Spur Gearing Calculation

1/19/2021 Spur gearing
Involute gearing - theory

This part contains a summary of some theoretical information and formulas related to the geometry design, calculation of force
and performance parameters as well as the strength control of involute gearing. These data were used in the calculations below.
Spur gearing external
Spur gearing internal
Planetary Gearing with Spur and Helical Toothing
Spur gear - Rack
Content:
1. Geometry, dimensions
2. Moment, power, forces, efficiency
3. Planetary Gearing
4. Spur gear - Rack
5. Stress and safety ISO 6336:2006
6. Stress and safety ANSI/AGMA 2001-D04
1. Geometry, dimensions.
Applied formulas (calculation of gearing geometry).
Some of the most important formulas for calculation of the gearing geometry are specified below. In the formulas, indexes 1 and
2 are used for a pinion and a wheel (which is a pair: a sun and a planet, or a planet and a ring gear). For the internal gearing
(ring gear), a negative value for the number of internal gear teeth is used, i.e. also a negative value for the centre distance and
diameters.
In the case of planetary gearing, the individual gears are dependent on each other and the gearing must be handled as a whole,
including the respective constraining conditions (see below).
Basic profile parameters: mn (module, DP for inch calculation), a (pressure angle), ha*, c*, rf* (cutting tool parameters)
Pinion and wheel parameters: z1, z2 (number of teeth of pinion and wheel), x1, x2 (addendum modification), b (helix
angle), b (width of gearing)
1. Transmission ratio
i = z2 / z1
2. Module
mt = mn / cos(b) ... Transverse
3. Circular pitch
p = p • mn ... Circular pitch
pt = p / cos(b) ... Transverse circular pitch
ptb = pt • cos(at) ... Base circular pitch
4. Pressure angle
at = arctg(tg(a) / cos(b)) ... Transverse pressure angle
awn = arcinv(2 • (x1 + x2) / (z1 + z2) • tg(a) + inv(a)) ... Pressure angle at the pitch cylinder
awt = arcinv(2 • (x1 + x2) / (z1 + z2) • tg(a) + inv(at)) ... Transverse pressure angle at the pitch cylinder
5. Base helix angle
bb = arcsin(sin(b) • cos(a))
6. Diameter
d = z • mt ... Reference diameter
db = d • cos(at) ... Base diameter
dw = d • cos(at) / cos(awt) ... Operating pitch diameter
da = mn • (z / cos(b) + 2 • (ha* + x - DY) ... Tip diameter
df = d - hf ... Root diameter
7. Center distance
a = (z1 + z2) • mn / (2 • cos(b)) ... Center distance (pitch)
av = a + (x1 + x2) • mn ... Center distance (production)
aw = a • cos(at) / cos(atw) ... Center distance (working)
DY = (a - aw) / mn + (x1 + x2) ... Unit correction
https://www.mitcalc.com/doc/gear1/help/en/gear_theory_txt.htm 1/22
8. Contact ratio
ea = ((da1^2 - db1^2)^0.5 + (da2^2 - db2^2)^0.5 - 2 • aw • sin(awt)) / (2 • p • cos(at) / cos(b)) ... Transverse
contact ratio
eb = b / mn / p • sin(b) ... Transverse overlap ratio
eg = ea + eb ... Total overlap ratio
Principle of corrections, use of corrections.

Approaching and withdrawal of the production tool from the gear center changes the shapes and therefore also properties of the
involute toothing. This creates corrected toothing. The illustration shows:
A. Production tool
B. Produced gear
Correction (addendum modification) of toothing enables:

Achieve the exact axis distance.
Prevent undercutting of teeth (roots of a small number of teeth might be undercut; this decreases the coefficient of
duration of the meshing and reduces loading capacity of the teeth)
Eliminate sharpness of teeth
Prevent creation of production and operational interference of teeth
Improve the contact ratio (achieve a contact ratio >1)
Reduce noise and vibrations of the gearing
Improve efficiency
Increase loading capacity of the gearing (contact, bend, seizure, wear)
Example of a tooth profile (z=10, a=20;b=0), where at X=0 the teeth are undercut and the value x=0.7 causes sharpness of
teeth.
Hint: It is recommended to look for more detailed information on possibilities and methods of corrections in specialized
literature.
Recommended values - optimization.
When determining values of corrections, first it is necessary to fulfill functional requirements for toothing, where the most
important items include
Desired axis distance (given sum of both corrections)
Elimination of teeth undercutting
Elimination of teeth sharpness
After securing function requirements, it is possible to further optimize corrections in order to improve one or more important
toothing parameters. From the frequently used optimizing methods, it is possible to optimize the toothing in order to balance
specific slips [5.14 - 5.17] and minimize specific slips [5.18]. For other optimizing processes there is a wide range of
recommendations in professional literature, namely the so-called diagrams (charts) of limit corrections, providing a clear view of
possibilities and selection of corrections.
2. Moment, power, forces, efficiency

Moment, power, forces in gearing

Torsional moment
Mk [Nm] = Pw * 9550 / n .............. (SI units)
T [lb.in] = PP * 63000 * / n ........... (Imperial)
Pw, PP ... power [kW, HP]
n ........... speed [/min]
Power (Spur gear - Rack)

Pw = Ft * v / 1000
Ft ... Tangential force
v .... Rack speed
Forces calculation:
Tangential force
Ft = Mk * 2000 / dw
dw ... Operating pitch diameter
MK ... Torsional moment
Axial force
Fa = Ft * tan(b) / cos(awt)
b ... Base helix angle
awt ... Transverse pressure angle at the pitch cylinder
Radial force
Fr = Ft * tan(awt)
Normal force
Fn = (Ft2 + Fa2 + Fr2)0.5
Bending moment
Mo = Fa * (dw / 2000)
Efficiency and losses.
The losses in planetary gearing can be divided into losses due to idle run and losses due to loading. The losses due to idle run
(lubrication, unloaded mesh, bearings) are difficult to specify analytically and in general, they are significantly lower than losses
due to loading. The losses due to loading arise during power transmission and include:
Losses in gearing
The loss coefficient can be approximately described according to the formula:
Spur gearing: zz = 0.5 • f • p • e • (1/z1 +- 1/z2)
Helical gearing: zz = 0.25 / cos(b) • f • p • e • (1/z1 +- 1/z2)
with:
z1, z2 - number of teeth
f - friction coefficient (0.04 - 0.08)
e - mesh ratio
b - helix angle
Plus sign (+) for external gearing, (-) for internal gearing.
Losses in bearings
The loss output can be determined from the relation:
PVL = w • F • f • r
with:
w - angular velocity
F - resulting bearing loading (carrier, centrifugal force)
f - friction coefficient (0.001 - 0.005)
r - mean bearing radius
Note: The friction coefficient (for both gearing and bearing) is estimated in the calculation based on the selected accuracy level
(gearing roughness) and used lubricant.
For the calculation of loss (efficiency) of the planet gearing, we will use the losses in the helical gearing (carrier stopped) with:
with:
zz0/z1 - loss coefficient sun - planet
zz1/z2 - loss coefficient planet - ring gear

