AGNA GOO4-F MM 0687575 0002209 437 mm ANSI/AGMA 6004-F88 e ‘May 1988 (Revision of AGMA 321.05) AMERICAN NATIONAL STANDARD Gear Power Rating for Cylindrical Grinding e Mills, Kilns, Coolers and Dryers e AGMA STANDARDcot byt AGMA BOO4-F MM Ob87S75 OOD22,0 353 mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers AGMA 6004-F88 (Revision of AGMA 321.05) {Tables or other self-supporting sections may be quoted or extracted in their entirety, Credit line should read: Extracted from AGMA Standard 6004-F88, Gear Power Rating for Cylindrical Grinding ‘Mills, Kilns, Coolers and Dryers, with the permission of the publisher, American Gear Manufacturers Asvociation, 1500 King Street, Suite 201, Alexandria, Virginia 22314.] AGMA standards are subject to constant improvement revision or withdrawal as dictated by experience. Any person who refers to any AGMA Technical Publication should determine that it is the latest information available from the Association on the subject. ABSTRACT ‘This Standard specifies a method for rating the pitting resistance and bending strength of open or semi-enclosed spur, single helical, double helical, and herringbone gears for cylindrical grinding mils, kilns, coolers and dryers. Copyright ©, 1988 American Gear Manufacturers Association 1500 King Street, Suite 201 Alexandria, Virginia, 22314 May 1988 ISBN: 1-55589-499-2 ANSI/AGMA 6004-F8cot by an Aig 08 16:48:38 AGMA BOO4N-F MH 087575 0002233 098 mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers FOREWORD [The foreword, footnotes, and eppendices, if any, are provided for informational purposes only and should not be construed as part of American Gear Manufacturers Association Standard 6004-F88, Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers.) Tentative standard AGMA 321.01 was originally developed to cover gears used primarily for ball and rod mills, and for kilns and dryers. It was approved in October, 1943, and later modified in June, 1946. In June, 1951, AGMA 321.03 was approved as a standard. Further changes and additions were approved in June, 1959, and AGMA 321.04 was issued in March, 1960. AGMA 321.05 was approved in March, 1968 and ingued in March, 1970. In February, 1979, the mill gearing committee was reorganized to review AGMA 321.05 and revise it in accordance with a proposed new standard, Rating the Pitting Resistance and Bending Strength of Spur ‘and Helical Involute Gear Teeth. This new standard became AGMA 218.01 in December, 1982. With AGMA 218.0! as @ guide, the committee submitted the [irst draft of 6004-F88 in March 1984, The format of this Standard was revised to conform with the ANST (American National Standard Institute) style manual. The values for Life Factors, Cy and Kz. Dynamic Factors. C, and Ky, Hardness Ratio Factor, Cy, Reliability Factors, Cp and Kz , Allowable Stress Numbers, 4, and j,,, and Load Distribution Factors, Gy and Kjq, have been revised in this Standard. ‘The Overload Factors. C, and X,, , has been replaced by a redefined Application Factors, C,, and K, , and the Service Factors, Cp and Kp, have been defined and introduced. ‘The grouping of the variables into Cj, Cy, and C, factors in the pitting resiaance formula and K;,, and K, factors in the bending strength formula has been dropped. Another change made isthe addition of separate service factors for bending strength and pitting resistance. A speed limitation has also been added. Values for factors assigned in previous standards are not applicable to this Standard, values assigned in this Standard applicable to previous standards. are the The ability to design gears, and the knowledge and judgment required to properly evaluate the various rating factors comes primarily from years of accumulated experience in gearing. The detailed treatment of the general rating formulas for specific applications is best accomplished by those experienced in the field AGMA 6004-F88 supersedes AGMA 321.05, Design Practice for Helical and Herringhone Gears Jor Cylindrical Grinding Mills, Kiins, Coolers, and Dryers. \t was approved by the AGMA membership in January 1988 and approved as an American National Standard on May 31, 1988. Suggestions for the improvement of this Standard will be welcome. They should be sent to the American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, Virginia, 22314 ANSVAGMA, itt 6004-F88 Se Aran Geor ntactAGHA LOO4-F MM 0687575 ODOR2I2 Tey mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers PERSONNEL of the AGMA Committee for Mill Gearing e Chairman: R. J. Zab (Joy Technologies, Inc.) Vice Chairman: D. F. Kress (Falk) ACTIVE MEMBERS K. A. Seitz (Kennedy Van Saun) G. A. Teasley (Aluminum Company of America) ASSOCIATE MEMBERS R, G, Allenby (Hamilton Gear) J.C, Leming (Arrow Gear) (Deceased) P, Losekamp (Xtek) G. E, Olson (Cleveland Gear) B. Schierenbeck (Xtek) E, R. Sewall (Sewall Gear) D. A. Sylvester (Dresser) ANSUVAGMA iv 6004-F88, cot by an iy 08 164AGMA BOO4-F MM Ob87575 00022)3 460 me Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers e ‘Table of Contents Section Title Page 1. Scope 11 Applicability .. 1 1.2 Limitations .. : 1 13 Metallurgy : 1 2. Responsibility ..... 1 Symbols and Terms 6.00.66 00ccccseeceteessee sees cseesseeeteetseeneee 1 4, Rating Formulas 4a Pitting Resistance . 3 42 Pitting Resistance Power Rating ..........csscssseeeesees rd 43 Bending Strength 4 44 Bending Strength Power Rating ...