Cylindrical gear pair, spur

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KISSsoft Release 2022 -SP5

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Contents

1 Messages 3
2 Load spectrum 3
3 Results 3
4 Overview 4
5 Tooth geometry 4
6 Materials 4
6.1 Roughnesses 5
6.2 Lubrication 5
7 Geometry 5
7.1 Reference profiles 5
7.2 Basic data 6
7.3 Diameters and their allowances 6
7.4 Tip clearances and tooth heights 7
7.5 Roll angle 7
7.6 Tooth thickness and pitch 7
7.7 Sliding 7
7.8 Contact ratios 8
8 General influence factors 8
8.1 Forces and circumferential speed 8
8.2 Contact stiffness 9
8.3 Calculation of K factors 9
8.4 K factors 9
9 Calculation of tooth root strength (fracture) 9
9.1 Safety factors 10
10 Calculation of flank strength (pitting) 10
10.1 Safety factors 11
11 Micropitting 11
12 Scuffing load capacity 11
12.1 Flash temperature-criteria 11
12.2 Integral temperature-criteria 12
13 Measurements for tooth thickness 12
13.1 Tooth thickness tolerances 12
13.2 Base tangent lengths 12
13.3 Measurement over balls and pins 12
13.4 Tooth thickness 12
13.5 Backlash 13
14 Toothing tolerances 13
15 Modifications and determination of the tooth form 13
15.1 Profile and tooth trace modifications 14
15.2 Data for the tooth form calculation 14
16 Supplementary data 14
16.1 Masses, stiffnesses and moments of inertia 14
16.2 Wear, power loss, sound pressure level 14
17 Service life, damage, load distribution 14
17.1 Damage 15
17.2 Equivalent load 15
17.3 F.E.M. Classification 16
17.4 Load distribution 16
18 Remarks 16
18.1 Conventions 16
18.2 Calculations and factors 16

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1 Messages

Calculation of scuffing:
The entered gear pair data is outside the boundary of the calculation method!

The application of ISO/TS 6336-21 has following limitations:

1.0 m/s <= v(=0.1 m/s) <= 50.0 m/s

2 Load spectrum

Own input
Number of bins in the load spectrum: 2
Reference gear: Gear 1
Application factor KA = 1.00

Load Frequency Power Speed Torque Factors

bin
No % kW 1/min Nm Kv KHβ KFβ KHα Kγ YM1 YM2
1 97.0000 3.3510 16.0 2000.0000 1.002 1.741 1.512 1.000 1.000 1.000 1.000
2 3.0000 4.0212 16.0 2400.0000 1.001 1.617 1.431 1.000 1.000 1.000 1.000

Numbers of load cycles

Load Frequency Load cycle Load cycle
bin Gear 1 Gear 2
No %
1 97.00000 18624000 4718080
2 3.00000 576000 145920
SUM 100.00000 19200000 4864000

The number of load cycles applies for the tooth root load

Consider load bins with 0% frequency: Yes

S-N curve (Woehler line) in the long life domain according: according to standard

Note:
Calculation with methods ISO 6336 and AGMA 2001 results in a reduction of resistance in the domain of fatigue resistance (from circa 107 to
1010 cycles). The lifetime calculation takes this into account (also with the S-N curve (Woehler Curve) of the Mine

3 Results

Safeties, calculated with load spectrum:

------- Gear 1 ----------------- Gear 2 -------
Root safety [SF] 6.150 4.527
Flank safety [SH] 1.585 1.026

Safeties against scuffing/micropitting/EHT/TFF are indicated for the most critical element of the load spectrum:
Safety against scuffing (integral temperature) [SintS] 4.716
Safety against scuffing (flash temperature) [SB] 21.673

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Analysis of critical elements in load spectrum: See Service life, Damage

Calculation with reference power

This section is for information purposes only. All strength values relate to the reference power, with no influence from the load
spectrum.

