportion to the pitch line velocity of the rotating part. Excessive unbalance can result in premature bearing, gear or other component fallure. itis the responsibilty of the manufacturer ofthe drive components to determine the need for balancing and assure that it is done without affecting the structural integrity of the rotating mass. 7.8 Shrink discs Shrink dis¢s are one option to connect. hollow shaft gear drive to the drive shaft. The shrink disc is an external locking device installed over a hollow shaft projection. By tightening the locking screws, the locking collars exert radial forces on the tapered inner ring and the hub. After bridging the fit clearances, radial clamping pressure is generated between the drive shaft and the holiow shaft establishing a solid, frictional connection. jo sv ANSVAGMA 6010-F97- During the selection process, the following items should be considered: ~ hollow shaft and drive shaft yield point of material; coefficient of friction between the hollow shaft, and the drivé shaft; = tolerance and fits of the mating surfaces; ~ effect of diameter change when the shrink discs applied; ~ surface finishes of the hollow shaft and drive shaft; ~ axial forces applied to the assembly; = starting and peak loads transmitted through the drive system. ‘The shrink disc should be selected according to the ‘manufacturer's recommendatons. 7.9 Other components See clause 9 of ANSVAGMA 6001-97 for brief discussions on the following components: = shims, 9.1; - gaskets, 9.2; = all seals, 8.3 (see note below); ~ breathers, 9.4 (see note below); = expansion chambers, 8.5 (see note below); = olllevel indicators, 9.6; = bearing retainers, 9.7; = grease retainers, 9.8; ~ dowels and pins, 9. spacers, 9.10; ~ seal retainers, 9.11; = locking devices for fasteners, 9.12; ~ tolerance and fits of mating surfaces. NOTE: It is recognized thet gear chives applied in certain industries and under certain atmospheric conditions should be equipped with special seals and breathers designed for those conditions. Examples are units installed in the dusty or corosive atmospheres of chemical plants, cement mills and taconite processing plants. Its also recommended that units which are to be exposed to severe mosture and vapor laden atmospheres be equipped wth moisture barrier seals ‘and breathers, Some applications in wet locations ‘subject to direct or indirect wash down may prectude the use of breathers, such as in the paper and food industries. In these cases, expansion chambers may be used 7ANSI/AGMA 6010-F97 8 Service factors 8.1 Selection of service factors Before an enclosed gear drive can be selected for an application, an “equivalent power rating” must be determined. Thisis done by multiplying the specified transmitted power by the service factor. Since service factors represent the normal relationship between gear unit design power rating and the maximum potential transmitted power, it is sug- gested that the service factor be applied to the nameplate rating of the driven machine or prime mover, as applicable. Manufacturer and user must agree upon which power, prime mover rating or driven machine Tequirements, should dictate the selection of the gear drive. It is necessary that the gear drive selected have a rated load capacity equal to or in ‘excess of this “equivalent power rating’, Service factor has been used to include the combined effects of Zy, Yi, Ke and X, in an ‘empirically determined single factor. The mathemat- ical contribution of each of these factors has not been established. See ANSYAGMA 2001-C95, clause 10. Inthe absence of more specific load data, a service factor, Ker, shown in table A.2 of annex A, may be used. 82 Listing of service factors The table of “Service Factors", shown in annex A, has been developed from the experience of manu- facturers and users of gear drives for use in common applications and has been found to be generally satisfactory for the listed industries when gears are rated using AGMA standards. It is suggested that service factors for special applications be agreed upon by the user and the gear manufacturer when variations of the tabulated value may be necessary. ‘This standard is based on the premise that the user is defining a catalog rating. 8.3 Determining service factors Service factors may be selected from annex A or may be determined by an analytical method. Listed below are some of the more important factors to be considered. 8.3.1 Operational characteristics ‘Some of the operational characteristics that could affect an increase or decrease in service factors are: 18 AMERICAN NATIONAL STANDARD Type ot prime mover. Differenttypes of prime movers are electric motors, hydraulic motors, steam of gas turbines, and internal combustion. engines having single or multiple oylinders. = Starting conditions. Starting conditions where peak loads exceed 200 percent of rated load and frequency or duration as defined in 3.1. Rated loadis defined as theunitrating with a service fac- tor of 1.0 When a soft start coupling is used between the prime mover and the gear drive, the selection of service factors can De based on the gear drive manufacturer's analysis for the application. = Overloads. Loads which are in excess of the rated load are considered overloads. Overloads can be of momentary duration, periodic, quasi- steady state, or vibratory in nature. The magnitude and the number of stress cycles require special anclysis to prevent low cycle fatigue or yield stress failure. Applications such ashigh torque motors, extreme repetitive shock, or where high energy loads must be absorbed, as when stalling, require special consideration, = Overspeeds. Overspeeds contributing to ex- temal transmitted loads and dynamic loads re- ‘quire special analysis. = Brake equipped applications, When a gear dive Is equipped with a *working” brake that is used to decelerate the motion of the system, select the drive based on the brake rating or the transmitted power, whichever is greater. If the brake is used for holding only, andis applied after the motion of the system has come to rest, the brake rating should be less than 200 percent of the base unit rating. If the brake rating is greater than 200 percent ct the unit rating, or the brake Is located on the output shaft of the gear drive, special analysis is required. ~ Reliability and life requirement. Applications requiring @ high degree of dependability or unusu- ally long life should be given careful consideration by the user and the gear manufacturer before assigning a service factor. 8.3.2 System conditions An essential phase in the design of a system of rotating machinery is the analysis of the dynamic (vibratory) response ofa system to excitation forces.AMERICAN NATIONAL STANDARD 83.2.1 Vibration analysis Any vibration analysis must consider the complete system including prime mover, gear drive, driven ‘equipment, couplings and foundations. The dy- namic joads imposed upon a gear drive are the result ofthe dynamic behavior of the total system and notof the gear drive alone. 8.3.2.2 Dynamic response The dynamic response ot a system results in additional loads imposed on the system and relative motion between adjacent elements in the system, The vibratory loads ere superimposed upon the ‘mean running load in the system and, depending upon the dynamic behavior ofthe system, couldiead to failure of the system components. 8.3.2.3 System induced failure Ina gear drive, system induced failures could occur as tooth breakage or severe surface deterioration of the gear elements, shaft breakage, bearing failure or failure of other component parts. 8.3.2.4 Special system considerations It should be pointed out that synchronous motors, certain types of high torque induction motors and: generator drives require special care in system design. Synchronous motors have high transient torques during starting and when they momentarily trip-out and restart, Induction motors of special high slip design can produce extremely high starting torques. Also, when the motor trips out for a very short time and then the trip re-closes, high torque loads are produced. Generators have extremely high loads when they are out of phase with the main system. Also, across-the-line shorts can produce torque loads up to twenty times the normal running torque. Al special torque conditions should be considered when determining a service factor. 8.3.3 Special considerations Agjustments to the gear drive selection may be necessary when one or more of the following conditions exists ~ Ambient conditions. Extremes of temperature and environment; ANSVAGMA 6010-F97, = Lubrication. Any lubricant not in accordance with manufacturer's recommendation Misalignment and distortions; = Reversing applications; High risk epplications involving human safety. 9 Lubrication and lubricants 9.1 Lubrication ‘These lubrication recommendations apply only to enclosed gear drives which are designed and rated in accordance with current AGMA standards. Additional recommendations are contained within ANSI/AGMA 9005-D94. These recommendations are not intended to replace any specific lubrication recommendations made by the gear drive manufacturer. The lubricant must be selected to provide adequate oil film thickness at all operating conditions. This may require seasonal change of lubricant, oil heaters for cold starting condtions, or oil cooler for high ambient temperatures. Oil film thickness is critical to limit wear of gears end bearings. 9.1.1 Ambient temperature ‘The ambient temperature range is ~40° to 190°F and Is defined as the air temperature in the immediate vicinity ofthe gear drive. Gear drives exposed to the direct rays of the sun or other radiant heat sources will run hotter and must therefore be given special consideration. 8.1.2 Other considerations Gear drives operating outside of these temperature ranges, ot those operating in extremely humid, chemical or dust laden atmospheres should be” referred to the gear drive manufacturer. 