z0,z2 - number of teeth of the sun and ring gear
For individual cases of output flow, it applies for the loss calculation:
z = ir • zr / (ir - 1) Sun => Planet (carrier)

z = zr Sun => Ring gear
z = ir • zr / (ir - 1 + zr ) Planet (carrier) => Sun
z = - zr / (ir - 1) Planet (carrier) => Ring gear
z = - zr / (ir - 1 - ir • zr) Ring gear => Planet (carrier)
z = zr Ring gear => Sun
Note: Detailed and accurate identification of losses in the planetary mechanism is demanding and depends on a detailed
knowledge of construction, the used materials and operating conditions. Therefore, it is necessary to consider the values from
the calculation as informative.
3. Planetary Gearing
Planetary gearings consist of a system of gearwheels and a carrier. The so-called suns are aligned with the carrier and the
central axis of the gear mechanism. The planets are the gearwheels mounted in a pivoting way on the carrier and they mesh
with the suns or with each other. The planets may have one, two or more gearings. Two or multi-speed planets have more
constructional variants with wider possibilities; however, they are more complex and expensive to manufacture.
You can see an example of a simple planetary gearing with single-speed toothing of the planet below. This basic type of
planetary gearing is also handled in complex in this program.
Simple planetary gearing (differential):

0 - Sun; 1 - Carrier; 2 - Ring gear; 3 - Planet.
If all three members of a simple planetary gearing (0, 1, 2) are free, the system is called a differential (2 degrees of freedom),
which enables it to compose / decompose two moves into one. That is used e.g. for machine tools (composition) or for a car
differential (move decomposition).
If one of the basic members (0 or 2) is connected to the frame, the system is called planetary gearing (1 degree of freedom),
specifically a reductor in case of a drive outwards from the sun or a multiplicator in case of a drive outwards from the carrier.
The system with the carrier connected to the frame is called a normal transmission or helical gearing.
Planetary gearings may be arranged in various ways. The most frequent way includes the serial arrangement, where the total
transmission ratio (efficiency) is determined by the product of partial transmission ratios (efficiency). The composed gearings
often use the possibility to brake individual members, i.e. gear changing.
Advantages:
Saving of space using an aligned arrangement of the driving and driven shafts
Lower weight compared to a normal transmission
High efficiency even at high transmitted outputs
Low radial loading of centre member bearings

Compact design
Disadvantages:
• Complicated construction, higher requirements for production and assembly accuracy
• Higher production costs
• Some limiting conditions (complex assembly)
Use:
With respect to the above-specified advantages, the use of planetary gearings is popular in a wide range of applications (e.g.
motor vehicle transmissions, building machinery, lifting equipment, marine transmissions, turbine reducers, etc.) The
combination of planetary gearing with hydraulic or friction gearing is also common.
Designing and geometrical relations.
The formulas below use the following indexes.
For:
Sun - 0
Planet - 1
Ring gear - 2
With respect to the possibilities of assembly and functioning of planetary gears, the geometry of the gearwheels cannot be
chosen at random. In order to provide proper functioning, the following several conditions must be followed and observed.
Condition of alignment.
The planets of the planetary gearings gear with the suns, possibly with other planets. This calculation applies to the joint mesh
of a planet with suns (planet, ring gear). As the planet and the ring gear have the same axis, the centre distance between the
planet and both suns must be the same.
It applies for the generally corrected wheels that:
aw (0,1) = aw (1,2)
with aw (0,1)=mt • (z0+z1)/2 • COS(alfat)/COS(alfawt(0,1))
with aw (1,2)=mt • (z1+z2)/2 • COS(alfat)/COS(alfawt(1,2))
Note: In the program, a violation of this condition is indicated by the cells with calculated centre distance highlighted in red.
Condition of assembly.
For simple planets and uniform planet distribution, the following condition must be complied with:
g = (abs (z0) + abs (z2))/P
With:
g - must be a random integer
P - number of planets
z - number of teeth
Note: This condition need not always be achievable (e.g. if a specific transmission ratio is required). This condition may be
bypassed by uneven distribution of the planets, which may result in greater demands on production, imbalance of the planet
carrier, imbalance of inner forces and increased stress.
Condition of backlash between neighbouring planets.
This condition provides minimum backlash between the planets vmin (1-2 mm, 0.05 in).
Maximum planets P = int(asin((da1+vmin)/(aw • 2)))
Note: In the program, a violation of this condition is indicated by the cells with number of planets highlighted in red.
4. Spur gear - Rack