4 Overview

Calculation method ISO 6336:2019

Drawing or article number:

Gear 1: 0.000.0
Gear 2: 0.000.0
------- Gear 1 ----------------- Gear 2 -------
Power (kW) [P] 4.021
Speed (1/min) [n] 16.0 4.1

Torque (Nm) [T] 2400.0 9473.7

Application factor [KA] 1.00
Required service life (h) [H] 20000.00

Gear driving (+) / driven (-) + -

Working flank Gear 1: Right flank
Gear 1 direction of rotation: Clockwise

5 Tooth geometry

Geometry calculation according to ISO 21771:2007

------- Gear 1 ----------------- Gear 2 -------

Center distance (mm) [a] 430.000
Center distance tolerance ISO 286:2010 Measure js7
Normal module (mm) [mn] 9.0000
Normal pressure angle (°) [αn] 20.0000
Helix angle at reference circle (°) [β] 0.0000
Number of teeth [z] 19 75
Facewidth (mm) [b] 80.00 75.00
Hand of gear Spur gear
Accuracy grade [Q-DIN 3961:1978] 7 7
Inner diameter (mm) [di] 50.00 50.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

6 Materials

Gear 1
18CrNiMo7-6, Case hardening steel, case-hardened, ISO 6336-5 Figure 9/10 (MQ), Core hardness >=30HRC

Gear 2
42 CrMo 4 (3), Through hardened steel, nitrided, ISO 6336-5 Figure 13b/14b (MQ)

------- Gear 1 ----------------- Gear 2 -------

Surface hardness HRC 61 HV 550
Material treatment according to ISO 6336:2006 Normal, Life factors ZNT and YNT ≥ 0.85
Infinite life strength for tooth root stress (N/mm²) [σFlim] 500.00 370.00

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Fatigue strength for Hertzian pressure (N/mm²) [σHlim] 1500.00 1000.00
Young's modulus (N/mm²) [E] 206000 206000
Poisson's ratio [ν] 0.300 0.300
Tensile strength (N/mm²) [σB] 1200.00 1100.00
Yield point (N/mm²) [σS] 850.00 900.00

6.1 Roughnesses

------- Gear 1 ----------------- Gear 2 -------

Roughness average value DS, flank (µm) [RAH] 0.60 3.00
Roughness average value DS, root (µm) [RAF] 3.00 3.00
Mean roughness height, Rz, flank (µm) [RZH] 4.80 20.00
Mean roughness height, Rz, root (µm) [RZF] 20.00 20.00

6.2 Lubrication

Lubrication type Oil bath lubrication

Type of oil ISO-VG 320
Lubricant base Mineral-oil base
Oil nominal kinematic viscosity at 40°C (mm²/s) [ν40] 320.00
Oil nominal kinematic viscosity at 100°C (mm²/s) [ν100] 22.00
Specific density at 15°C (kg/dm³) [ρ] 0.900
Oil temperature (°C) [TS] 70.000

7 Geometry

7.1 Reference profiles

Reference profile Gear 1

Reference profile 1.25 / 0.38 / 1.0 ISO 53:1998 Profil A
Dedendum coefficient [hfP*] 1.250
Root radius factor [ρfP*] 0.380
[ρfPmax*] 0.472
Addendum coefficient [haP*] 1.000
Tip radius factor [ρaP*] 0.000
Protuberance height coefficient [hprP*] 0.000
Protuberance angle [αprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [αKP] 0.000
not topping
Smallest radius of curvature, root rounding (mm) [ρmin.e/i] 3.774 / 3.783

Reference profile Gear 2

Reference profile 1.25 / 0.38 / 1.0 ISO 53:1998 Profil A
Dedendum coefficient [hfP*] 1.250
Root radius factor [ρfP*] 0.380
[ρfPmax*] 0.472
Addendum coefficient [haP*] 1.000
Tip radius factor [ρaP*] 0.000
Protuberance height coefficient [hprP*] 0.000
Protuberance angle [αprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [αKP] 0.000
not topping
Smallest radius of curvature, root rounding (mm) [ρmin.e/i] 3.445 / 3.447

7.1.1 Information on final machining

------- Gear 1 ----------------- Gear 2 -------

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Dedendum reference profile [hfP*] 1.250 1.250
Tooth root radius reference profile [ρfP*] 0.380 0.380
Addendum reference profile [haP*] 1.000 1.000
Protuberance height coefficient [hprP*] 0.000 0.000
Protuberance angle (°) [αprP] 0.000 0.000
Tip form height coefficient [hFaP*] 0.000 0.000
Ramp angle (°) [αKP] 0.000 0.000

Type of profile modification: for high load capacity gearboxes

Tip relief (µm) [Ca L/R] 36.0 / 36.0 36.0 / 36.0

7.2 Basic data

Overall transmission ratio [itot] -3.947

Gear ratio [u] 3.947
Transverse module (mm) [mt] 9.000
Transverse pressure angle (°) [αt] 20.000
Working pressure angle (°) [αwt] 22.423
(°) [αwt.e/i] 22.433 /22.412
Working pressure angle at normal section (°) [αwn] 22.423
Base helix angle (°) [βb] 0.000
Helix angle at operating pitch circle (°) [βw] 0.000
Reference center distance (mm) [ad] 423.000
Sum of profile shift coefficients [Σxi] 0.8238