9.1.3 Oil sump temperatures ‘The maximum oil sump tomperature for minerat based oils is limited to 200°F. This sump tempera- ture is considered maximum because many lubricants are unstable above the stated maximum, temperature, CAUTION: Sump temperatures in excess of 200°F may requite special materials for non-metallic ‘components such as oll seals and shims. 9.1.4 Food and drug ‘The lubricants recommended in this standard are not recommended for food and drug industry 19ANSVAGMA 6010-F97 applications where incidental contact with the prod- uct being rnanufactured occurs. NOTE: The user must assume the responsibility for selecting the proper lubricant for all focd and drug in- dustry applications. 9.1.5 Mounting position ‘All gear drives are considered to operate in the manufactuter's specified mounting position. 9.2 Lubricant viscosity Lubricant viscosity recommendations are specified by AGMA lubricant numbers. The corresponding viscosity ranges are shown in ANSV/AGMA 9005-D94, table 4 9.3 Lubrication recommendations Recommended lubricants are shown in ANSYAGMA, 9005-D94, table 5. 9.3.1 External cooling If the drive lubrication system is equipped with a cooler which limits the oil supply temperature to 125°F, the lubricant grade recommended for 15° to 50°F in ANSVAGMA 8005-D94, table 5 may be also used at the higher temperature range. 9.3.2 Gearing considerations ‘When there is a large difference in pitch line velocity between the high and low speed gear stages, the use of a lower viscosity lubricant may be more desirable than that recommended in ANS/AGMA, 9005-D94, table 5. Also a lower viscosity lubricant may be desirable when there is a combination of sleeve and roller element bearings. 94 Cold temperature starting 9.4.1 Low temperature conditions Gear unit lubrication, either by splash or pump, must be given special attention ifthe unitis to be started or operated at temperatures below which the oil can be effectively splashed or pumped. Preheating the oil may be necessary under these low ambient tem perature conditions. The gear manufacturer must ‘always be informed when units are to operate under these conditions. 9.4.2 Low temperature gear oils Gear drives operating in cold areas mustbe provided with ol that circulates freely and does not cause high starting torques. An acceptable low temperature gear oil, n addition to meeting AGMA specifications, must have a pour point at least 10°F below the AMERICAN NATIONAL STANDARD ‘expected ambient temperature, and a viscosity vwhich is low enough to allow the oil to flow freely at the start-up temperature but high enough to carry the load at operating temperature. For synthetic lubricant recommendations, refer to ANSI/AGMA 8005-D94, 9.4.3 Sump heaters. Hasuitable, low temperature gear ollis not available, the gear drive must be provided with a sump heater to bring the oil up to a temperature at which it will Circulate freely for starting. The heater should be selected so as to avoid excessive localized heating which could result in rapid degradation of the lubricant, 9.5 Lubricant types Refer to ANSYAGMA 9005-D94, clause 3. 95.1 Rust and oxidation inhibited gear lubricants ‘These lubricants are commonly referred to as R&O gear oils. They are petroleum base liquids which have been formulated to include chemical additives which are mote resistant to rust and oxidation than il without these special features. 9.5.2 Anti-scutf (extreme pressure) lubricants Anti-scutf (extreme pressure (EP)) gear lubricants ‘are petroleum based lubricants containing special chemical additives. EP gear lubricants recommended for enclosed gear drives are those containing sulphur, phosphorous or similar type additives. EP gear lubricants should be used only when specified by the gear drive manufacturer (see ANSV/AGMA 8005-D94, table 5), NOTE: The lead naphthenate type is no longer recommended because of limited availabilty and poor stability in comparison to the more modem types of lubricants, WARNING: Do not use extreme pressure lubricant oF lubricants with formulations including sulphur, chlorine, lead and phosphorous derivatives, as well as graphite ‘and molybdenum disuifide in gear drives equipped with ‘an intemal backstop, unless approved by the gear ‘manufacturer or the backstop manufacturer. 9.5.3 Synthetic gear lubricants Diesters, polyglycols and synthetic hydrocarbons (Polyalphaolefins) have been used in enclosed gear drives for special operating conditions. Synthetic, lubricants can be advantageous over mineral cls in that they generally are more stable, have a longer life, and operate over a wider temperature range.AMERICAN NATIONAL STANDARD Synthetics are not *cure-alls’. Each type has different characteristics, and many of them have Gistinet disadvantages. Such things as compatibility with gear drive and other lube system components, behavior in the presence of moisture, lubricating qualities, overall economics and compatibility with Internal coatings should be carefully analyzed for each type of synthetic lubricant under consideration. Inthe absence of field experience in similar applica- tions, the use of a synthetic lubricant should be carefully coordinated between the user, the gear manufacturer and the lubricant supplier. CAUTION: Specie! authorization is required from the manufacturer prior to using a synthetic lubricant In a Unit equipped with an internal backstop. 9.5.4 Synthetic lubricant selection ‘The recommendations for synthetic lubricants ere based on gear drive manufacturers’ experience with ‘synthetic hydrocarbons of the polyaiphaolefin type. While other types of synthetic lubricants may be used, lack of experience prevents thelr recommen- dation. The viscosity recommendations may be used as a guide in selection of these other types of lubricants along with the considerations of 9.1.2. 9.6 Maintenance of lubri Lubricants must be tree of solid contaminants such ‘8s dirt and weer particles, free of water, and contain sufficient additives to maintain their original performance. The best way to maintain lubricant performance is by regular oil changes. Reter to ANSYAGMA 9005-D94, clause 6. 9.6.1 Initial lubricant maintenance ion system ‘The lubricant in a new gear drive should be drained efter 500 hours or four (4) weeks of operation, whichever occurs first. The gear case should be thoroughly ‘cleaned with a commercial grade of flushing oil that is compatible with the seals and operating lubricant. ‘The original lubricant can be used for refiing fithas been fitered through a fer of 80 microns of less, itis, free of water, and the original additive strength is maintained; otherwise, new lubricant must be used. Lubricants should not be filtered through fuller's earth or any fiters which remove lubricant additives. 9.6.2 Subsequent oil change interval Under normal operating conditions, the lubricant should be changed every 2500 operating hours or ANSVAGMA 6010-F97 six months, whichever comes first. Conditions that may require more frequent oll change periods include: = ambient conditions of extreme dust, dirt, ‘moisture and chemical particles or fumes; - sustained lubricant sump temperatures approaching 200°F; = duty cycle or ambient conditions causing large and rapid sump temperature changes; seasonal ambient temperature changes causing changes in recommended lubricant. Extending the change period recommended may be preferred based on type of lubricant, amount of lubricant, system down time, or environmental impact of used oil. This can be done through proper implementation of a comprehensive lubricant testing program. Asa minimum, the program should include testing for: changes in appearance and odor; ~ lubricant viscosity (oxidation); ~ water concentration; ~ contaminant concentration; ~ sediment and sludge; = additive concentration and condition. Inthe absence of more specific limits, the guidelines listed as follows may be used to indicate when to ‘change oit: ~ water content greater than 0.05% (600 ppm); iron content exceeds 150 ppm; silicon (dustdirt) exceeds 25 pprn; viscosity changes more than 15%. These tests should be performed on the initial charge of the gear unit to establish a base line for ‘comparison. Subsequent test intervais should be established based on the unt manufacturer's and lubricant supplier's recommendations. 9.6.3 Cleaning and flushing ‘The lubricant should be drained white the gear drive Is at operating temperature. The drive should be cleaned with a flushing oil. 9.6.4 Used lubricants Used lubricant and flushing oll should be completely removed from the system to avoid contaminating the new charge. atANSYAGMA 6010-F97 9.6.5 Cleaning with solvents The use of a solvent should be avoided unless the gear drive contained deposits of oxidized or contami- nated lubricant which cannot be removed with a fiushing oi, When persistent deposits necessitate the use of a solvent, a flushing oil should then be Used to remove all traces of solvent from the system. 9.6.6 Inspection AMERICAN NATIONAL STANDARD viewing a specified shaft from a specified free end position, Designation of shaft rotation on drawings or in tables may be shown by letter abbreviations or circular arrows as shown in figure 2. 10.2 Assembly designations Standard assembly designations are shown in figures 3, 4 and 5. The interior surfaces should be inspected where ir \\ possible, and all races of foreign material removed. Ciockwise ‘The new charge of lubricant should be added and rotation circulated to coat all internal parts. LT 10 Assembly and rotation — Ho (oO clockwise ol 10.1 Shaft rotation direction rotation —, Rotational direction of both high and low speed Side End shafts is either clockwise (CW) or counterclockwise views views (CCW). Direction of shatt rotation is determined by Figure 2 - Shaft rotation re LR LL R-R RL q qf bb ==] t t t t, J [ LR LR-L LR-R RLR qf qf bh =I =I t t t t Plan views LR-LR| Plan views qf b NoTES: 1. Code: L= Loft; R= Right 2. Arrows indicate line of sight to determine direction of shatt extensions. 3. Letters preceding the hyphen refer to number and direction of high speed shaft extensions. 