Geometry
This is a standard gearing calculation, where the rack is in gear with the pinion. The manufacturing tool profile can be specified
both for the pinion and the gear rack.
It is possible to select the number the pinion teeth, the pressure angle and the tooth slope. Since it has no meaning to correct
the gear rack in this case, only the pinion correction is possible (axial distance, gear condition and strength parameter
improvement).
Load selection
In the calculation it is possible to enter the tangential force, which is the force of the gear rack acting on the pinion, and the
speed of the gear rack (pinion circumferential speed). These two values are then used to calculate the power and torque
transferred via the pinion. Since it is possible to use the gear rack for a range of various design solution, it is then necessary to
calculate (estimate) and transfer the transmission requirements on these two values.
Strength calculation
Since there are no standards related to the strength calculation of the pinion in gear with the rack, the
ISO6336(ANSI/AGMA2001-D04) standard is used for the strength calculation. The gear rack is replaced by a toothed wheel with
a high number of teeth (1 000 teeth).
Wheel relief coefficient – critical speed
There is no specific methodology of specifying the critical speed for a gear rack application. As a rough estimate, the calculation
of two toothed wheels may be used (the gear rack is substituted by a toothed wheel. For a light rack that is not connected to
the structure, use the coefficient sR/h=1; if the rack is connected to the structure, use the value of 20.
Number of cycles
To determine the lifetime coefficient (YNT, ZNT), a number of cycles must be known. Enter the number of the pinion and gear
rack loading cycles.
5. Allowable stress and safety for Involute Spur and Helical Gear Teeth
ISO 6336:2006.
In the following paragraphs, the method of the bearing capacity calculation is described. The ISO6336:2006 standard is used for
the calculation. The description includes the key formulas used as well as the notes important to understand the calculation and
to operate this application. This text does not replace the full text of the standards used.
ISO 6336-1:2006 Part 1: Basic principles, introduction and general influence factors
This part of ISO 6336 presents the basic principles of, an introduction to, and the general influence factors for, the calculation of
the load capacity of spur and helical gears.
Basic relations for the gears load
Ft = 2000 * T1,2 / d1,2 = 19098 * 1000 * P / (d1,2 * n1,2) = 1000 * P / v
w1,2 = 2000 * v / d1,2 = n1,2 / 9549
Ft ... (nominal) transverse tangential load at reference cylinder per mesh
T1,2 ... nominal torque at the pinion (wheel)
d1,2 ... reference diameter of pinion (wheel)
P ... transmitted power
n1,2 ... rotation speed of pinion (wheel)
v ... tangential velocity (without subscript, at the reference circle =tangential velocity at pitch circle)
w1,2 ... angular velocity of pinion (wheel)
Application factor KA
The application factor, KA, is used to modify the value of Ft to take into account loads additional to nominal loads, which are
imposed, on the gears from external sources. The empirical guidance values in table B.1 ISO 6336-6 can be used (for industry
gears and high speed gears).
Internal dynamic factor KV
(The internal dynamic factor KV makes allowance for the effects of gear tooth accuracy grade as related to speed and load.
There are three calculation methods (B2006), (C2006) a (C1996).)
The method B is suitable for all the types of spur gears. It is relatively complicated and may give completely unrealistic KV
values, if the materials or the degree of accuracy are not properly selected. Therefore it is possible to set the maximum limit for
the calculation (pre-set to 5.0). If this limit is exceeded, it is recommended to check the selected material in proportion to the
gearing load.
Internal dynamic factor KV(B)
N = n1 / nE1
For N < NS (Subcritical range)
NS = 0.5 + 0.35 * ( Ft * KA / b )0.5 ...... [ Ft * KA / b < 100 ]
NS = 0.85 ...... [ Ft * KA / b >= 100 ]
KV(B) = ( N * K ) + 1
K = ( CV1 * BP ) + ( CV2 * Bf ) + ( CV3 * BK )
BP = c' * fpb eff / ( Ft * KA / b )
Bf = c' * fta eff / ( Ft * KA / b )
BK = abs (1 + c' * Ca / ( Ft * KA / b ))
For Ns < N < 1.15 (Main resonance range)

KV(B) = ( CV1 * BP ) + ( CV2 * Bf ) + ( CV4 * BK ) + 1
For N >= 1.5 (Supercritical range)
KV(B) = ( CV5 * BP ) + ( CV6 * Bf ) + CV7
For 1.15 < N < 1.5 (Intermediate range)
KV(B) = KV(N=1.5) + ( KV(N=1.15) - KV(N=1.5)) / 0.35 * (1.5 - N)
Coeficients
1.0 < eg <=2.0 eg > 2.0

CV1 0.32 0.32
CV2 0.34 0.57 / (eg - 0.3)
CV3 0.23 0.096 / (eg - 1.56)
CV4 0.90 (0.57 - 0.05 * eg ) / (eg - 1.44)

CV5 0.47 0.47
CV6 0.47 0.12 / (eg - 1.74)
CV7 1.0 < eg <=1.5 0.75
CV7 1.5 < eg <=2.5 0.125 * sin(p * (eg - 1.74)) + 0.875
CV7 eg > 2.5 1.0
Cay1,2 1 / 18 * (sHlim1,2 / 97 - 18.45)2 + 1.5

Cay 0.5 * (Cay1 + Cay2)
Ca Ca = Cay
Internal dynamic factor KV(C)

Method C supplies average values which can be used for industrial transmissions and gear systems with similar requirements in
the following fields of application:
subcritical running speed range i.e. (v * z1 / 100) * (u2 / (1 + u2))0.5 < 10 m/s
external and internal spur gears
basic rack profile as specified in ISO 53
straight and helical spur gears with b <= 30
pinion with relatively low number of teeth z1 < 50
solid disc wheels or heavy steel gear rim
Method C can also generally be used, with restrictions for the following fields of application:
all types of cylindrical gears, if (v * z1 / 100) * (u2 / (1 + u2))0.5 < 3 m/s
For lightweight gear rim and helical gears where b > 30 are values unfavourable (Thus, calculated values tend to be
safe).
Method (C2006) is different from (C1996) by adding the coefficient K3.

Example for input values KA * Ft / b = 100; v = 3 m / s; Q = 7 and straight teeth.
KV(C..1996)
KVa,b = 1 + (K1 / ( Ft * KA / b ) + K2) * v * z1 / 100 * (u2 / (1 + u2))0.5 ... [ eb = 0; eb >= 1.0]
KV(C..2006)
KVa,b = 1 + (K1 / ( Ft * KA / b ) + K2) * v * z1 / 100 * K3 * (u2 / (1 + u2))0.5 ... [ eb = 0; eb >= 1.0]
KV = KVa - ea* ( KVa - KVb ) ... [0 < eb < 1.0]
Coeficients
K1 (Accuracy grades as speclfled in ISO1328-1) K2
3 4 5 6 7 8 9 10 11 12 All
Spur gears eb = 0 2.1 3.9 7.5 14.9 26.8 39.1 52.8 76.6 102.6 146.3 0.0193
Helical gears eb
1.9 3.5 6.7 13.3 23.9 34.8 47.0 68.2 91.4 130.3 0.0087
>=1.0
SRC = v * z1 / 100 * (u2 / (1 + u2))0.5
K3 = 2.0 ...... [SRC <= 0.2]
K3 = -0.357 * SRC + 2.071 ...... [SRC > 0.2]
Main resonance of a gear pair NE1