------- Gear 1 ----------------- Gear 2 -------

Profile shift coefficient [x] 0.2528 0.5710
Generating profile shift coefficient [xE.e/i] 0.2383/ 0.2307 0.5443/ 0.5320
Virtual gear no. of teeth [zn] 19.000 75.000
Involute length (mm) [l_dFa-l_dFf] 17.043 18.810

7.2.1 Tip chamfer or tip rounding

------- Gear 1 ----------------- Gear 2 -------
Tip chamfer (mm) [hK] 0.000 0.000
Tooth tip chamfer angle (°) [δhK] 45.000 45.000

7.3 Diameters and their allowances

------- Gear 1 ----------------- Gear 2 -------

Reference diameter (mm) [d] 171.000 675.000
Base diameter (mm) [db] 160.687 634.293
Tip alteration (mm) [k*mn] -0.414 -0.414

Tip diameter (mm) [da] 192.723 702.449

(mm) [da.e/i] 192.723 /192.677 702.449 /702.369

Tip diameter allowances (mm) [Ada.e/i] 0.000 / -0.046 0.000 / -0.080

Tip form diameter (mm) [dFa] 192.723 702.449

(mm) [dFa.e/i] 192.723 /192.677 702.449 /702.369

Active tip diameter (mm) [dNa] 192.723 702.449

(mm) [dNa.e/i] 192.723 /192.677 702.449 /702.369

Operating pitch diameter (mm) [dw] 173.830 686.170

(mm) [dw.e/i] 173.843 /173.817 686.220 /686.120

Root diameter (mm) [df] 153.051 662.777

Generated root diameter with xE (mm) [df.e/i] 152.790 /152.652 662.297 /662.077

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Active root diameter (mm) [dNf] 162.808 671.899
(mm) [dNf.e/i] 162.865 /162.782 671.981 /671.844

Root form diameter (mm) [dFf] 161.826 667.615

(mm) [dFf.e/i] 161.738 /161.692 667.178 /666.979

7.4 Tip clearances and tooth heights

------- Gear 1 ----------------- Gear 2 -------

Theoretical tip clearance (mm) [c] 2.250 2.250
Effective tip clearance (mm) [c.e/i] 2.655 / 2.459 2.521 / 2.349

Reserve (dNf-dFf)/2 (mm) [cF.e/i] 0.586 / 0.522 2.501 / 2.333

Addendum, mn(haP*+x+k) (mm) [ha] 10.861 13.725

(mm) [ha.e/i] 10.861 /10.838 13.725 /13.685

Dedendum, mn(hfP*-x) (mm) [hf] 8.975 6.111

(mm) [hf.e/i] 9.105 / 9.174 6.352 / 6.462

Tooth height (mm) [h] 19.836 19.836

7.5 Roll angle

------- Gear 1 ----------------- Gear 2 -------

Roll angle at dFa (°) [ξFa.e/i] 37.940 /37.910 27.265 /27.249
Roll angle to dNf (°) [ξNf.e/i] 9.465 / 9.281 20.043 /20.005
Roll angle at dFf (°) [ξFf.e/i] 6.561 / 6.418 18.688 /18.629

7.6 Tooth thickness and pitch

------- Gear 1 ----------------- Gear 2 -------

Tooth thickness, arc, in module [sn*] 1.7548 1.9864
Normal tooth thickness at tip circle (mm) [san] 5.777 6.798
(mm) [san.e/i] 5.699 / 5.614 6.653 / 6.533

Normal tooth thickness at tip form circle (mm) [sFan] 5.777 6.798
(mm) [sFan.e/i] 5.699 / 5.614 6.653 / 6.533

Normal space width at root circle (mm) [efn] 0.000 6.160

(mm) [efn.e/i] 0.000 / 0.000 6.182 / 6.193

Pitch on reference circle (mm) [pt] 28.274 28.274

Base pitch (mm) [pbt] 26.569 26.569
Transverse pitch on contact-path (mm) [pet] 26.569 26.569

7.7 Sliding

------- Gear 1 ----------------- Gear 2 -------

Max. sliding velocity at tip (m/s) [vga] 0.042 0.042
Specific sliding at the tip [ζa] 0.472 0.657
Specific sliding at the root [ζf] -1.919 -0.895
Mean specific sliding [ζm] 0.565