4. Letters following the hyphen refer to number and direction of low speed shaft extensions, Figure 3 - Parallel shaft spur, helical and herringbone gear drives, single or multiple stage 22AMERICAN NATIONAL STANDARD ANSVAGMA 6010-F97 Plan views 0 D ae Ra pa Crea ° ° ' t 1-D 2-D => D D 1-LR 2-LR ° ° 4 Jee sel U U Plan views NOTES: 1. Code: L = Left; R= Right 2. Arrowsindicate line of sight to determine direction of shatt extensions. 3. Numerals preceding the hyphen refer to number of high speed shaft extensions. 4. Letters following the hyphen refer to number and direction of iow speed shatt extensions. Figure 4 - Horizontal bevel gear drives, single stage; horizontal bevel-helical drives, muttiple stage Front views Up position-iow speed shaft; ‘Down position-low speed shaft. 2. Arrows indicate line of sight to determine direction of shait extensions, ‘3, Numerals preceding the hyphen refer to number of high speed shaft extensions. 4. Letters following the hyphen refer to number and. direction of low speed shaft extensions. Figure 5 - Vertical bevel gear drives, single stage; vertical bevel-helical drives, multiple stageANSVAGMA 6010-F97 11 Ratios The standard ratios are based upon the (1.5)? geometric numerical progression. ‘This progression is a modification of the ANSI “10 Series", The standard ratios are listed in table 11 Exact ratios should be obtained from the manufacturer. Table 11 - Nominal ratios Hatio| Ratio | Ratio __|_Ratio 725 | ass0 | 7062 | S363 1500 | 1139 | 8650 | 6568 1.837 13.95 105.9 804.5 2.250 17.09 129.7 985.3 2.756 20.93 158.9 1207 3.375 25.63 194.6 1478 4.134 31.39 238.4 1810 5.062 | 3344 | 2019 | 2017 6200 | 4708 | 3575 | aris z504_| s7e7_| 4379 | 3925 12 Marking 12.1 Nameplate data suitable nameplate should be attached to the gear rive with the following minimum information: - size; ~ ratio; - Service power rating; = high speed shatt rpm; = service factor; - lubrication specification. 12.2 AGMA monogram Use of the AGMA monogram certifies that the manufacturer of the gear drive is a member of AGMA, and does not in any way indicate the manufacturer's compliance with AGMA standards or practices. 24 AMERICAN NATIONAL STANDARD 13 Storage 13.1 General ‘These general storage recommendations should be used when specific manufacturer's instructions are not available, They apply to gear designs in which the rotating elements are contained in a suitable enclosed housing. See annex E. Proper protection, storage and inspection of gear drives is considered to be the responsibilty of the owner. Itis recommended that reducers be storedin a dry, temperature controlled environment. Within this environment, the ambient temperature change should not be altowed to pass through the dew point since this would cause moisture condensation on gear drive surfaces. 13.2 Normal storage During manufacture anc for intervals of storage upto four months, internal components of gear drives should be coated with a suitable oll based rust preventative. This rust preventative should contain water displacement and fingerprint suppressant additives. External machined surfaces should be coated with a similar rust preventative during manufacture, A suitable petroleum base rust preventative should be applied to external surfaces before the drives are placed in storage. Such coating should be self-healing and contain water displace- ment and fingerprint suppressant additives suitable ‘or protecting the surfaces against rust fora period of up to 12 months. External and internal inspection of the gear drive should be made monthly. Any moisture observed should be removed at this time and components and surfaces recoated with rust preventative as necessary. Drives should be inspected prior to charging with lubricant to ensure that no condensate is present in the oil sump. 13.3 Adverse conditions or long term storage |n conditions of long periods of storage or storage in environments subject to high humidity, extreme temperature change, or exposure to an oxidation enhancing atmosphere, gear drives should be completely filed to overflowing with a high quality oi! base rust inhibiting lubricant. In cases where it is impractical to fil the gear drive to overflowing, the lubricant should be circulated to coat all internalAMERICAN NATIONAL STANDARD ‘components and the gear drive sealed to help prevent condensation. Care must be taken to ensure thatall enclosed areas are properly vented to prevent the entrapment of moist alr. All external machined surfaces should be coated with a solvent based rustinhibiting undercoating and. top coated with an asphalt base rust preventative, Under such adverse or long term storage condition, inspection of the gear drive should be performed on weekly basis, The sump drain should be opened and a small amount of oll removed along with any condensate which might be present. The drive should be refilled to overflowing and reseaied. Outside surfaces should be recoated as necessary. CAUTION: Some gear drives contain features where overfill vith lubricants not feasible or practical. These {features include such items as drywells on vertical shaft Units and labyrinth seals on shaftextensions. Forthese drives, add the appropriate type and amount of vapor phase ustinhibitor and seal any openings. Inspect the gear drive on a weekly basis and add the required ‘amount of lubricant. Drives fitted with labyrinth seals cannot be filed with oil or have @ vapor phase rust inhibitor installed as both will leak from the unit 14 Installation To ensure long service and dependable perform- ance, an enclosed gear drive must be rigidly supported and the shafts accurately aligned. The following describes the minimum precautions ‘required to accomplish this end. ‘The gear reducer manutacturer’s installation manual should be followed, asit may include more detailed procedures than appear in this standard. For owner's responsibilities, see annex E. 14.1 Foundation The responsibility for the design and construction of the foundation lies with the user. The foundation must be adequate to withstand normal operating loads and possible overloads which may occur without damage to itsett or any of the system components and to maintain alignment of the Components under such loads, 14.1.1 Mounting position Unless @ unit is specifically ordered for inclined ‘mounting, the foundation must be level and flat. The lubrication system may not operate properly if the ANSVAGMA 6010-F57, unit is not mounted in the position for which it is designed. It may be desirable to elevate the foundation to facilitate oll drainage. 14.1.2 Concrete foundation Ifa. concrete foundation is used, steel mounting pads and bolts of sutfcient size to distribute the stress into the concrete should be grouted into the foundation, 14.1.3 Steel foundation If @ structural steel foundation is used (.e., wide flange beams or channels), a base plate or sole plate of suitable thickness should be used and should extend under the entire unit, 142 Foot mounted units Use shims under the feet of the unit to align the output shaft tothe driven equipment. Make sure that all fest are supported so that the housing will not distort when it is bolted down. Improper shimming will reduce the life of the unit and may cause failure. Install dowel pins as instructed by the manufactur- e's installation manual to prevent misalignment and ensure proper realignment if removed for service. 1423 Shaft mounted units ‘Shaft mounted drives should be mounted as close to the driven equipment bearing support as possible to minimize bearing loads due to overhung load. Design of the joint connection between the torque ‘arm and the foundation is the user's responsibility. 14.3.1 Lubricate shafts Both the hollow shaft and the driven shaft should be liberally lubricated before essembly. The unit must slide freely onto the driven shaft. Do not hammer or force the unit into place. 14.32 Axial retention Follow the manufacturer's instructions for axial retention af the unit on the driven shaft, 14.3.2.1 Set screws Ifset screws are used for axial retention, they should, be tightened evenly, Flats may be filed on the driven shaft and a thread locking adhesive used for more positive retention. 143.22 Thrust plate In applications which are subject to high vibratory loads, a thrust plate will provide greater resistance to axial movement. Follow the manufacturer's recommendations for assembly.ANSVAGMA 6010-F97 14.3.2.3 Shrink dise fa shrink disc is used to secure the hollow shaft to the driven shaft, follow the shrink dis manufacturer's assembly procedure. if the shrink disc manufacturer's procedures are not available, the following may be used: a) Any protective spacers between the locking collars should be removed; b) Tighten slightly any three equally spaced locking bolts until the inner ring can just be rotated. Overtightening at this time can damage the inner ring. Measure the gap between the lock- ing collars at several points around the circumference to ensure that they are parallel ©) Slide the shrink disc over the hollow shaft. Tighten the bolts in gradual increments following circumferential pattern until all bolts are tight- ened to the specified torque. Check the gap between the locking collars to be sure that they are parallel. 14.3.3 Torque arm ‘The torque arm should always be mounted within the angular limits specified by the manufacturer. The preferred mounting position is perpendicular to alin through the output shaft center and the point of attachment of the torque arm to the unit housing. In this position the minimum load on the torque arm will be experienced. Design of the joint connection between the torque arm and foundation is the user's responsibilty. 144 Prime mover mounting Align the prime mover to the unit input shaft using shims under the feet. Make sure that the feet are ‘supported. Dowel the prime mover toits foundation. 14.5 Shaft connections 145.1 Fits Clearance or interference fits for coupling hubs should be in accordance with ANS/AGMA 9002-A86. Outboard pinion and sprocket fits should be as recommended by the pinion or sprocket manufacturer. Coupling hubs, pinions and sprock- ets with interference fits should be heated according ‘to the manufacturer's recommendations, generally 250°F to 300°F, before assembling to the shaft. 