nE1 = 30000 / ( p * z1 ) * ( cga / mred )0.5
where:
mred = m*1 * m*2 / ( m*1 + m*2 )
m*1,2 = J*1,2 / (rb 1,2)2 [kg/mm]
J*1,2 = J1,2 / b1,2
cga = c' * (0.75 * ea + 0.25)

c' = c'th * CM * CR * CB * CE * CFK * cos(b)
c'th = 1 / (0.04723 + 0.15551/zn1 + 0.25791/zn2 - 0.00635*x1 - 0.11654*x1/zn1 - 0.00193*x2 - 0.24188*x2/zn2 + 0.00529*x12
+ 0.00182*x22)
c'th = 1 / (0.04723 + 0.15551/zn1 - 0.00635*x1 - 0.11654*x1/zn1 - 0.00193*x2 + 0.00529*x12 + 0.00182*x22) ... for internal
gearing
CM = 0.8
CR = 1 + ln(bs / b) / (5 * e(sR/(5 * mn))) ...... [0.2 < bs < 1.2 ]
CB = 0.5 * (CB1 + CB2); CB1,2 = (1 + 0.5 * (1.2 - hf1,2 / mn)) * (1 - 0.02*(20 - aPn))
CE = (( 2 * E1 * E2 ) / ( E1 + E2 )) / 206
CFK = (( Ft * KA / b ) / 100 )0.25...... [ CFK<= 1.0 ]
zn1,2 = z1,2 / cos(b)3

Main resonance of gear with idler gears, inner gears and planet gears are calculated by different process. Details in ISO6336-1.
Coefficient KHb (KFb)
This coefficient takes into account the effect of the non-uniform distribution of load over the gear face. Uneven load distribution
is caused by an elastic deformation of gears and housing, manufacturing deviations and thermal distortion. Methods, principles
and assumptions are given in standard ISO6336-1. Because the determination of the coefficient is dependent on a number of
factors and primarily on the specific dimensions and design of the gearbox, is for the design purposes selected the coeficient
KHb from graphs based on practical experiences. The calculation is in paragraph [18].
Determination KHb (method C)
Detail description is in ISO6336-1. Here is just a selection of formulas, information and comments that are related to the
calculation KHb.
a) KHb = (2 * Fby * cgb / (Fm / b))0.5 ...... [ Fby * cgb / (2 * Fm / b) >= 1.0; KHb >= 2.0 ]
b) KHb = 1 + Fby * cgb / (2 * Fm / b) ...... [ Fby * cgb / (2 * Fm / b) < 1.0; KHb > 1.0 ]
where:
Fm = Ft * KA * KV
Fby = Fbx * yb
cgb = 0.85 * cga
b ...... gear width
yb ... Running-in allowance from graph
where:
1) Fbx = Choosing your own values
2) Fbx = 1.33 * B1 * fsh + B2 * fma ....... [ Fbx >= Fbxmin ]
3) Fbx = abs( 1.33 * B1 * fsh - fHb6) ...... [ Fbx >= Fbxmin ]
4) Fbx = 1.33 * B1 * fsh + fsh2 + fma + fca +fbe
where:
B1, B2 coeficients, table 8, ISO6336-1
fHb6 ... Helix slope deviation for Q=6, ISO1328-1
fsh ... Component of equivalent misatignment. It is possible to use several methods (calculation, measurement, estimation).
Used formula:
fsh = Fm / b * 0.023 * (abs(B' + K' * l * s / d12 * (d1 / dsh)4 - 0.3) + 0.3) * (b / d1)2 ... [s / l < 0.3]
fsh = Fm / b * 0.046 * (abs(B' + K' * l * s / d12 * (d1 / dsh)4 - 0.3) + 0.3) * (bB / d1)2 ... [s / l < 0.3]
fsh2, fca, fbe ... can be determined by ISO6336-1
B' = 1.0 ... for both spur and single helical gears, for the total transmitted power
K' = arrangement coefficient, gray indicates the less deformed helix of a double helical gear
K' with stiffening without stiffening

A 0.48 0.80
B -0.48 -0.80
C 1.33 1.33
D -0.36 -0.60
E -0.60 -1.00
l, s .... picture
dsh ... shaft diameter
fma ... mesh misalignment. It is possible to use several methods (calculation, measurement, estimation). Used formula:
fma = (fHb12 + fHb22)0.5 .
Determination KHb (Simplified formula)
a) KHb = Acoef * (2 * Fby * cgb / (Fm / b))0.5 ...... [ Fby * cgb / (2 * Fm / b) >= 1.0; KHb > 1.0 ]
b) KHb = Acoef * (1 + Fby * cgb / (2 * Fm / b)) ...... [ Fby * cgb / (2 * Fm / b) < 1.0; KHb > 1.0 ]
where:
Fm = Ft * KA * KV
Fby = Fb * 0.8 ..... [Fb from ISO 1328]
cgb = 0.85 * cga
b ...... gear width
Acoef = 1.0 ..... Double-sided symmetrically supported gearing
Acoef = (0.9 + 0.15 * (b1 / d1)2 + 0.23 * (b1 / d1)3) ..... Double-sided non-symmetrically supported gearing
Acoef = (0.9 + (b1 / d1)2) ..... Overhung gearing
Determination KHb (Approximation from the table)
For the preliminary design is possible to use values from these graphs.
X Axis: Ratio gear width to gear diameter
Y Axis: Factor KHb ..... [min. value = 1.05]
Accuracy grade 7
Not-hardended gears, VHV<370, design type A-F ... calculation paragraph [2.0]
Hardended gears, VHV<=370, design type A-F ... calculation paragraph [2.0]
Coefficient KFb
KFb = ( KHb )NF
NF = (b / h)2 / (1 + b / h + (b / h)2) ...... [když b / h < 3; pak b / h = 3] ([if b / h < 3; then b / h = 3])
The smaller of the values b1/h1, b2/h2 is to be used as b/h.
Coefficient KHa (KFa)
KHa = KFa = eg / 2 * (0.9 + 0.4 * (cga * (fpb - ya)) / (FtH / b)) ...... [eg <= 2.0]
KHa = KFa = 0.9 + 0.4 * (2.0 * (eg - 1.0) / eg)0.5 * cga * (fpb - ya) / (FtH / b) ...... [eg > 2.0]
Pro: (For:)
KHa > eg / ( ea * Ze2) ...... KHa = eg / ( ea * Ze2)
KHa < 1.0 ...... KHa = 1.0
Pro: (For:)
KFa > eg / (0.25 * ea + 0.75) ...... KFa = eg / (0.25 * ea + 0.75)
KFa < 1.0 ...... KFa = 1.0
fpb = fpt (ISO1328-1)
ya ... Material: St, St(cast), V, V(cast), GGG(perl.), GGG(bai.), GTS(perl.)
ya = fpb * 160 / σHlim [ v < 5m/s ]
ya <= 12800 / σHlim [ 5m/s < v <= 10m/s ]
ya <= 6400 / σHlim [ v > 10m/s ]
ya ... Material: GG, GGG(ferr.)