Sliding factor on tip [Kga] 0.289 0.289

Sliding factor on root [Kgf] -0.289 -0.289

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7.8 Contact ratios

------------------ Pair ----------------------

Minimal length of contact line (mm) [Lmin] 75.000
Transverse contact ratio [εα] 1.509
[εα.e/m/i] 1.513 / 1.507/ 1.501
Overlap ratio [εβ] 0.000
Total contact ratio [εγ] 1.509
[εγ.e/m/i] 1.513 / 1.507/ 1.501
Length of path of contact (mm) [ga] 40.105
(mm) [ga.e/i] 40.187 /39.887

------- Gear 1 ----------------- Gear 2 -------

Addendum contact ratio [ε] 0.755 0.755
[ε.e/i] 0.755 / 0.752 0.757 / 0.749

Length T1-A and T2-A (mm) [T1A,T2A] 13.097 150.921

(mm) [.e/i] 13.014 / 13.273 150.921 /150.827
Length T1-B and T2-B (mm) [T1B,T2B] 26.632 137.385
(mm) [.e/i] 26.632 / 26.591 137.303 /137.509
Length T1-C and T2-C (mm) [T1C,T2C] 33.152 130.865
(mm) [.e/i] 33.136 / 33.169 130.799 /130.931
Length T1-D and T2-D (mm) [T1D,T2D] 39.666 124.351
(mm) [.e/i] 39.583 / 39.842 124.351 /124.258
Length T1-E and T2-E (mm) [T1E,T2E] 53.201 110.816
(mm) [.e/i] 53.201 / 53.160 110.733 /110.940
Length T1-T2 (mm) [T1T2] 164.017
(mm) [.e/i] 163.935 /164.100

Diameter of single contact point B (mm) [d-B] 169.285 691.249

(mm) [d-B.e/i] 169.285 /169.259 691.184 /691.348
Diameter of single contact point D (mm) [d-D] 179.204 681.308
(mm) [d-D.e/i] 179.131 /179.360 681.308 /681.240

8 General influence factors

8.1 Forces and circumferential speed

------- Gear 1 ----------------- Gear 2 -------

Nominal circum. force at pitch circle (N) [Ft] 28070.2
Axial force (N) [Fa] 0.0 0.0
Radial force (N) [Fr] 10216.7 10216.7
Normal force (N) [Fnorm] 29871.7 29871.7
Nominal circumferential force per mm (N/mm) [w] 374.27

Only as information: Forces at operating pitch circle:

Nominal circumferential force (N) [Ftw] 27613.2
Axial force (N) [Faw] 0.0 0.0
Radial force (N) [Frw] 11394.1

Circumferential speed reference circle (m/s) [v] 0.14

Circumferential speed operating pitch circle (m/s) [v(dw)] 0.15

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8.2 Contact stiffness

Running-in value (µm) [yp] 1.3

Running-in value (µm) [yf] 1.4
Tolerances fpe, ff and fHβ, matching the tolerances in section 7
Correction factor [CM] 0.800
Gear blank factor [CR] 1.000
Basic rack factor [CBS] 0.975
Material coefficient [E/Est] 1.000
Single stiffness (N/mm/µm) [c'] 14.529
Meshing stiffness (N/mm/µm) [cγα] 20.080
Meshing stiffness (N/mm/µm) [cγβ] 17.068
Reduced mass (kg/mm) [mRed] 0.09932
Resonance speed (min-1) [nE1] 7146
Resonance ratio (-) [N] 0.002
Subcritical range

8.3 Calculation of K factors

Running-in value (µm) [yα] 0.7

8.3.1 KHb calculated as specified in ISO 6336-1:2006, Annex E

Load distribution and deformation calculated with Kγ*KA*Tnom.
------- Gear 1 ----------------- Gear 2 -------
Torque, 0: -, 1: < I, 2: < II, 3: < from shaft calculation 0 0

Axis alignment (µm) [fΣβ / fΣδ] 0.0 / 0.0

Deviation error of axis error (µm) [fpar] 12.30

Toothing tolerance (µm) [ΣfHβ] 16.50
KHβ is determined as the greatest value from the following 5 variants:
1) 0/0 2) -fpar/-ΣfHβ 3) -fpar/+ΣfHβ 4) +fpar/-ΣfHβ 5) +fpar/+ΣfHβ