14.52 Location Coupling hubs should be mounted flush with the shaft ends, unless specifically ordered for overhung 26 AMERICAN NATIONAL STANDARD mounting. Pinions, sprockets and sheaves should be mounted as close as possible to the unit housing to minimize bearing loads and shatt deflection. 14.5.3 Coupling alignment Shaft couplings should be installed according to the gear manufacturer's recommendations for gap, angular and parallel alignment. In many installa- tions, it is necessary to allow for thermal and mechanical shaft movement when determining shaft alignment. The gear manufacturer's recommenda- tions should be followed. © Where no recommendations are made by the gear drive manufacturer, follow the coupling manufacturer's recommendations. 14,5.3.1 Axial displacement The gap between shaft ends should be the same as the specified coupling gap unless overhung mounting of the coupling hub is specified. The coupling gap and shait gap must be sufficient to accommodate any anticipated thermal or mechanical axial movement. 14.5.3.2 Angular alignment Insert a spacer or shim stock equal to the required coupling gap between the coupling hub faces and measure the clearanceusing feeler gauges. Repeat this at the same depth at 90 degree intervals to determine the amount of angular misalignment. 145.33 Parallel alignment Mounta dial indicator toone coupling hub, and rotate this hub, sweeping the outside diameter of the other hub. The parallel misalignment is equal to one-half of the total indicator reading. Another method is to resta straight edge squarely on the outside diameter cof the hubs at 90 degree intervals and measure any gaps with feeler gauges. The maximum gap measurement is the parallel misalignment. 14.5.3.4 Checking alignment After both angular and parallel alignments are within specified limits, tighten all foundation bolts securely and repeat the above procedure to check alignment. If eny of the specified limits for alignment are exceeded, realign the coupling. 14.54 Sprocket or sheave alignment ‘Align the sheaves or sprockets square and parallel by placing a straigh! edge across their faces. Alignment of bushed sheaves and sprockets should be checked atter bushings have been tightened.“AMERICAN NATIONAL’ STANDARD. ‘Check horizontal shaft alignment by placing a level vertically against the face of the sheave or sprocket. ‘Agjust belt or chain tension per the manufacturer's specified procedure. 14.5.5 Outboard pinion ignment Align the pinion by adjusting the gear tooth clearance according to the manufacturer's recommendations ‘and checking for acceptable outboard pinion tooth ANSVAGMA 6010-F97 contact. The foundation belts may have to be loosened and the unit moved slightly to obtain this contact. When the unit is moved to correct tooth contact, the prime mover should be realigned. 14.5.6 Recheck alignment After a period of operation, recheck alignment and adjust as required. 27ANSVAGMA 6010-F97 AMERICAN NATIONAL STANDARD (This page is intentionally left blank) 28AMERICAN NATIONAL STANDARD. ANSVAGMA 6010-F97 ‘Annex A (informative) Service factors [The foreword, footnotes and annexes, if any, are provided for informational purposes only and should not be construed as a part of ANSYAGMA 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives.) AA Purpose This annex provides a detailed guide for determining service factors for enclosed gear drives. A1.1 Selection of service factors Before an enclosed speed reducer or increaser can be selected for any application, an equivalent unit power rating (service factor = 1.0) must be deter- mined. This is done by multiplying the specified power by the service factor. Since the service factor represents the normal relationship between the gear unit rating and the required application power, suggested thal the service factor be applied to the nameplate rating of the prime mover or driven machine rating, as applicable. Manufacturer and user must agree upon which power, prime mover rating or driven machine requirements, should dictate the selection of the gear drive. It is necessary that the gear drive selected have a rated unit capacity equal to or in excess of this "equivalent unit power rating". All service factors listed are 1.0 or greater. Service factors less than 1.0 can be used in some applica- tions when specified by the user and agreedto by the manufacture. Table A2 should be used with caution, since much higher values have occurred in some applications. Values as high as ten have been used. On some applications up to six times nominal torque can ‘occur, such as: Turbine/Generator drives, Heavy Plate and Billet rolling mills. A2 Listing of service factors The table of service factors has been developed from the experience of manufacturers and users of ‘gear drives for use in common applications. It is suggested that service factors for special applications be agreed upon by the user and the gear manufacturer when variations of the values in the table may be required. A3 Determining service tactors In addition to the tables, an analytical approach may be used to determine the service factor. See 8.3 for the important factors to be considered. AA Service factor tables Service factors have served industry well when the application has been identified by knowledgeable and experienced gear design engineers. The tables are provided for information purposes only and should be used only after taking into account all of the extemal influences which may affect the operation of the enclosed gear drive. A4.1 Use of tables Service factors shown in table A.2 are for gear drives driven by motors (electric or hydraulic) and turbines (steam or gas). A42 Driver influence When the driver is a single cylinder or multi-cyinder engine, the service factors from table A.2 must be ~ converted to the values from table A for the appropriate type of prime mover. AS Example If the application is a centrifugal blower, the service factor from table A2 is 1.25 for a motor or turbine. Table A1 converts this value to 1.50 for a multi- cylinder engine and 1.75 for a single cylinder engine. CAUTION: Any user of enclosed gear drives should make sure he has the latest available data on the fac- tots affecting the selection ofa gear drive. When betler load intensity information is available on the driving or riven equipment, this should be considered when a service facior is selected.ANSV/AGMA 6010-F97 AMERICAN NATIONAL STANDARD Table A.1 - Conversion table for single or multi-cylinder engines to find equivalent single or multi-cylinder service factor ‘Steam and gas turbines, hydraulic or electric motor Single cylinder engines Multi-cylinder engines 7.00 750 15 1.25 1.78 1.50 1.50 2.00 1.75 1.75 2.25 2.00 2.00 2.50 2.25 2.25 275 2.50 2.50 3.00 | 2.75 2.75 3.25 3.00 3.00 3.50 3.25 turbines (steam or gas) ‘Table A.2 - Service factors for enclosed gear drives driven by motors (hydraulic or electric) or Toad duration Application Upto Shours | 310 10 hours | Over 10 hours per day per day per day (Agitators (mixers) Pure liquids 4.00 1.00 1.25 Liquids and sovids 1.00 1.25 1.50 Liquids - variable density 1.00 1.25 1.50 Blowers, Centrifugal 4.00 1.00 4.25 Lobe 1.00 1.25 1.50 Vane 1.00 1.25 1.50 Brewing and cistiling Bottling machinery 1.00 1.00 1.25 Brew kettles - continuous duty 1.25 1.25 1.25 Cookers - continuous duty 1.25 1.25 1.25 Mash tubs - continuous duty 1.25 1.25 1.25 Scale hopper - frequent starts 1.25 1.25 1.50 Can filing machines 1.00 1.00 1.25 Car dumpers 1.50 1.75 2.00 Car pullers 1.00 1.25 1.50 Clarifiers 4.00 1.00 1.25 Classifiers 1.00 1.25 1.50 Clay working machinery Brick press 1.50 1.75 2.00 Briquette machine 1.50 1.75 2.00 Pug mill 4.00 1.25 1.50 Compactors 2.00 2.00 2.00 Compressors Centrifugal 4.00 1.00 1.25 Lobe 1.00 1.25 1.50 Reciprocating, multi-cylinder 1.50 1.50 175 Reciprocating, single-cylinder 4.75 1.75 2.00 (continued)AMERICAN NATIONAL STANDARD aes we > ANSYAGMA 6010-F97 be Table A.2 (continued) Toad duration Application Upto S hours | Sto 10 hours [Over 10 hours per day per day per day Cranes Dry dock Main hoist 250 2.60 2.50 Auxiliary hoist 250 2.50 3.00 Boom hoist 2.50 2.50 3.00 Slewing drive 250 2.50 3.00 Traction drive 3.00 3.00 3.00 Container Main hoist 3.00 8.00 3.00 Boom hoist 2.00 2.00 2.00 Trolley drive Gantry drive 3.00 3.00 3.00 Traction drive 2.00 2.00 2.00 Mill duty Main hoist 350 3.50 3.50 Auxiliary 3.50 3.50 3.50 Bridge 2.50 3.00 3.00 Trolley travel 2.50 3.00 3.00 Industrial duty Main 2.50 250 3.00 Auxiliary 2.50 2.50 3.00 Bridge 250 3.00 3.00 Trolley travel 2.50 3.00 3.00 Crusher Stone or ore 175 178 2.00 Dredges Cable reels 1.25 1.25 1.50 Conveyors 1.25 1.25 1.50 Cutter head drives 2.00 2.00 2.00 Pumps 2.00 2.00 2.00 Screen drives 1.75 1.75 2.00 Stackers 1.25 1.25 1.50 Winches 1.25 4.25 1.50 Elevators Bucket 4.00 1.25 1.50 Centrifugal discharge 1.00 1.00 1.25 Escalators 4.00 1.00 1.25 Freight 1.00 1.25 1.60 Gravity discharge 4.00 1.00 1.25 Extruders General 1.50 1.50 1.50 Plastics Variable speed drive 1.80 1.50 1.50 Fixed speed drive 1.75 4.75 1.75 Rubber Continuous screw operation 175 1.78 1.75 Intermittent screw operation 1.75 1.75 1.75 (continued) 31ANSI/AGMA 6010-F97 ‘Table A-2 (continued) AMERICAN NATIONAL STANDARD 32 Toad duration Application Upto Shours | 3to 1 hours | Over 10 hours per day per day per day Fans Centrifugal 4.00 1.00 1.25 Costing towers 2.00 2.00 2.00 Forced draft 1.25 1.25 1.25 Induced draft 150 1.50 1.50 Industrial & mine 1.50 1.50 1.50 Feeders ‘Apron 1.00 1.25 1.50 Bett 4.00 125 1.50 Disc 1.00 41.00 1.25 Reciprocating 1.50 175 2.00 Screw 1.00 1.25 1.50 Food industry Cereal cooker 1.00 1.00 1.25 Dough mixer 1.25 1.25 1.60 Meat grinders 1.25 1.25 1.50 Slicers 1.25 1.25 1.50 Generators and exciters 1.00 1.00 1.25 Hammer mills 1.75 175 2.00 Hoists Heavy duty 1.75 1.75 2.00 Medium duty 1.25 1.25 1.50 Skip hoist 1.25 1.25 1.50 Laundry Tumblers 1.25 1.25 1.50 Washers 1.50 50 