ya = fpb 0.275 [ v < 5m/s ]
ya <= 22 [ 5m/s < v <= 10m/s ]
ya <= 11 [ v > 10m/s ]
ya ... Material: Eh, IF, NT(nitr.), NV(nitr.), NV(nitrocar.)

ya = fpb 0.075 [ ya <= 3 ]
ISO 6336-2:2006 Part 2: Calculation of surface durability (pitting)

This part of ISO 6336 specifies the fundamental formulae for use in the determination of the surface load capacity of cylindrical
gears with involute external or internal teeth. It includes formulae for all influences on surface durability for which quantitative
assessments can be made. lt applies primarily to oil-lubricated transmission, but can also be used to obtain approximate values
for (slow-running) grease-lubricated transmissions, as long as sufficient lubricant is present in the mesh at all times.
Safety factor for surface durability (against pitting), SH
Calculate SH separately for pinion and wheel:
SH1,2 = σHG1,2 / σH1,2 > SHmin
Contact stress σH
σH1 = ZB * σH0 * (KA * KV * KHb * KHa)0.5
σH2 = ZD * σH0 * (KA * KV * KHb * KHa)0.5
The nominal contact stress at the pitch point σH0
σH0 = ZH * ZE * Ze * Zb * (Ft / (b * d1) * (u + 1) / u)0.5
Permissible contact stress σHP: Method B

σHP = ZL * ZV * ZR * ZW * ZX * ZNT * σHlim / SHmin = σHG / SHmin
The pitting stress limit σHG
σHG = σHP * SHmin
Zone factor ZH
ZH = (2 * cos(bb) * cos(awt) / (cos(at)2 * sin(awt)))0.5
Single pair tooth contact factors ZB and ZD
M1 = tan(awt) / ((((da1 / db1)2 - 1.0)0.5 - 2 * p / z1) * (((da2 / db2)2 - 1.0)0.5 - (ea - 1.0) * 2 * p / z2))0.5
M2 = tan(awt) / ((((da2 / db2)2 - 1.0)0.5 - 2 * p / z2) * (((da1 / db1)2 - 1.0)0.5 - (ea - 1.0) * 2 * p / z1))0.5
Spur gears with, ea > 1.0

ZB = 1.0 ... [ M1<= 1.0 ]
ZB = M1 .... [ M1 > 1.0 ]
ZD = 1.0 ... [ M2<= 1.0 ]
ZD = M2 .... [ M2 > 1.0 ]
Helical gears with, eb >= 1.0

ZB = ZD = 1.0
Helical gears with, eb < 1.0

ZB = M1 - eb * (M1 - 1.0) ... [ ZB >= 0 ]
ZD = M2 - eb * (M2 - 1.0) ... [ ZD >= 0 ]
(For internal gears, ZD shall be taken as equal to 1.0)

Elasticity factor ZE
ZE = (p * ((1.0 - n12) / E1 + (1 - n22) / E2))-0.5
where
n1,2 ... Poisson's ratio
E1,2 ... modulus of elasticity
Contact ratio factor Ze

Ze = ((4.0 - ea) / 3 * (1.0 - eb) + eb / ea)0.5 ... [ 0 <= eb < 1.0 ]
Ze = (1.0 / ea)0.5 ... [ eb >= 1.0 ]
Helix angle factor, Zb

Zb = 1 / (cos(b))0.5
Life factor ZNT
X axis ... number of cycles

Y axis ... ZNT
Lubricant factor ZL
ZL = CZL + 4 * (1.0 - CZL) / (1.2 + 80 / n50)2 = CZL + 4 * (1.0 - CZL) / (1.2 + 134 / n40)2
CZL = 0.83 ... [ σHlim < 850 ]
CZL = σHlim / 4375 + 0.6357 ... [ 850 <= σHlim <= 1200 ]
CZL = 0.91 ... [ 1200 < σHlim ]
n50 ( n40) ... Nominal viscosity in 50°C (40°C) [mm2/s]
Diagram viscosity / temperature for viscosity index VI = 50