For interim results, refer to file: KHbeta_calc12.tmp

8.4 K factors

Dynamic factor [Kv] 1.001

Face load factors

- Flank [KHβ] 1.617
- Tooth root [KFβ] 1.431
- Scuffing [KBβ] 1.617

Transverse load factors

- Flank [KHα] 1.000
- Tooth root [KFα] 1.000
- Scuffing [KBα] 1.000

Application factor [KA] 1.000

Mesh load factor [Kγ] 1.000

9 Calculation of tooth root strength (fracture)

Calculation of Tooth form coefficients according method: B

------- Gear 1 ----------------- Gear 2 -------
Calculated with generating profile shift coefficient [xE.i] 0.2307 0.5320
Tooth form factor [YF] 1.46 1.30

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Stress correction factor [YS] 1.98 2.27
Load application angle (°) [αFen] 22.19 22.47
Load distribution influence factor [fε] 1.000
Load application diameter (mm) [den] 179.204 691.249
Bending moment arm (mm) [hF] 9.44 10.69
Tooth thickness at root (mm) [sFn] 18.54 20.86
Tooth root radius (mm) [ρF] 4.48 3.58
Bending moment arm (-) [hF/mn] 1.049 1.188
Tooth thickness at root (-) [sFn/mn] 2.060 2.318
Tooth root radius (-) [ρF/mn] 0.497 0.398
Calculation cross section diameter (mm) [dsFn] 155.768 665.353
Tangents on calculation cross section (°) [αsFn] 30.000 30.000
Notch parameter [qs] 2.071 2.911

Helix angle factor [Yβ] 1.000

Deep tooth factor [YDT] 1.000
Gear rim factor [YB] 1.00 1.00
Effective facewidth (mm) [beff] 80.00 75.00
Nominal stress at tooth root (N/mm²) [σF0] 112.55 123.34
Tooth root stress (N/mm²) [σF] 161.34 176.82

Permissible bending stress at root of Test-gear

Notch sensitivity factor [YdrelT] 0.996 1.017
Surface factor [YRrelT] 0.957 0.990
Size factor, tooth root [YX] 0.960 0.960
Life factor [YNT] 0.963 0.990
YdrelT*YRrelT*YX*YNT 0.881 0.957
Alternating bending factor, mean stress influence coefficient
[YM] 1.000 1.000
Stress correction factor [YST] 2.00
YST*σFlim (N/mm²) [σFE] 1000.00 740.00
Permissible tooth root stress σFG/SFmin (N/mm²) [σFP] 629.44 506.01
Limit strength tooth root (N/mm²) [σFG] 881.22 708.42

9.1 Safety factors

------- Gear 1 ----------------- Gear 2 -------

Required safety [SFmin] 1.40 1.40

10 Calculation of flank strength (pitting)

------- Gear 1 ----------------- Gear 2 -------

Zone factor [ZH] 2.343
Elasticity factor (√N/mm²) [ZE] 189.812
Contact ratio factor [Zε] 0.911
Helix angle factor [Zβ] 1.000
Effective facewidth (mm) [beff] 75.00
Nominal contact stress (N/mm²) [σH0] 671.10
Contact stress at operating pitch circle (N/mm²) [σHw] 854.03
Single tooth contact factor [ZB,ZD] 1.09 1.00
Contact stress (N/mm²) [σHB, σHD] 929.97 854.03

Lubricant coefficient for NL [ZL] 1.060 1.071

Speed factor at NL [ZV] 0.914 0.900
Roughness factor for NL [ZR] 0.895 0.877
Material hardening factor for NL [ZW] 1.000 1.000
Life factor [ZNT] 1.075 0.983
[ZL*ZV*ZR*ZNT] 0.933 0.831

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Limited pitting is permissible: No
Size factor (flank) [ZX] 1.000 1.000

Permissible contact stress, σHG/SHmin (N/mm²) [σHP] 1398.93 831.12

Pitting stress limit (N/mm²) [σHG] 1398.93 831.12

10.1 Safety factors

------- Gear 1 ----------------- Gear 2 -------

Required safety [SHmin] 1.00 1.00

11 Micropitting

Calculation method according to ISO/TS 6336-22:2018

Calculation has not been carried out, lubricant: Load stage micropitting test not known

12 Scuffing load capacity

Calculation method according to ISO/TS 6336-20/21:2017

------- Gear 1 ----------------- Gear 2 -------

Thermal contact coefficient (N/mm/s^.5/K) [BM] 13.780 13.780
Relevant tip relief (µm) [Ca] 36.00 36.00
Optimal tip relief (µm) [Ceff] 25.76
Ca taken as optimal in the calculation. 0=no, 1=yes 1 1