2.00 Lumber industry Barkers - spindle feed 1.25 1.25 1.50 Main drive 1.75 1.75 1.75 Conveyors ~ burner 1.25 1.25 1.50 Main or heavy duty 1.50 1.50 1.50 Main log 1.75 1.75 2.00 Re-saw, merry-go-round 1.25 1.25 1.50 Conveyors Slab 1.75 1.75 2.00 Transfer 1.25 1.25 1.50 Chains Floor 1.50 1.50 1.50 Green 1.50 1.50 175 Cut-off saws Chain 1.50 1.50 1.75 Drag 4.50 1.50 1.75 Debarking drums 1.75 1.75 2.00 Feeds Edger 1.25 1.25 1.50 Gang 1.75 1.75 1.75 Trimmer 4.25 1.25 1.50 (continued)AMERICAN NATIONAL STANDARD ions sANSUVAGMA 6010-F97 Table A-2 (continued) Toad duration Application Upto Shouts | Sto Tohours | Over 10 hours per day per day per day Lumber indusiry (continued) Log deck 1.75 1.75 1.78 Log hauls - incline - well type 1.75 1.75 1.75 Log tuning devices 175 1.75 1.75 Planer feed 125 1.25 1.50 Planer titing hoists 1.50 1.50 1.50 Rolls - live-off bearing - roll cases 1.75 1.75 1.75 Sorting table 1.25 1.25 1.50 Tipple hoist 4.25 1.25 1.50 Transfers Chain 1.50 1.50 1.75 Craneway 1.50 1.50 1.75 Tray drives 1.25 1.25 1.50 Veneer lathe drives, 1.25 1.25 1.50 Metal mills Draw bench carriage and main drive 1.25 1.25 1.50 Runout table Non-reversing Group drives 1.50 1.50 1.50 Individual drives 2.00 2.00 2.00 Reversing 2.00 2.00 2.00 Slab pushers 1.50 1.50 1.60 Shears 2.00 2.00 2.00 Wire drawing 1.25 125 1.50 Wire winding machine 1.25 1.50 1.50 Metal strip processing machinery Bridles 1.25 1.25 1.50 oilers & uncoiters 4.00 1.00 1.25 Edge trimmers 1.00 1.25 1.50 Flatteners 1.25 1.25 1.50 Loopers (accumulators) 1.00 4.00 1.25 Pinch rolls 1.25 125 1.50 ‘Scrap choppers 1.25 1.25 1.50 Shears 2.00 2.00 2.00 Siiters 1.00 1.25 1.50 Mill, rotary type Ball & rod Spur ring gear 2.00 2.00 2.00 Helical ring gear 1.50 1.50 1.50 Direct connected 2.00 2.00 2.00 Cement kilns, 1.50 1.50 1.50 Dryers & coolers 1.50 1.50 1.50 Mixers Concrete 1.25 1.25 1.50 Paper mits?) ‘Agitator (mixer) 150 150 1.80 Agitator for pure liquors 1.25 1.25 1.25 Barking drums 2.00 2.00 2.00 (continued)ANSVAGMA 6010-F97 Table A-2 (continued) AMERICAN NATIONAL STANDARD Toad duration Application Upto Shours | Sto 10 hours [Over 70 hours per day per day per day | Paper mils? (continued) Barkers ~ mechanical - aA - Beas 1.50 1.50 +50 Broaker stack 1 te 12 alone 1.25 125 125 Chipper 200 2.00 200 Chip sede 1.50 1.50 1.50 Coating rolls te tes ‘eB Conveyors Chip, bark, chemical 12 125 tos Carns ee a Coxe 1.25 1.25 4.25 ae 2.00 2.00 2.00 Cylinder molds 20° 738 +30 Dryers?) ; : Paper machine 105 es 1205 ‘Conveyor type i br} 12 Embosser i te ie Eire ne 130 180 150 Fourdrinier rolls (includes lump breaker, dandy rol, |_| 50 eed 1 wire turning, and return rolls) 13 hed 13 dordan 1150 450 1.50 hens 1125 1.25 1.25 enone Tol 1.25 1.25 1:25 coerce 150 150 150 Plat : 125 1.25 1:25 Presses - felt & suction 335 2 338 eee 4150 4.50 1.80 = : 42 Reel (surface type) 128 : 2 Screens 150 180 150 Rae 1.50 1.50 1.50 de 2.00 2.00 2.00 Vibrating 4.25 1.25 1.28 Size press : : 1.25 125 1:25 Super calentier® 1.50 1'50 150 Thickener (AC motot) re ie ie cmos 150 1.50 150 eee 1.25 1.25 1.25 (OC motor) 1.00 1.00 1.00 Wind and unwind stand ie +00 +00 Winders (surface type) i ie ia Yankee dryers®) ” ” Plastics industry Primary processing Intensive intemal mixers Batch mixers 1.75 1.78 1.78 Continuous mixers 150 150 1150 (continued)AMERICAN NATIONAL STANDARD ANSYAGMA 6010-F97 Table A-2 (continued) Toad duration Application Upto S hours | Sto 10 hours | Over 10 hours: per day per day per day [Plastics industry (continued) Batch drop mill - 2 smooth rolls 1.25 1.25 1.25 Continuous feed, holding & blend mill 1.25 1.25 1.25 ‘Compounding mili 1.25 1.25 1.25 Calenders 1.50 1.50 1.50 ‘Secondary processing Blow moiders 1.50 1.50 1.60 Coating 1.25 4.25 1.25 Film 125 1.25 1.25 Pipe 1.25 1.25 1.25 Pre-plasticizers 1.50 1.60 1.50 Rods 1.25 1.25 125 Sheet 1.25 1.25 1.25 Tubing 1.25 1.25 1.50 Pullers ~ barge haul 1.25 1.25 1.60 Pumps Centrifugal 1.00 1.00 1.25 Proportioning 1.25 1.25 1.50 Reciprocating Single acting, 3 or more cylinders 1.25 1.25 150 Double acting, 2 or more cylinders 1.25 1.25 1.50 Rotary Gear type 1.00 1.00 1.25 Lobe 1.00 4.00 1.25 Vane 1.00 1.00 1.25 Rubber industry Intensive internal mixers Batch mixers 1.75 175 1.75 Continuous mixers 1.60 1.50 1.50 Mixing mill - 2 smooth rolls (i corrugated rolls are used, then use the same service factors that 1.50 1.50 1.50 are used for a cracker warmet) Batch drop mill - 2 smooth rolls 1.50 1.50 1.50 ‘Cracker warmer ~ 2 rolls; 1 corrugated roll 175 1.75 175 Cracker ~ 2 comugated rolls 2.00 2.00 2.00 Holding, feed & blend mill - 2 rolls 1.25 1.25 1.25 Refiner ~ 2 rolls 1.50 1.50 1.60 Calenders 1.50 1.50 1.50 Sand muller 4.25 1.25 1.50 ‘Sewage disposal equipment Bar screens 1.25 1.25 1.25 ‘Chemical feeders 1.25 1.25 1.25 Dewatering screens 4.50 1.50 1.50 Scum breakers 1.50 1.50 1.50 Slow or rapid mixers 1.50 1.50 1.50 Sludge collectors 1.25 125 1.25 Thickeners 1.50 1.50 4.50 Vacuum fiters 1.50 1.50 1.50 (continued) 35ANSVAGMA 6010-F97 Table A-2 (concluded) AMERICAN NATIONAL STANDARD Toad duration ‘motor rated based speed. 3) Anti-friction bearings only. Use 1.5 for sleeve bearings. Application Upto Thours [Sto 10 hours [Over To hows per day per day per day ‘Sereens ~| Air wasting 1.00 4.00 1.25 Rotary - stone or gravel 125 1.25 150 Traveling water intake 1.00 41.00 1.25 ‘Sugar industry Beet slicer 2.00 2.00 2.00 Cane knives 1.50 4.50 1.50 Crushers 150 1.50 1.50 Mills (low speed end) 175 1.75 178 “Textil industry Batchers 1.25 1.25 1.80 Calenders 1.25 1.25 1.50 Cards 1.25 4.25 1.50 Dry cans 1.25 1.25 1.50 Dryers 1.25 125 1.50 Dyeing machinery 1.25 1.25 1.50 Looms 1.25 4.25 1.50 Mangles 1.25 1.25 1.50 Nappers 1.25 1.25 1.50 Pads 1.25 1.28 1.50 Slashers 1.25 1.25 1.50 Soapers 1.25 1.25 1.50 Spinners 1.25 1.25 1.50 TTenter frames 1.25 1.28 1.50 Washers 1.25 1.25 1.50 Winders 1.25 1.25 1.50 NOTES: 1 Grane drives are to be selected based on gear tooth bending strength. Contact gear manufacturer for strength ratings. Service factor in durabilty should be a minimum of 1.0 2) Service ‘actors for paper mill applications are applied to the nameplate rating ofthe electric dive motor at the 4) A service factor of 1.00 may be applied at base speed of a super calender operating over-speed range of part ange constant horsepower, part range constant torque where the constant horsepower speed range is greater than 1.5101. A service factor of 1.25 is applicable to super calenders operating over the entire speed range at constant torque or where the constant horsepower speed range is less than 1.5 to 1 36+ AMERICAN NATIONAL STANDARD ANSVAGMA 6010-F97,, Annex B (informative) Keys and keyways for shaft extensions [The foreword, footnotes and annexes, ifany, are provided for informational purposes only and should not be construed as a part of ANSVAGMA 6010-F97, Standard for Spur, Helical, Heringbone and Bevel Enclosed Drives.) B.1 Purpose The purpose of this annex is to present recom- mended standard sizes of keys and keyways to be used on shatt extensions af standard gear reducers. This annexisin conformance with ANSI B17.1-1987 ‘and ANSVAGMA 9002-A86. ‘The intent of the recommended standardization is to simplify the accommodation of power transmission accessories on these gear drives. These accesso- ties typically include shaft couplings, sheaves and sprockets, While it is recognized that there are occasional reesons to deviate from these recommendations, general conformance will eliminate confusion and misinterpretation between vendor or supplier and user as well as ensure compatibility. B2 Keys Recommended key sizes are shown in table B.1. ‘Square keys are preferred through 6.5 inches shaft diameter. Rectangular keys are preferred over 6.5 Inches shaft diameter. For tapered shatts, the largest tapered diameter determines the key size. B3 Keyways Keyway sizes should normaly be selected to result ina commercial fit with the key. A commercial fit will result in a clearance fit wth the sides of a key. Under certain circumstances, it may be necessary to provide a radius in the keyway. The recommenda- tions for keyway radii and key chamfer are shown in table B.2. Table B.1 - Key sizes and tolerances for square and rectangular keys (inches) Tiominal shaft diameter Recommended key size Recommonded Key width & halght tolerance 7 ‘Commercial cass rediaion class ‘Square | Rectangular Rectangular Width & hat | Width & hat, With Height FE OGEI-B. 008 | +0:000)-0.005 ODOTT-0000 | +0.005)-0.005 +0.000/-0.002 | +0.000/-0.008 +40.001/-0.000 | +0.008/-0.005 +0.000/-0.002 | +0.000/-0.008 40.001/-0.000 | +0.008)-0.008, +40.000/-0.008 | +0.000/-0.008 +¥0.001/-0.000 | +0.005/-0.005, +0:000/-0.002 | +0.000/-0.008 +40.001/-0.000 | +0.006)-0.005 +40.000/-0.000 +40.001/-0.000 | +0.008V-0.005, +40.000/-0.008 +40.01/-0.000 | +0.006y-0.005 +40.000/-0.003 +0.0017-0 000 | +0.005y-0.005 ++0.000/-0.008 +40.001/-0.000 | +0.008/-0.005 +40,000/-0.006 ++0.001/-0.000 | +0.008/-0.005 40:000/-0.008 +40.01/-0.000 | +0.008)-0.005, 40.000/-0.008 40.201/-0.000 | +0.008)-0.005, 40,000/-0.008 40.0021-0.000 | +0.008-0.005 49:000/-9.005 +40.002/-0.000 | +0.005)-0.005, +0.0004-0.005, +40.002/-0.000 | +0,008)-0.005 ‘Over ‘Square | Rectangular Bquare Wiath & hat OORT B00 +40.001/-0.000 +40.001/-0.000 +40.001/-0.000 +40.001/-0.000 +40.001/-0.000 ++0.001/-0.000 4¥0.001/-0.000 +¥0.001/-0.000 +40.001/-0.000 ++0.001/-0.000 +40,001/-0.000 +40.002/-0,000 -s0.002/-0.000 +40.002/-0.000 Te net) one ose2s 0.8750 41.2600 1.9750 1.7500 2.2500 2.7500 3.2500 8,7800 4.5000 5.5000 65000 7.5000 9.0000 Oa 0378 0.8625 0.8750 4.2500 08ST ONSET = 0.1250 0.1250 | 0.125000557 0.1875x0.1875 | 0.1875 0.1280 0.2500x0.2500 | 0.25000.1875 ostasxost2s | 0312502500 osrsoxa.s780 | 0.3750%0.2500 ‘05000x0.5000 | 0.5000,0.8780 06250 x0.6250 | 0.6250x0.4875 .0.7500%0.7500 | 0.7500x0-5000 o.87s0x0.8750 | 0.8750x08250 #.000031.0000 | .00003<0.7500 +12800x1.2500 | 1.2500%08750 + 000x100 | 1.50001.0000 su7800x17800 | 1.7500%1.5000, 2.0000x2.0000 | 2.0000% 5000 1.2760 1.7500 2.2500 2.7500 3.2500 3.7500 4.5000 £000 65000 7.5000 NOTE: 1)” Tolerances agree with ANSI B17." +0.000/-0.002 +40.000/-0.003 +0,000/-0.003 +40.000)-0.008 +0,000/-0.008 +0.000/-0.004 +0,000/-0.004 1967, Reatfirmed 1989. 