Velocity factor ZV
ZV = CZV + 2 * (1.0 - CZV) / (0.8 + 32 / v)0.5
CZV = CZL + 0.02
Roughness factor, ZR
ZR = (3 / Rz10)CZR
CZR = 0.15 ... [ σHlim < 850 ]
CZR = 0.32 - 0.0002 * σHlim ... [ 850 <= σHlim <= 1200 ]
CZR = 0.08 ... [ 1200 < σHlim ]
Rz10 = Rz * (10 / rred)(1/3)
rred = (r1 * r2) / (r1 + r2)
r1,2 = 0.5 * db1,2 * tan(awt)
Work hardening factor, ZW
The work hardening factor, ZW takes account of the increase in the surface durability due to meshing a steel wheel (structural
steel, through-hardened steel) with a hardened or substantially harder pinion with smooth tooth flanks.
Pinion Surface-hardened, Gear through-hardened
ZW = 1.2 * (3 / RzH)0.15 ... [ HB < 130 ]
ZW = (1.2 - (HB - 130) / 1700) * (3 / RzH)0.15 ... [ 130 <= HB <= 470 ]
ZW = (3 / RzH)0.15 ... [ HB > 470 ]
ZW for static stress
ZW = 1.05 ... [ HB < 130 ]
ZW = 1.05 - (HB - 130) / 680 ... [ 130 <= HB <= 470 ]
ZW = 1.0 ... [ HB > 470 ]
RzH = Rz1 * (10 / rred)0.33 * (Rz1 / Rz2)0.66) / ( n40 * v / 1500)0.33) ... [ 3 <= RzH <=16 ]
Through-hardened pinion and gear
ZW = 1.0 ... [ HB1/HB2 < 1.2 ]
ZW = 1.0 + A * (u - 1.0) ... [ 1.2 <= HB1/HB2 <= 1.7 ]
ZW = 1.0 + 0.00698 * (u - 1.0) ... [ 1.7 < HB1/HB2 ]
A = 0.00898 * HB1/HB2 - 0.00829
ZW for static stress
ZW = 1.0
ISO 6336-3:2006 Part 3: Calculation of tooth bending strength.
This part of ISO 6336 specifies the fundamental formulae for use in tooth bending stress calculations for involute external or
internal spur and helical gears with a rim thickness sR > 0.5 * ht for external gears and sR >1.75 * mn for internal gears.
Safety factor for bending strength (safety against tooth breakage), SF
Calculate SF separately for pinion and wheel:
SF1,2 = σFG1,2 / σF1,2 >= SFmin
Tooth root stress σF
σF = σF0 * KA * KV * KFb * KFa
The nominal tooth root stress σF0
σF0 = Ft / (b * mn) * YF * YS * Yb * YB * YDT
Permissible bending stress σFP : Method B

σFP = σFlim * YST * YNT * YdrelT * YRrelT * YX / SFmin = σFG / SFmin
Tooth root stress limit σFG
σFG = σFP * SFmin
The form factor, YF : Method B
YF = (6 * hFe / mn * cos(aFen)) / ((sFn / mn)2 * cos(an))
Tooth root normal chord sFn ; radius of root fillet rF ; bending moment arm hFe
Dimensions and basic rack profile of the teeth (finished profile)

A...without undercut
B...with undercut
auxiliary values
E = p / 4 * mn - hfP * tan(an) + spr / cos(an) - (1 - sin(an) * rfP / cos(an)
spr = pr - q
spr = 0 when gears are not undercut
rfPv = rfP ... external gears
rfPv = rfP + mn * (x0 + hfp/mn - rfP/mn)1.95 / (3.156 * 1.036z0) ... internal gears
x0 ... the pinion-cutter shift coefficient
z0 ... the number of teeth of the pinion cutter
G = rfPv / mn - hfP / mn + x
H = 2 / zn * (p / 2 - E / mn) - T
T= p / 3 ... external gears

T= p / 6 ... internal gears
q = 2 * G / zn * tan(q) - H
Determination of normal chordal dimensions of tooth root critical section for Method B
A...external gears
B...internal gears
Tooth root normal chord sFn

sFn / mn = zn * sin(p/3 - q) + (3)0.5 * (G / cos(q) - rfPv / mn) ... external gears
sFn / mn = zn * sin(p/6 - q) + (G / cos(q) - rfPv / mn) ... internal gears
Radius of root fillet rF

rF / mn = rfPv / mn + 2 * G2 / (cos(q) * (zn * cos(q)2 - 2 * G))
Bending moment arm hFe
hFe / mn = 0.5 * ((cos(ge) - sin(ge) * tan(aFen)) * den / mn - zn * cos(p/3 - q) - G / cos(q) + rfPv / mn)) ... external gears
hFe / mn = 0.5 * ((cos(ge) - sin(ge) * tan(aFen)) * den / mn - zn * cos(p/6 - q) - (3)0.5 * (G / cos(q) - rfPv / mn))) ... internal
gears
Parameters of virtual gears
bb = arcsin(sin(b) * cos(an))
zn = z / (cos(bb))3
ean= ea / (cos(bb))2
dn = mn * zn
pbn = p * mn * cos(an)
dbn = dn * cos(an)
dan = dn + da - d
den = 2 * z / abs(z) * ((((dan / 2)2 - (dbn / 2)2)0.5 - p * d * cos(b) * cos(an) * (ean - 1) / abs(z))2 + (dbn / 2)2)0.5
*The number of teeth z is positive for external gears and negative for internal gears
aen = arccos(dbn / den)
ge = (0.5 * p + tan(an) * x) / zn + inv(an) - inv(aen)
aFen = aen - ge
Stress correction factor YS
The stress correction factor YS is used to convert the nominal tooth root stress to local tooth root stress.
YS = (1.2 + 0.13 * L) * qs(1 / (1.21 + 2.3 / L))
L = SFn / hFe
qs = SFn / (2 * rF)
Stress correction factor for gears with notches in fillets YSg
YSg = 1.3 * YS / (1.3 - 0.6 * (tg / rg)0.5) ... [ (tg / rg)0.5 < 2.0 ]
Helix angle factor Yb

Yb = 1 - eb * b / 120 ... [if b > 30; b = 30]
Rim thickness factor YB
external gears
YB = 1.0 ... [sR / ht >= 1.2]
YB = 1.15 * ln(8.324 * mn / sR) ... [0.5 < sR / ht < 1.2]
internal gears
YB = 1.0 ... [sR / mn >= 3.5]
YB = 1.6 * ln(2.242 * ht / sR) ... [1.75 < sR / mn < 3.5]
Deep tooth factor YDT
YDT = 1.0 ... [ean <= 2.05] or [accuracy grade > 4]
YDT = -0.666 * ean + 2.366 ... [2.05 < ean <= 2.5] and [accuracy grade <= 4]
YDT = 0.7 ... [ean > 2.5] and [accuracy grade <= 4]
Life factor YNT
X axis ... number of cycles

Y axis ... YNT
Relative notch sensitivity factor YdrelT for reference stress
YdrelT = Yd / YdT = (1 + (r' * c*)0.5) / (1 + (r' * cT*)0.5)
c* = cP* * (1 + 2 * qs)
cP* = 1 / 5 = 0.2
cT* = cP* * (1 + 2 * 2.5)
Material: GG [σB=150MPa], GG, GGG(ferr.)[σB=300MPa]
r' = 0.31
Material: NT, NV
r' = 0.1005
Material: St, V, GTS, GGG(perl.), GGG(bai.)
r' = MAX(MIN(13100 / Rp0.2(2.1) - (MAX(600;Rp0.2)-600)(0.35) / 1600;0.32);0.0014)
Material: Eh, IF(root)
r' = 0.003
Relative notch sensitivity factor YdrelT for static stress
Material: St, V, GGG(perl.), GGG(bai.)
YdrelT = (1 + 0.82 * (YS - 1) * (300 / σ0.2)(1/4)) / (1 + 0.82 * (300 / σ0.2)(1/4))
Material: Eh, IF, IF(root)
YdrelT = 0.44 * YS + 0.12
Material: NT, NV
YdrelT = 0.20 * YS + 0.60
Material: GTS
YdrelT = 0.075 * YS + 0.85
Material: GG, GGG(ferr.)