------------------ Pair ----------------------

Helical load factor for scuffing [KBγ] 1.000
Lubrication coefficient for lubrication type [XS] 1.000
Scuffing test and load stage [FZGtest] FZG - Test A / 8.3 / 90 (ISO 14635 - 1) 12
Multiple meshing factor [Xmp] 1.000
Relative structural factor, scuffing [XWrelT] 1.000
Effective facewidth (mm) [beff] 75.000
Applicable circumferential force/facewidth (N/mm) [wBt] 606.120
KBγ = 1.000, wBt*KBγ = 606.120
Angle factor [Xαβ] 1.013
ε1 =0.755, ε2 =0.755

12.1 Flash temperature-criteria

------------------ Pair ----------------------

Lubricant factor [XL] 0.818
Tooth mass temperature (°C) [θMi] 72.87
θMi = θoil + XS*0.47*Xmp*θflm
Average flash temperature (°C) [θflm] 6.11
Scuffing temperature (°C) [θS] 344.89
Γ coordinates (point of highest temperature) [Γ] -0.361
[Γ.A]= -0.605, [Γ.E]= 0.605
Maximum contact temperature (°C) [θB] 82.68
Flash factor (°K*N^-.75*s^.5*m^-.5*mm) [XM] 50.058
Approach factor [XJ] 1.000
Load sharing factor [XΓ] 0.599
Dynamic viscosity (mPa*s) [ηM] 56.16 (70.0 °C)
Coefficient of friction [μm] 0.146

11/16
12.2 Integral temperature-criteria

------------------ Pair ----------------------

Lubricant factor [XL] 1.000
Tooth mass temperature (°C) [θMC] 71.99
θMC = θoil + XS*0.70*θflaint
Integral scuffing temperature (°C) [θSint] 359.60
Flash factor (°K*N^-.75*s^.5*m^-.5*mm) [XM] 50.058
Running-in factor, well run in [XE] 1.000
Contact ratio factor [Xε] 0.283
Dynamic viscosity (mPa*s) [ηOil] 56.16 (70.0 °C)
Mean coefficient of friction [μm] 0.120
Geometry factor [XBE] 0.258
Meshing factor [XQ] 1.000
Tip relief factor [XCa] 1.586
Mean flash temperature (°C) [θflaint] 2.84
Integral tooth flank temperature (°C) [θint] 76.26

13 Measurements for tooth thickness

13.1 Tooth thickness tolerances

------- Gear 1 ----------------- Gear 2 -------

Tooth thickness tolerance DIN 3967 cd25 DIN 3967 cd25
Tooth thickness allowance (normal section) (mm) [As.e/i] -0.095 / -0.145 -0.175 / -0.255

13.2 Base tangent lengths

------- Gear 1 ----------------- Gear 2 -------

Number of teeth spanned [k] 3.000 10.000
Base tangent length (no backlash) (mm) [Wk] 70.374 265.376
Base tangent length with allowance (mm) [Wk.e/i] 70.285 /70.238 265.212 /265.136
(mm) [ΔWk.e/i] -0.089 / -0.136 -0.164 / -0.240
Diameter of measuring circle (mm) [dMWk.m] 175.377 687.491

13.3 Measurement over balls and pins

------- Gear 1 ----------------- Gear 2 -------

Theoretical diameter of ball/pin (mm) [DM] 16.679 15.871
Effective diameter of ball/pin (mm) [DMeff] 18.000 16.000
Radial single-ball measurement backlash free (mm) [MrK] 101.803 353.883
Radial single-ball measurement (mm) [MrK.e/i] 101.713 /101.666 353.676 /353.582

Diameter of measuring circle (mm) [dMMr.m] 177.092 685.055

Diametral measurement over two balls, no backlash (mm) [MdK] 202.971 707.614
Diametral measurement over two balls (mm) [MdK.e/i] 202.793 /202.699 707.201 /707.012
Diametral measurement over pins without clearance (mm) [MdR] 202.971 707.614
Measurement over pins according to DIN 3960 (mm) [MdR.e/i] 202.793 /202.699 707.201 /707.012

Measurement over 3 pins without play (mm) [Md3R] 202.339 707.462

Measurement over 3 pins (mm) [Md3R.e/i] 202.162 /202.068 707.049 /706.860

13.4 Tooth thickness

------- Gear 1 ----------------- Gear 2 -------

Reference chordal height from da.m (mm) [ha] 11.214 13.823
Chordal tooth thickness (mm) [sc] 15.771 17.876