37ANSVAGMA 6010-F97 AMERICAN NATIONAL STANDARD Table B.2 - Values for keyway fillet radius and suggested key chamfer Keyway depth ~ [To | Keymay fillet | Suggested Over | (incl) | radius | key chamfer [ 18 1164 17132 x 45° V4 1192 3/64 x 45" ws} we ays2 5/64 x 45° 2 | 78 5/32 5/82 x 45° ze | 4-1/4 7102 7182 x 45" 38AMERICAN NATIONAL STANDARD Annex C (informative) Heo ANSVAGMA 6010-FS7 lustrative examples [The foreword, footnotes and annexes, # any, are provided for informational purposes only and should not be construed as part of ANSVAGMA 6010-F97, Standard for Spur, Helical, Heringbone and Bevel Enclosed Drives.) Introduction ‘The examples shown in this annex are based on the assumption that the gear set is the minimum rated component. In practice all component ratings must be calculated to determine the lowest rated compo- nents. Tables, figures and equation references are taken from ANSIAGMA 2001-C35 and ANSI/ ‘AGMA 2003-A86. C.1 Uniform loading Calculate the application horsepower for the gears of a single reduction helical speed reducer used to drive a uniformly loaded conveyor belt. The input shaft and pinion are driven by an 870 rpm motor. The gear sel is represented by the following data: Tem Pinion Gear ‘Number of teeth at e Diametral pitch, normal 8 Pressure angle, normal 20° Helix angle 15° Face width, inch 2.00 Material Grade 1 Carburized Steel Hardness 60 HRC Genter distance, inch 8.0015 Both gear and pinion are standard addendum, cut with standard pre-shave hobs, and shaved. Heat treat distortion is controlled to produce both gears as AGNA Quality Level 8. The allowable horsepower of the gear set will be determined for both surface pitting strength and root bending strength. The application horsepower, Ps, of the gear set will be the lesser of these allowable horsepowers. Surface pitting allowable power at unity service factor: 2 @ sae Zy Sa = 750.4182) = 98 635 Ibyin As this is grade 2 carburized steel, ¢ = 65 000 Ibn? (see 2001, table 4). m2 ¥x = 5000 = 49 182 Ibfin? 03558 ANSVAGMA 6010-F97 Solving the equation Yi = 1.3558.N-°%78 for N; 562 (23558)? _ 2 Ny “Bs 4.48 x 10° cycles 1.3558)? 4 Ny = (23558) "= 1.73 x 10! cycles As Ys > 1.0, solve the equation Yy = 6.1614N-01192 for; is a» Wy = (S254) = 3.96 x 10% cycies Lite (0.90(42720)) _ (0.05(42 720) 4.48 x 10% 1.73 x 10% : + (SSR) - rssh ‘As can be seen, this gear set will not reach the 2000 hours life requirement, as the pinion teeth will theoretically fracture at 1854 hours. ©.3 Overload conditions pinion stand drive of the characteristics shown is expected to be subjected to infrequent (less than 100) momentary overloads. Determine the maxt- mum peak momentary overload to which the gear set may be subjected without the teeth yielding, PK Sey Ky ® Wan 3 TK (see 2001, Eq. 45) Gear Set Data: =90in a =9875in Jp ©0517 Material: Steel, 940 HB min, therefore: }31 080 Ibvin? (see 2001, figure 16) 0.75 (industrial practice) Ky 0.0144(9) + 1.07 = 1.1996 (see 2001, Eq. 46) Solving Eq, 45 for Wax? )_(2.1996) )VsiNG.H (131.080)0.75) = Winas(3 203 373 1b = Waiax ‘The maximum momentary peak overload allowable is 203 873 Ibs. Converting this load to torque yields: 7 = Hed _ 8370379) _ 953 5101 in atANSV/AGMA 6010-F97 AMERICAN NATIONAL STANDARD C4 Uniform loading T Sg = Ky = 12+ 1.32) = bevel gear set, with the following data, used in & NOTE: T= 1» _..(se8 2003, Eq, 10.1) single reduction right angle reducer used to drive a 700 ara . rpm input, dri = G79) uniform ioad at 870 rpm input, driving a uniform load Pee TED TEEH OO U Ttem jon Gear 180 000(8.571) 09110)" _ 6 Number of teeth 8 3a 2390(0.735) 1d) » Diametral pitch 2a _ Pitch diameter, inch 8571 28.095 one em erate nal eee Face width, inch 3.75 ie " Pressure angle 20° IK Palece Spiral angle 35° T2500 K, Ky Ke Py Ky Kp Mean cone distance, inch 12.811 20 2003, Eq, 6.8) Cutter radius, inch 9.0 4 Tooth taper eeaiea J 20.271 (see 2003, appendix C) “Tool edge radius 121Py B= Cy= 0.846 Hardness (C&H) min. 55HRC 55 HRC Key = Cm = 1.584 Design life 10 000 hrs. Sq = 55.000 Ibfin? ‘The application is considered to be “general com- mercial’. The gearset is manufactured to AGMA quality 8 tolerances and is lapped. The gears are crowned. One member is straddle mounted. ‘The surface pitting allowable power at unity service factor is calculated as follows: a eR 1Gy (Sud OCH TR6 000 CiCnC Cale \CpCy Crp, «(See 2003, Eq. 5.4) %» —-=8701pm y% —-=1950fpm 1 0,132 (se8 2003, appendix C) a= Cu =Cr=Cy=1.0 1.32 (808 2003, table 2) Ge = 1.5 (608 2008, clause 11) Sac 180 000 Ibjin® Cp = 2290 (ibyin?)08 G 20735 eee # = Fos 59 000 --(8ee 2003, Eq, 8.4) 85 —10(0.385) = 81.146 (see 2003, Eq. 8.2) 81.146 81.146 + 1950, = 0846 (see 2003, Eq. 8.1) 42 ---(se8 2003, clause 12) 1.156 + 0.789 = 1.107 ..(See 2003, Eq. 12.1) k, = 02u(5%5) 2.1928) = 1330 Py, = 8208.15) 0.271 (1.107) (0.846) = "126000 1330 (1.584) (1) 55.000 (8.571) 0.880 imei Cy C.5 Thermal example x 616 hp Calculate the thermal rating of a two stage helical gear reducer operating at 1780 rpm input in @ ‘counterclockwise direction ot rotation. The ambient air temperature is a maximum of 100°F and the teducer sump temperature shall be limited to 200°F. ‘The unit will be operated in a large indoor space, located at sea level, where the alr velocity will exceed 275 FPM. The gear reducer is splash lubricated with 180 220 weight mineral oll, and is subjected to continuous operation. The starting point depends upon experience. The final iterative solution is shown for this example, The solution for the thermal rating of a gear reducer involves balancing the heat generated under operat- ing conditions with the heat dissipation capability ofAMERICAN NATIONAL STANDARD the gear case. Since the heat generated under operating conditions consists of both load depen- dent and non-load dependent losses, the solution becomes iterative. ‘The final iterative value for this example is based on 105 hp. C51 Calculate heat generation C.5.1.1 Bearing power losses, Py and Pup ‘The reducer is equipped with tapered roller bearings ‘on each shaft. The forces on each bearing must be ccaloulated based on the assumed thermal rating of 105 hp. Using simple beam equations, the forces on each bearing can be solved. Please note that the forces listed are the equivalent radial loads and Inolude the combined effects of both radial and thrust loads on each shaft. Table C.1 gives both the operating and geometric characteristics for each bearing that is necessary for calculating bearing power losses. The bearing power losses must be calculated for each bearing individually and then summed for the total bearing power loss. The load dependent power losses for each bearing are calculated using equations 10 and 11. The load dependent losses for bearing #1 follows: Calculate rolling torque, 7, using equation 11. The coefficient of friction, f,, comes from table 2. Sh, W(do + di) 1, -h¥le tal p, = (0.0018) (1182) (5.875 + 3.000) > 4 T, = 472 Bb in Next calculate the power loss, Ps, for bearing #1 using equation 10, Typ Pa 63025 (822) 0780) Po = e305 Py = 0.33 hp ANSVAGMA 6010-F87 Table C.1 - Bearing operating conditions and geometry Tapat shat ‘Shaft speed, rpm (x) 1780 Bearing #1 Outside diameter (d) 5.875 in Bore diameter (4) 3.000 in Bearing “K-factor” (Ks) 1.61 Bearing length through bore (8) | 2.135 in Mean roller diameter (Dz) 0.66 in Equivalent radial load (7) 1182 Ib Bearing #2 Outside diameter (4) 4.063 in Bore diameter (4) 1.938 in Bearing *K-factor” (Ks) 1.97 Bearing length through bore (B) 1.781 in Mean roller diameter (De) 0.48 in Equivalent radial load (0%) 1008 tb Intermediate shatt Shafl speed, rpm (7) 1483 Bearing #3 Outside diameter (d,) 6.000 in Bore diameter (4) 2.125 in Bearing “K-factor” (K:) 1.96 Bearing length through bore (8) | 2.068 in Mean roller diameter (Dz) 0.66 in Equivalent radial load (17) 2367 Ib Bearing #4 Outside diameter (d,) 4.813 in Bore diameter (d) 2.625 in Bearing "K-factor" (Ks) 1.73 Bearing length through bore (B) | 1.510 in Mean roller diameter (De) 0.58in Equivalent radial load (W) 147 Ib (Output shatt Shatt speed, rpm (7) 349 Bearing #5 ‘Outside diameter (2) 8875 in Bore diameter (d) 4.500 in Bearing “K-factor” (Ks) 1.79 Bearing length through bore (8) | 2.625 in Mean roller diameter (De) 0.92 in Equivalent radial load (1%) 2433 Ib Bearing #6 Outside diameter (4,) 6375 in Bore diameter (d) 8.000 in Bearing "K-factor” (Ks) 1.46 Bearing length through bore (8) | 2.169 in Mean roller diameter (De) 0.66 in Equivalent radial load (W) 1618 ibANSYAGMA 6010-F97 In alike fashion the torques and power losses can be calculated for bearings #2 through #6. Torques (75) |Bearing F2 Bian Bearing #3 7.59 Ib in Bearing #4 4.94 Ib in Bearing #5 14.10 Ib in Bearing #6 6.82 Ib in Power losses (Pa) Bearing #2 O77 tp Bearing #3 0.179 hp Bearing #4 0.116 hp Bearing #5 0.078 hp Boaring #6 0.038 hp ‘The total load dependent power loss is the sum of he six individual bearing load dependent power losses. ze, ), = 0133 + 0.077 + 0.179 + 0.116 n=l + 0.078 + 0.038 = 0.621 hp ‘The non-load dependent losses for bearings are calculated only for tapered roller bearings. For all other styles of bearings, the non-load dependent losses are included in the load dependent loss calculation. The non-load dependent losses for each bearing are calculated using equations 23, 24 and 25 or 26. ‘The non-load dependent losses for bearing #1 are calculated as follows: First solve for the arrangement constant, A, using equation 23. Since it was stated that thie reducer is lubricated using ISO 220 mineral oil and since the maximum oll sump temperature is 200° F, then the absolute oil viscosity at maximum oil sump tempera- ture will be 16 centipoises. a= m0 a = 22440 A = 20 = 1403 Next solve for the cup angle, ag, for the bearing. Since the cup angle was expressed in this example as a"K-factor’, Ks, use equation 26. on = (2B) Ks 0.389) og = (Tr 6) dp = 13.58" AMERICAN NATIONAL STANDARD Now solve for the non-load dependent (windage and: churning) losses, Piyg, {or beating #1 using equation 24, Pug * (24) where: P (ass73y (1780)? (2.135) (cos 13. (126 OOK) (0.78\ 1203) Py = 0.186 hp In a like fashion the non-load dependent losses, Piya, can be calculated for bearings #2 through #6. Power losses (Pws) Beating #2 CoSshp Bearing #3 0.083 hp Bearing #4 0.057 hp Bearing #5 0.026 hp Bearing #6 0.008 hp ‘The total non-load dependent power loss is the sum of the six individual bearing non-load dependent power losses. 