YdrelT = 1.0
Relative surface factor YRrelT for reference stress
Rz < 1 mm
Material: V, GGG(perl.), GGG(bai.), Eh, IF
YRrelT = 1.12
Material: St
YRrelT = 1.07
Material: GG, GGG(ferr.), NT, NV
YRrelT = 1.025
1mm < Rz < 40 mm
Material: V, GGG(perl.), GGG(bai.), Eh, IF
YRrelT = 1.674 - 0.529 * (Rz + 1)0.1
Material: St
YRrelT = 5.306 - 4.203 * (Rz + 1)0.01
Material: GG, GGG(ferr.), NT, NV
YRrelT = 4.299 - 3.256 * (Rz + 1)0.0058
Relative surface factor YRrelT for static stress
YRrelT = 1.0
Size factor YX
YX = 1.0 ... All materials for static stress
YX ... Material: St, St(cast), V, V(cast), GGG(perl.), GGG(bai.), GTS(perl.)
YX = 1.0 ... [ mn <= 5 ]
YX = 1.03 - 0.006 * mn ... [ 5 < mn < 30 ]
YX = 0.85 ... [ mn >= 30 ]
YX ... Material: Eh, IF(root), NT, NV, NT(nitr.), NV(nitr.), NV(nitrocar.)
YX = 1.0 ... [ mn <= 5 ]
YX = 1.05 - 0.01 * mn ... [ 5 < mn < 25 ]
YX = 0.80 ... [ mn >= 25 ]
YX ... Material: GG, GGG(ferr.)
YX = 1.0 ... [ mn <= 5 ]
YX = 1.075 - 0.015 * mn ... [ 5 < mn < 25 ]
YX = 0.70 ... [ mn >= 25 ]
ISO 6336-5 Strength and quality of materials.
This part of ISO 6336 describes contact and tooth-root stresses, and gives numerical values for both limit stress numbers. It
specifies requirements for material quality and heat treatment and comments on their influences on both limit stress numbers.
The allowable stress numbers, σH lim, and the nominal stress numbers, σF lim, can be calculated by the following equation:
a) σHlim = A * x + B
b) σFlim = A * x + B
where x is the surface hardness HBW or HV and A, B are constants
Requirements for material quality and heat treatment
The three material quality grades ML, MQ and ME, stand in relationship to
- ML stands for modest demands on the material quality and on the material heat treatment process during gear manufacture.
- MQ stands for requirements that can be met by experienced manufacturers at moderate cost.
- ME represents requirements that must be realized when a high degree of operating reliability is required
In this calculation, except σHlim and σFlim, are proposed other material parameters that are necessary for calculating the
gearing. The values of Ro, E and Poisson constant are commonly available. For the proposal of the tensile strength Rm and yield
strength Rp0.2 was used information from the ISO 1265 and specialized literature. Parameters for the time-strength curves were
obtained from ISO6336-2 and 3. These curves can be seen in a small graph in the calculation.
All calculated values are design and based on empirical experience. The exact values for a concrete material you can obtain from
your manufacturer or from material tests.
Hardness notice
Values HB for HB<=450 steel ball, HB>450 carbide ball
Values HB used recalculation HB=HV-HV/20
Values HRC used recalculation HRC=(100*HV-14500)/(HV+223)
6. Allowable stress and safety for Involute Spur and Helical Gear Teeth
ANSI/AGMA 2001-D04
Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth ANSI/AGMA
2001-D04
dynamic factor, Kv
Kv = (C / (C + vt))−B
C = 50 + 56 * (1.0 − B) ... [ 6 ≤ Av ≤ 12 ]
B = 0.25 * (Av − 5.0)0.667
vt max = [C + (14 − Av)]2
Overload factor, Ko
The empirical guidance values from table B.1 ISO 6336-6 are used.
Elastic coefficient, Cp
Cp = (1 / p * (((1 - mP2) / EP) + ((1 - mG2) / EG)))0.5 ... [lb/in2]0.5
mP and mG is Poisson’s ratio for pinion and gear, respectively; EP and EG is modulus of elasticity for pinion and gear [lb/in2].
Surface condition factor, Cf
Cf = 1.0
Hardness ratio factor, CH
Through hardened gears
CH = 1.0 + A * (mG - 1.0)
A = 0.00898 *(HBP / HBG) - 0.00829
HBP is pinion Brinell hardness number [HB]; HBG is gear Brinell hardness number,[HB].
This equation is valid for the range 1.2 ≤ HBP / HBG ≤ 1.7 For HBP / HBG < 1.2, A = 0.0 HBP / HBG > 1.7, A = 0.00698
Surface hardened/through hardened values
CH = 1.0 + B * (450 - HBG)
B = 0.00075 * (2.71828)-0.0112 * (fp)
fp is surface finish of pinion, microinches, Ra
if fp>64 ... CH = 1.0
Load distribution factor, Km
Km = f (Cmf, Cmt)
Km = Cmf
Face load distribution factor, Cmf
Cmf = 1.0 + Cmc * (Cpf * Cpm + Cma * Ce)
Cmc is 1.0 for gear with unmodified leads; Cmc is 0.8 for gear with leads properly modified by crowning or lead correction.
Cpf = F / (10 * d) − 0.025 ... [F<=1.0]
Cpf = F / (10 * d) − 0.0375 + 0.0125 * F ... [1.0<F<=17.0]
Cpf = F / (10 * d) − 0.1109 + 0.0207 * F − 0.000228 * F2 ... [17.0<F<=40.0]
Cpm = 1.0 ... [S1 / S < 0.175]
Cpm = 1.1 ... [S1 / S >= 0.175]
Cma = A + B * F + C * F2
A B C
1…Open gearing 0.247 0.0167 -0.0000765
2…Commercial enclosed gearboxes 0.127 0.0158 -0.0001093
3…Precision enclosed gearbox 0.0675 0.0128 -0.0000926