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 (mm) [sc.e/i] 15.679 /15.630 17.702 /17.623

Tooth thickness, arc (mm) [sn] 15.793 17.878

(mm) [sn.e/i] 15.698 /15.648 17.703 /17.623

13.5 Backlash

------------------ Pair ----------------------

Circumferential backlash from Aa (mm) [jtw_Aa.e/i] 0.026 / -0.026
Radial backlash (mm) [jrw.e/i] 0.526 / 0.302
Circumferential backlash (transverse section) (mm) [jtw.e/i] 0.433 / 0.248
Normal backlash (mm) [jn.e/i] 0.397 / 0.232

Center distance allowances (mm) [Aa.e/i] 0.032 / -0.032

Backlash free center distance (mm) [aControl.e/i] 429.667 /429.506
Backlash free center distance, allowances (mm) [jta] -0.333 / -0.494

------- Gear 1 ----------------- Gear 2 -------

dNf.i with aControl (mm) [dNf0.i] 162.410 671.045
Reserve (dNf0.i-dFf.e)/2 (mm) [cF0.i] 0.336 1.934
Tip clearance (mm) [c0.i(aControl)] 1.996 1.886

Torsional angle on input with output fixed:

Total torsional angle (°) [j.tSys] 0.2852/ 0.1638

14 Toothing tolerances

------- Gear 1 ----------------- Gear 2 -------

According to DIN 3961:1978
Accuracy grade [Q-DIN3961] 7 7
Profile form deviation (µm) [ff] 19.00 19.00
Profile slope deviation (µm) [fHa] 13.00 13.00
Total profile deviation (µm) [Ff] 23.00 23.00
Helix form deviation (µm) [fbf] 12.00 12.00
Helix slope deviation (µm) [fHb] 14.00 14.00
Total helix deviation (µm) [Fb] 18.00 18.00
Normal base pitch deviation (µm) [fpe] 15.00 17.00
Single pitch deviation (µm) [fp] 15.00 17.00
Adjacent pitch difference (µm) [fu] 19.00 21.00
Total cumulative pitch deviation (µm) [Fp] 52.00 67.00
Sector pitch deviation over z/8 pitches (µm) [Fpz/8] 32.00 42.00
Runout (µm) [Fr] 40.00 50.00
Tooth Thickness Variation (µm) [Rs] 23.00 29.00
Single flank composite, total (µm) [Fi'] 60.00 72.00
Single flank composite, tooth-to-tooth (µm) [fi'] 26.00 28.00
Radial composite, total (µm) [Fi"] 43.00 54.00
Radial composite, tooth-to-tooth (µm) [fi"] 19.00 24.00

Axis alignment tolerances recommendation acc. to ISO TR 10064-3:1996, Quality 7

Maximum value for deviation error of axis (µm) [fΣβ] 27.73 (Fβ=26.00)
Maximum value for inclination error of axes (µm) [fΣδ] 55.47

15 Modifications and determination of the tooth form

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15.1 Profile and tooth trace modifications

Gear 1
Symmetric (both flanks)
- Tip relief, linear
Caa = 36.000 µm LCa = 0.735 *mn dCa = 185.746 mm
Gear 2
Symmetric (both flanks)
- Tip relief, linear
Caa = 36.000 µm LCa = 0.735 *mn dCa = 696.866 mm

15.1.1 Tip relief verification

------- Gear 1 ----------------- Gear 2 -------
Diameter (mm) [dcheck] 192.497 702.189
Tip relief left/right (µm) [Ca L/R] 35.0 / 35.0 34.6 / 34.6

Diameter (mm) [dNa.i] 192.677 702.369

Tip relief left/right (µm) [Ca L/R] 35.9 / 35.9 35.7 / 35.7

15.2 Data for the tooth form calculation

Data not available.

Please run the calculation in the "Tooth form" tab and open the main report again.