6 = (Pye), = 0-186 + 0.052 + 0.083 + 0.0 + 0.026 + 0.008 = 0.412hp C.5.1.2 Gearing power losses, Py, and Pc ‘The mesh power loss, P;,, must be calculated based on the assumed thermal rating of 105 hp since the coefficient of friction is dependent upon the contact load factor, K. Table C.2 which follows provides the gear geometry characteristics which must be deter- mined prior to calculating the gearing power losses, Py and Pr ‘The gearing power losses must be calculated for each mesh individually and then summed for the total gear power loss. ‘The load dependent power losses for each mesh are calculated using equation 12. Equations 13 through 17 are also required to calculate some of the factors used in equation 12. ‘The load dependent losses for the first stage follow: The first step is to calculate the mesh mechanical advantage, M, using equation 15, This calculation Tequires the solution of the sliding ratio at the start of approach, H,, equation 16, and the sliding ratio at the end of recess, H,, equation 17. a* AMERICAN NATIONAL STANDARD Table C.2 - Gear geometry characteristics First stage jon teeth Np = 30 Gear teeth Ng = 36 Gear ratio Img = 1.20 Center distance 250 in Transverse operating be = 24.62721" pressure angle Pinion outside radius ro = 3.509 in Gear outside radius Ry = 4.155 in inion operating pitch radius | rw = 3.295 in Gear operating pitch radius | Ry = 8.955 in Pinion speed, rpm Pinion torque Effective face Pitch line velocity Operating helix angle Pinion operating pitch dy = 6.591 in diameter Gear operating pitch Dy = 7.909 in diameter Pinion total face i, = 2.125 in Gear total face .750 In Normal diametral pitch ‘Second stage Pinion teeth Np = 12 Gear teeth Gear ratio mg = 4.25 Center distance Tranaverse operating hw = 23.74476° pressure angle Pinion outside radius fo = 1.670in Gear outside radius R= 6.040 in jon operating pitch radius Gear operating pitch radius Pinion speed, rpm Pinion torque 4372 1b in Effective face (000 in Pitch line velocity y= 1073 fpm Operating helix angle ‘Yo = 8.90276" Pinion operating pitch y= 2.762 in diamneter Gear operating pitch Day = 11.738 in diamoter Pinion total face LF; = 6.040 in Gear total face F, =5.000in Normal diametral pitch Pa ANSVAGMA 6010-F97 Sliding ratio at start of approach: Hs = (mg + le a we.) = ws won) (8 = sin24,62721°] = 0.242 oo(16) Sliding ratio at end of recess: - =o.) a0 os = cos?! asean’) — sin 24,62721°] = 0.253 oof17) Mesh mechanical advantage: 2008 oye (Hs + Hi) es ae y= 200824.62721" (0242 + 0.253 (0242? + 0.255? M 15) M = 1342 ‘The second step is to calculate the mesh coefficient, Of friction, fa, using equation 13. This calculation also requires the solution ofthe contact load factor, K, using equation 14. Contact load factor: xa Tele + No) 2F (ING ai K = — 371800 + 36) (ia) 2(1.750¥3.295)°36) K = 1793 Ibfin? Mesh coefficient of frictian: x03 fas Eas 179.3035 = vane (13) eo.n07 ©) Jn = 0.012 where: Cy (from table 8) = 80.1 45ANSVAGMA 6010-F97 Now calculate the load dependent mesh power loss: Py _ Jin Tp Mp COS? Www BOM __ (0.012)(3718)(1780) cos? 19.72250° Pa = 63 025(7.342) Py = 0152 hp (2) In alike fashion, using the same equations, the load dependent losses for the second stage af gearing can be calculated: H, = 0956 H = 0.479 M 4.292 K 283 Ibjin? tn 0.018 Pu = 0425 hp ‘The total load dependent power loss is the sum ofthe two individual gear stage load dependent power losses: 2 = (Py), = 0452 + 0425 net 2 & ley, = 057 ‘The non-load dependent losses (windage and churning), Pw, for the gearing are calculated for ‘each gear and pinion individually using equations 19 ‘and 20 and then summed for the total non-load dependent gear loss. Note that the arrangement constant, A, equation 23, is the same value as was previously calculated for the bearings. Non-load dependent loss for the first stage pinion: P, 12 F, 0082 Yow we = 726000 Pa (6.591)°(1780)"(2.125) cos? 19.77250" (126 00051403) Pyp = 0.276 hp (20) In alike fashion, the non-load dependent losses can be calculated for the other gears and pinions in the gear train: stage gear 0.227 hp ‘Second stage pinion 0.124 hp Second stage gear 0.102 hp 46 AMERICAN NATIONAL STANDARD The total non-load dependent power loss for the gears and pinions: €.5.1.3 Oil seal power loss, P, ‘The gear reducer in this example has a single extended input shaft with a single 3.000 inch diameter BUNA-N oil seal and a single extended output shaft with a single 4.500 inch BUNA-N oil seal. The input shaft rotates at 1780 rpm and the ‘output shatt rotates at 249 rpm. Equation 18 is used to calculate the oil seal power losses. Input shaft oil seal power loss: Tsn Ps = 3028 T, (from figure 1) = (0.536)(3) T, = 1.608 Ib in (18) p, = 6.008780) 63 025 P, = 0.045 hp Inallke fashion the oil sea! power loss for the output shaft can be calculated to be: P,=0.013 bp The total oil seal power 2 ZX @d, = 0.045 + 0.013 1 for the gear reducer is: 2 =X dq = 0058hp nei C.5.1.4 Total heat generated, Py ‘The total heat generated, Py, in the gear drive is the total of the load dependent losses, 7, and the non-load dependent losses, Py. Use equations 2,3, 8 and 9 to total the heet generated, Py, as follows: 6 2 a= E alt E ud, Eaiueeii 7 = 06 +057 te) 1,198 hpAMERICAN NATIONAL STANDARD Pym DPst DPuct DP t DPe Py = 0058 + 0.729 + 0412 +0 (8) Py = 1.199 hp Py=P + Py Py = 1.198 +1.199 (8) Py=2397hp .5.2 Heat dissipation, Py ‘The gear reducer has a cast iron gear case with a surface available for heat transfer of 21.8 f®. The heat dissipation is calculated using equation 30. Po =AckAT (80) Ac = 21812 (rom table 4) = 0.0011 hp/(h? AT = 100°F Pq = 218) (0.0011) (100) Po = 2398 hp Since the gear drive is in thermal equilibrium, Po=Py, the assumed thermal rating of 105 hp becomes the calculated thermal capacity, Py. If through this calculation method, Py % Po then another assumption must be made for the thermal rating. This new assumption must be used to Fecalculate the load dependent losses, ANSUAGMA 6010-F97 P, = YPy + DP 84 tional assumptions made for the thermal rating until such time as Py = Po. C53 Efficiency, n The efficiency is calculated using equation 6. PrtP, n= 100 - 4p + Py x 100 Py n= 200 HIPS £118 5 309 6) ne 977i ‘The thermal capacity of the gear drive is calculated using equation 7, Pr = 105 hp Note that the calculated thermal power rating, Pr, is the same value as the assumed thermal power rating under conditions of thermal equilibrium. a7ANSVAGMA 6010-F97 AMERICAN NATIONAL STANDARD (This page is intentionally left blank)AMERICAN NATIONAL STANDARD ANSVAGMA 6010-F97, Annex D (informative) Test and inspection procedures [The foreword, footnotes and annexes, ifany, are provided for informational purposes only and should not be construed as a part of ANSYAGMA 6010-F87, Standard for Spur, Helical, Heringbone and Bevel Enclosed Drives.) D.1 Purpose This annex covers the testing and inspection proce- dures for assembled gear drives. Individual compo- nent inspection and process control are beyond the scope of this standard, ‘When testing of the gear drive is required, the drive should be properly mounted for running the test in the intended operating position to ensure that all facets of the assembly are correct. Under normaltest conditions the gear drive is connected by coupling or bett drive to an electric motor that is available for the Purpose at the manufacturer's test facility. The following applies to only those gear drives which are lubricated in accordance with manufacturer's rec- ‘ommendations and tested in a system of connected rotating parts. During testing, the system should be free from critical speeds, torsional vibrations and. overloads as tested at the gear drive manufacturer's facility D.2 Inspection of the assembled gear drive ‘The correct mating of a gear set depends not only on the accuracy of the gear teeth, but also on the position and the alignment of the gear axes relative to each other. The components, having been fully approved prior to assembly, are assembled, and proper tooth contact, backlash and bearing settings are verified. D.2.1 Tooth contact inspection Checking the tooth contact pattern (tooth bearing area) is frequently an important test of the gear drive and is of special value when gears have been mountedin a housing, because the test willindicateif the helix and pressure angles and the resultant base pitch of the mating gears meet the specified require- ments and achieve optimal gear performance. The pinion profiles are generally coated with a marking ‘compound and then rotated in mesh with the mating (gear, and the resulting tooth pattern can be docu- Tented. See AGMA 390.03a, AGMA Handbook - Gear Classification, Materials and Measuring Moth- ods for Bevel, Hypoid, Fine Pitch Wormgearing and Racks only as Unassembled Gears, 1980, Part Ii, ‘Section 9, “Tooth Contact Patter” and ANSYAGMA 2000-A88, Gear Classification and Inspection Handbook - Tolerances and Measuring Methods for Unassembled Spur and Helical Gears (Including Metric Equivalents), 1988, Appendix D, “Contact Pattern Check’ ‘The percentage of tooth contact will vary depending upon the loading of the gears, but the patter obtained even under ano load condition will provide the manufacturer with Important information. 