4…Extra precision enclosed gearbox 0.038 0.0102 -0.0000822
Ce = 0.8 ... [gearing is adjusted at assembly; gearing is improved by lapping]
Ce = 1.0 ... [for all other conditions]
Reliability factor, KR
KR = 1.50 [Fewer than one failure in 10 000]
KR = 1.25 [Fewer than one failure in 1000]
Rim thickness factor, KB
KB = 1.6 * ln(2.242 / mB) ... [for mB<1.2]
KB = 1.0 ... [for mB>=1.2]
mB = tR / ht
tR is gear rimthickness below the tooth root [in]; ht is gear tooth whole depth [in]
Pitting resistance
The contact stress number formula for gear teeth is:
sc = Cp (Wt * Ko * Kv * Ks * Km * Cf / (d * F * I))0.5
Allowable contact stress number
The relation of calculated contact stress number to allowable contact stress number is:
sc ≤ (sac * ZN * CH) / (KT * SH * KR)
Pitting resistance power rating
The pitting resistance power rating is:
Pac = (p * np * F / 396 000) * I / (Ko * Kv * Ks * Km * Cf) * ((d * sac * ZN CH) / (Cp * SH * KT * KR))2
Safety coefficient for surface durability
SH = sac / sc * (ZN * CH) / (KT * KR)
Bending strength
The fundamental formula for bending stress number in a gear tooth is:
st = Wt * Ko * Kv * Ks * (Pd * Km * KB / (F * J))
Allowable bending stress number
The relation of calculated bending stress number to allowable bending stress number is:
st ≤ (sat * YN) / (SF * KT * KR)
Bending strength power rating
The bending strength power rating is:
Pat = (p * np * F / 396 000) * (F * J) / (Ko * Kv * Pd * Ks * Km * KB) * (sat * YN) / (SF * KT * KR)
Safety coefficient for bending strength
SF = sat / st * YN / (KT * KR)
Transmitted tangential load
Wt = 33000 * P / vt = 2 * T / d = 396000 * P / (p * np * d)
P is transmitted power [hp]; T is transmitted pinion torque [lb*in]; vt is pitch line velocity at operating pitch diameter, [ft/min]
vt = p * np * d / 12
Allowable stress numbers, sac and sat ANSI / AGMA 2001-D04
This part of ANSI / AGMA 2001-D04 describes the allowable stress numbers sac and sat, for pitting resistance and bending
strength.
Allowable stress numbers in this standard are determined or estimated from laboratory tests and accumulated field experiences.
They
are based on unity overload factor, 10 million stress cycles, unidirectional loading and 99 percent reliability. For service life other
than 10
million cycles, the allowable stress numbers are adjusted by the use of stress cycle factors YN and ZN
The allowable stress numbers sac and sat can be calculated by the following equation:
a) sac = A * x + B
b) sat = A * x + B
where x is the surface hardness HBW and A, B are constants
Requirements for material quality and heat treatment.
These requirements are specified in this standard and are divided in three material quality grades 1,2 an 3.
In this calculation, except sac and sat, are proposed other material parameters that are necessary for calculating the gearing.
The values of p, E and Poisson constant are commonly available. For the proposal of the tensile strength Rm and yield strength
Rp0.2 was used information from the ISO 1265 and specialized literature. All calculated values are design and based on
empirical experience. The exact values for a concrete material you can obtain from your manufacturer or from material tests.
Hardness notice
Values HB for HB<=450 steel ball, HB>450 carbide ball
Values HB used recalculation HB=HV-HV/20
Values HRC used recalculation HRC=(100*HV-14500)/(HV+223)

Spur Gearing Calculation

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Spur Gearing Calculation

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1/19/2021 Spur gearing

Involute gearing - theory

Principle of corrections, use of corrections.

Correction (addendum modification) of toothing enables:

2. Moment, power, forces, efficiency

Moment, power, forces in gearing

Power (Spur gear - Rack)

zz1/z2 - loss coefficient planet - ring gear

z = ir • zr / (ir - 1) Sun => Planet (carrier)

Simple planetary gearing (differential):

Low radial loading of centre member bearings

4. Spur gear - Rack

For Ns < N < 1.15 (Main resonance range)

1.0 < eg <=2.0 eg > 2.0

CV3 0.23 0.096 / (eg - 1.56)

CV4 0.90 (0.57 - 0.05 * eg ) / (eg - 1.44)

CV7 1.0 < eg <=1.5 0.75

CV7 1.5 < eg <=2.5 0.125 * sin(p * (eg - 1.74)) + 0.875

CV7 eg > 2.5 1.0

Cay1,2 1 / 18 * (sHlim1,2 / 97 - 18.45)2 + 1.5

Internal dynamic factor KV(C)

Method (C2006) is different from (C1996) by adding the coefficient K3.

Main resonance of a gear pair NE1

cga = c' * (0.75 * ea + 0.25)

zn1,2 = z1,2 / cos(b)3

K' with stiffening without stiffening

ya ... Material: GG, GGG(ferr.)

ya ... Material: Eh, IF, NT(nitr.), NV(nitr.), NV(nitrocar.)

ISO 6336-2:2006 Part 2: Calculation of surface durability (pitting)

Permissible contact stress σHP: Method B

Spur gears with, ea > 1.0

Helical gears with, eb >= 1.0

Helical gears with, eb < 1.0

(For internal gears, ZD shall be taken as equal to 1.0)

Contact ratio factor Ze

Helix angle factor, Zb

Life factor ZNT

X axis ... number of cycles

Diagram viscosity / temperature for viscosity index VI = 50

Permissible bending stress σFP : Method B

Dimensions and basic rack profile of the teeth (finished profile)

T= p / 3 ... external gears

Tooth root normal chord sFn

Radius of root fillet rF

Helix angle factor Yb

Life factor YNT

X axis ... number of cycles

Material: GG, GGG(ferr.)

3…Precision enclosed gearbox 0.0675 0.0128 -0.0000926

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