16 Supplementary data

16.1 Masses, stiffnesses and moments of inertia

------- Gear 1 ----------------- Gear 2 -------

Mass (kg) [m] 13.475 213.760
Total mass (kg) [mGes] 227.235
Moment of inertia for system, relative to the input:
calculation without consideration of the exact tooth shape
Gears individually ((da+df)/2...di) (kg*m²) [J] 0.05456 12.51727
System (da+df)/2...di (kg*m²) [J] 0.85789

16.2 Wear, power loss, sound pressure level

Torsional stiffness at driving gear with fixed driven gear:

Torsional stiffness (MNm/rad) [cr] 8.129
Torsion when subjected to nominal torque (°) [δcr] 0.017
Average coefficient of friction according to Niemann [μm] 0.075
Wear sliding coef. by Niemann [ζw] 0.853
Loss factor [HV] 0.131
Gear power loss (kW) [PVZ] 0.039
Meshing efficiency (%) [ηz] 99.020
Sound pressure level based on Masuda, without PPTE/δs [dB(A)] 53.541

17 Service life, damage, load distribution

Calculation with load spectrum

Required safety for tooth root [SFmin] 1.40
Required safety for tooth flank [SHmin] 1.00
Required service life [H] 20000.00

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Service life (calculated with required safeties):
System service life (h) [Hatt] 63977

------- Gear 1 ----------------- Gear 2 -------

Tooth root service life (h) [HFatt] 1e+06 1e+06
Tooth flank service life (h) [HHatt] 1e+06 6.398e+04
Note: The entry 1e+006 h means that the Service life > 1,000,000 h.

17.1 Damage

Damage relative to the required service life (H, 20000.0 h)

No. F1 (%) F2 (%) H1 (%) H2 (%)

1 0.00 0.00 0.00 23.43
2 0.00 0.00 0.00 7.83
Σ 0.00 0.00 0.00 31.26

Damage relative to the system service life (Hatt, 63977.1 h)

No. F1 (%) F2 (%) H1 (%) H2 (%)
1 0.00 0.00 0.00 74.94
2 0.00 0.00 0.00 25.06
Σ 0.00 0.00 0.00 100.00

Damage calculated on basis of individual service life HFatt & HHatt

HFatt1 HFatt2 HHatt1 HHatt2
(h) 1.000e+06 1.000e+06 1.000e+06 6.398e+04

No. F1 (%) F2 (%) H1 (%) H2 (%)

1 0.00 0.00 0.00 74.94
2 0.00 0.00 0.00 25.06
Σ 0.00 0.00 0.00 100.00

Most critical duty cycle elements for Scuffing (SB, SInt), Tooth Flank Fracture (SFF), hardened layer (SEHT) and Micropitting (Sλ)
SB: 2
SInt: 2

17.2 Equivalent load

Application factor calculated according to ISO 6336-6, Annex A.3

(The slope of the S-N curve (Woehler lines) in the range of endurance limit according to ISO 6336-6, Table A.1 is used.)

Gear p Teq KA
1 Tooth root 8.738 2208.5 KA,F 1 0.920
1 Tooth flank 6.611 2000.0 KA,H 1 0.833
2 Tooth root 17.035 8254.5 KA,F 2 0.871
2 Tooth flank 5.709 8285.0 KA,H 2 0.875

------------------ Pair ----------------------

Application factor, ISO 6336-6 A.3 [KAmax] 0.920
[KA,Fmax/KA,Hmax] 0.920 / 0.875

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17.3 F.E.M. Classification

Classification according to F.E.M., Edition 1.001, 1998

Spectrum factor [km] 0.591
Spectrum class [L] 4
Application class, predefined service life [T] 7
Machine class, predefined service life [M] 8
Application class, achievable service life [T] 9
Machine class, achievable service life [M] 8

17.4 Load distribution

Load distribution (ISO 6336-1, Annex E)

No KHß wm wI wII wmax σHm σHI σHII σHmax

(N/mm) (N/mm) (N/mm) (N/mm) (N/mm²) (N/mm²) (N/mm²) (N/mm²)
1 1.7405 398.3 577.7 577.7 693.2 665.6 801.6 801.6 878.1
2 1.6171 398.3 644.1 644.1 644.1 665.6 846.4 846.4 846.4

Index m, I, II stand for: Middle of facewidth, Side I and Side II

18 Remarks

18.1 Conventions

- Specifications with .e/i mean: Maximum value .e and Minimum value .i, taking all tolerances into account.
- Specifications with .m mean: Mean value within tolerance.

- The center distance tolerances and the tooth thickness allowance are taken into account for the backlash tolerance. The maximum and
minimum clearance corresponding to the largest and smallest allowances are shown. The calculation is performed for the operating pitch
circle.

18.2 Calculations and factors

- Details of calculation method:

cγ according to Method B
Kv according to Method B
- The logarithmically interpolated value must be entered for factors ZL, ZV, ZR, ZW, ZX, YdrelT, YRrelT and YX. This value is calculated from the
infinite life strength and static strength values, based on the number of load cycles.

End of report (lines: 726)

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