0.22 Backlash Backlash in gears is the clearance or play between mating tooth surfaces. The backlash will be a function ofthe tolerances ontooth thickness, runout, {ead, profile, center distance, and by the tempera- {ure differences between the housing and the gears, Functional backlash is the backlash at the tightest point of mesh on the pitch circle ina direction normal tothe tooth surfaces when the gears are mounted in their assembled positions Backlash is typically measured with feeler gauges or dial indicators normal to the gear tooth for a given mesh. Circumferential backlash of the assembled unit with gears other than spur gears should take into account ‘the axial float of the shafts involved. 1.2.3 Rolling element bearings. When rolling element bearings are used, the manu: facturer, based on his experience, the application, and the recommendations of his bearing supplier, will determine the type of bearings and their settings. Assembly procedures normally require a tolerance to be established for the desired setting. An incorrectly set bearing can bea source of damage for the gear drive. Bearing end piay may be set one shaft at a time and finally checked when both end cover plates are bolted in place with the required shims. End play should be checked to ensure compliance with the specification. Full end play is, typically measured with the shaft moved all the way 49ANSVAGMA 6010-F97 in one direction and then moved fully in the other direction. Total movement is the end play. D.3 Testing procedure For the purpose of a running test the following conditions would apply. D.3.1 Speed A gear drive intended for service at a single speed shall be tested at that speed unless otherwise agreed upon between gear manufacturer and purchaser. The test speeds of a gear unit intended for service over a range of operating speeds shall span the range of operating speeds, unless other- wise negotiated between the manufacturer and the purchaser. The direction ot rotation during the test shall be the same as that intended in service, if known, D.32 Loading Gear drives may be operated with or without ioad at the gear manufacturer's discretion unless specific test loads are agreed upon and included as a part of the purchase contract. In individual cases, espe- cially where unusually high speeds or power are involved, alternate operating conditions may be negotiated. CAUTION: Itis recommended that gear drives not be tested with loads in excess of unit rating, since such practice will reduce the design life ofthe unit D.3.3 Test requirements ‘The duration ofthe running test will be decided by the drive manufacturer unless a specific time has been contractually agreed upon between manufacturer and purchaser. AMERICAN NATIONAL STANDARD Features such as oil tightness, noise level, tompora- lure rise, axial and radal play of input and output shafts, contact pattern of the gear meshes, and lubrication system may be checked and recorded at this time. CAUTION: tis recommended that gear drives not be tested with loads in excess of gear unit rating, since such practice will reduce the design life of the unit D.3.4 Lubrication system performance ‘The lube system must be choked for adequacy at certified speed or at both ends of speed range if the speed is variable: - _Onsplash systems, the oil level must be high ‘enough to lubricate all components. it must not be unnecessarily high because sound and heat will be generated; ~ On pressure lube systems, oil lines, troughs, ‘gauges, pumps, fiters, elc., must be chacked for Performance and any leakage. Flow, pressure, ‘and temperature are to be recorded at regular intervals. D.3.5 General = Any deviations from any applicable specifica- ‘tions on the certified print will be noted on the test report; = All deficiencies such as oil leaks, excessive sound level, vibration, abnormal temperature tise, and insufficient tooth contact must be corrected before the gear drive is shipped; - _Theratio should be verified along with the as- ‘sembly, shaft extension details, and direction of rotation,AMERICAN NATIONAL STANDARD ANSVAGMA 6010-FO7 Annex E (informative) Owner responsibilities [The foreword, footnotes and annexes, itany, are provided for informational purposes only and should not be construed as a part of ANSVAGMA 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives.) This annex lists which applicable items must be considered and properly provided for by the owner. Many different types of units for widely varying applications are covered by this standard. This section, whichis arranged as a checklist, is intended to actas aguide. Specificitems should be applied as, appropriate for the particular unit for the specific Owner has the responsibility to specify to the manufacturer such items as the required loads and the operating environment. E2 Storage and handling = Proper storage of unit until installed; = Proper preservation of the unit until it is placed into service Proper handling of the unit: = safety of personnel comes first; = Iv only at adequate iting points; = protect the mounting surface from damage. E. Installation ~ Proper installation of unit on an adequate foundation: ~ adequately supported; = securely bolted into place; ~ properly leveled so as not to distort the gear case. ~ Properly install couplings suitable for the application and connected equipment; = Ensure accurate alignment equipment; with other - Fumish and install adequate machinery guards as needed to protect operating personnel and as required by the applicable standards of the Occupational Safety and Health Administration (OSHA), and by other applicable safety regulations; = Ensure that driving equipment is running in the correct direction before coupling to gear drive designed to operate in a specific direction. E44 Start-up = _ Ensure that switches, alarms, heaters, cool- ers and other safety and protection devices are installed and operational for their intended pur- poses; ~ Ona unit equipped with a separately driven lubrication pump, run the pump and check out the lubrication system prior to starting the unit; ~ Fill the unit or sump to proper level with correct lubricant before starting drive. Refill as necessary immediately after starting the unit; - Ensure that all grease points have received the proper amount of grease. E.5 Operation and maintenance - Operate the equipment as it was intended to bbe operated: = donot overioad: = rumat correct speed. = Maintain lubricant in good condition and at proper tevel; ~ Dispose of used lubricent in accordance with applicable laws and regulations; ~ Apply proper amount of grease to specified locations at prescribed intervals; Perform periodic maintenance of the gear drive as recommended by the manufacturer. 51ANSYAGMA 6010-F97 AMERICAN NATIONAL STANDARD (This page is intentionally left blank)* AMERICAN NATIONAL STANDARD ANSUAGMA 6010-F97 Annex F (informative) Gear tooth mesh losses for bevel gears [The foreword, footnotes and annexes, if any, are provided for informational purposes only and should not be construed asa part of ANSVAGMA 6010-FS7, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives.) The following procedure for determining the heat generated by bevel gears is a new procedure; theretore, itis recommended that testing be included to verify resutts. The following equations can be used to estimate the gear tooth mesh losses, Pn, for bevel gears. See figures F.1 and F.2 for either taper or uniform depth tooth, P, 4) where Jn is coefficient of friction (see equation 13); Tp is pinion torque, Ib in; 1% is pinion speed, 1pm; 1 —_ismean spiral angle, degrees; ‘M_—ismesh mechanical advantage. __ 20054 (lls +H) Eee ae Figure F.2 - Taper depth tooth where is transverse pressure angle. _ isnormal pressure angle. For bevel gearing, pitch line velocity, v, used in equation 13, is calculated at large end of tooth. ‘The K-factor is given by the equation: = Ze We+ No) -(F.2) 2F ri Ng where Np is the number of pinion teeth; Ne isthe number of gear teeth; Fis face width in contact with mating element, in, Tm is mean reference radius, pinion, in, 83ANSVAGMA 6010-F97 The values for #, and Hy, are: a as Hy = (mG + 0) (= ~ oa) — sing, a AF.3) 0s 4, =) - sind (Fa) where meg is equivalent gear ratio; romp {8 equivalent mean reference radius, pinion, Tent: iS equivalent mean reference radius, gear, in; ‘eonp is equivalent tip radius at mid-face width, pinion, in; ‘eonGis: equivalent tip radius at mid-face width, ‘gear, The equation for equivalent mean reference radius is given by: (FS) AMERICAN NATIONAL STANDARD is pitch radius, in; is mean cone distance, in; is outer cone distance, in; is reference cone ar Po ‘The equivalent gear ratio can be calculated as: -F.6) AFD) TenP where 4m is mean addendum, at mid-face, in, ifthe addendum at outer end and the face angle are known, the addendum at mid-face can be calculated as: an =a — Panto — ¥) 2 where F ._ is face width, in; @ is addendum at outer end, in; + _ is face angle; for uniform depth teeth, =7; +y_ isreference cone angle. Equations £5, 7 and F8 are to be calculated for both pinion and gear member using respective pitch radius, r; pitch angle, y; mean addendum, aq; and face angle, Yo. APB)AMERICAN NATIONAL STANDARD ANSVAGMA 6010-F97 Bibliography The foreword, footnotes and annexes, if any, are provided for informational purposes only and should not be construed as a part of ANSVAGMA 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Diives | 1. Townsend, Dennis P., Dudley's Gear Hand- ‘book, Second edition, McGraw-Hill, New York, 1992, 2. The Timken Company: Bearing Torque; Heat Generation and Operating Temperature. 8. Palmgren, Dr. Eng.: Ball Roller Bearing Engi- neering, Third Edition 4, Eschmann, Hasbargen and Weigand, Ball Roller Bearings, Theory, Design and Application, Second edition, John Wiley and Sons, Ltd., Chi- chester, 1985. 5. ANSV/AGMA 6032-A88, Standard for Marine Gear Units: Rating. 6. Winter, H. and Michaelis, K., Scoring Load Capacity of Gears Lubricated with EP-Oils, AGMA Technical Paper P218.17. 7. Dudley, Darle E.: Solar Test Report, by M. Dunn (also ANSVAGMA 6032-A94, equation 8.19). 8. Rubber Manufacturers Association: Techni- cal Bulletin OS-15, 9, McAdams, Wiliam H., “Heat Transmission’, Third Edition, Chapter 9.ANSYAGMA 6010-F97 56 AMERICAN NATIONAL STANDARDPUBLISHED BY AMERICAN GEAR MANUFACTURERS ASSOCIATION 1600 KING STREET, ALEXANDRIA, VIRGINIA 27316