- 4 3, Dynamic Factors, Cy and XK, 54 Resonance : : 3 52 Approximate Dynamic Factors «4 .0++ +++ 3 6. Load Distribution Factors, Gy and Ky 6 ‘Transverse Load Distribution Factor, Gy, “7 62 Face Load Distribution Factor, Cyay Sr eaeeneeies e 7. Application Factors, Gg and Ky. 8. Allowable Stress Numbers. fy¢ and fy 8.4 Guide for Case Depth of Surface Hardened Gearing 82 Allowable Contact Stress Number, 4, «+ 83 Allowable Bending Stress Number, 4) .sscssceeceeeersnsseeeereree AD 9 Life Factors, G, and Ky 23 10. Hardness Ratio Factor, Cy, 10.4 ‘Through Hardened Gears .essssesseeeees settee oe 13 10.2 Surface Hardened/Through Hardened Values 14 LL, Reliability Factors, Cy and Ky 1s 12, Service Factors, Cgp and Kop +. os As 13. Geometry Factors, / and J 13.4 itting Resistance Geometry Factor, 1 cevecseeeeeeeeses 16 13.2 Bending Strength Geometry Factor, J ...... Deteetensseeeees 16 Appendices Appendix A Service Factor, Cop and Kop ou Appendix B —Ilustrative Examples 18 ANSI/AGMA v 6004-F88 Coptic by he Ait Gear HorfatreAGHA LOO4-F MM ObS7575 OOO2214 817 mw Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Table of Contents (cont) e Section Title Page Figures Fig S-1 Dynamic Factors, Cy andy Fig 6-1 Pinion Proportion Factor, Gy 8 Fig 6-2 valuation of Sand S; cette ee tteeeneees 8 Fig 6-3 Mesh Alignment Factor, Gg 9 Fig 8-1 Effective Case Depth for Carburized Pinions, h, e Fig 8-2 Effective Case Depth for Induction Hardened Pinions. hy <---2++0+0+- 11 Fig 8-3 Allowable Contact Stress Number for Steel Gears, 4, cose ID Fig 8-4 Allowable Bending Stress Number for Steel Gears, Sp 2 Fig 8-5 Recommended Hardening Pattern on Gear Teeth with Induction Hardening B Fig 10-1 Hardness Ratio Factor, C,, (Through Hardened) Fig 10-2 Hardness Ratio Factor, C,, (Surface Hardened) Tables Table 3-1 Symbols Used in Gear Rating Equations Table 8-1 Allowable Contact Stress Number, 5. ..+-.-2000+ un Table 8-2 Allowable Bending Stress Number, §,, . 13 ANSI/AGMA, vi 6004-F8s Coptic by he Ait Gear HorfatreAGHA BOOU-F MM Ob87575 0002215 733 mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers 1. Scope 1.1 Applicability. This Standard provides a method to determine the power rating of gear sets for cylindrical grinding mills, kilns, coolers, and dryers. The formulas are applicable to steel gears with machined spur, single helical, double helical, or herringbone gear teeth commonly used for this purpose, Calculations determine the allowable rat- ing for pitting resistance and bending strength of external spur and helical involute gear teeth. 4.2 Limitations. (A) Rating procedures are limited to open or semi-enclosed gearing where the gear reaction forces are transmitted through a structure which provides independent bearing support for the gear and pinion. Open gears operate without any en- closure. Semi-enclosed gears operate with a guard that provides some degree of protection against contamination from dust or dirt and retains lubri= cant. (2) Enclosed gear drives or speed reducers are expressly excluded from this Standard. (3) This gear rating practice is limited to maximum operating speeds of 2000 feet per min- tute (10.2 m/s) gear pitch line velocity or 450 revolutions per minute of the pinion. (4) When dual motors and pinions are used, each pinion will be designed for 60 percent of the (otal input power of both motors unless otherwise specified by contractual agreement. (5) This Standard does not include gearing which has been surface hardened by nitriding or flame hardening. This gear rating practice is lim- ited to through hardened gears operating with through hardened, carburized, or induction hard- ened pinions. (6) Face contact ratio of helical gear sets must be greater than 1. 1.3 Metallurgy. The allowable stress numbers, Sue ANd $y, + included herein are based on com- mercial steel making and heat treating practice. Hardness and tensile strength are the criteria for allowable stress numbers. Variation in microstruc ture will result in variation in gear capacity. ANSUAGMA. Responsibility ‘The users of AGMA design standards are ex- pected to have acquired experience in the field of gear design and application. This will offer cont dence in the selection of variables, and establish the ability to properly evaluate the gearing design. ‘The gear designer or manufacturer is not re- sponsible for the total system unless such a re: quirement is clearly identified in the contractual agreement. It is imperative that the system designer be satisfied that the system of connected rotating ‘parts is compatible, free from critical speeds and from torsional or other vibrations within the speci- fied speed range, no matter how induced CAUTION: Compliance with this Standard does not constitute a warranty of the rating Of the gear set under installed field service conditions. 3. Symbols and Terms The symbols used in pitting resistance and bending strength formulas are shown in Table 3-1. The terms used conform to the following, standards: AGMA 112.05-1976, Gear Nomenclature, Terms, Definitions, Symbols, and Abbreviations AGMA 600.01-1979, Standard for Metric Usage NOTE: The symbols and definitions used in this Standard may differ from other AGMA standards. The user should not as- sume that familiar symbols can be used without a careful study of these definitions. ST units of measure are shown in parentheses in Table 3-1 and in the text. Where equations re- quire a different format or constant for use with SL units, a second expression is shown after the first, indented, in smaller typo, and with “M" included in the equation number. Example: B= Rugtos Vy (Eq 4.6) ars (Eq 4.6M) 6004-F88 Coptic by he Ait Gear Horfatre an Aig 08 16:48:38Coptic by he Ait Gear Horfatre an Aig 08 16:48:38 AGNA BOON-F MM Ob87575 OOU221b LT a Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Table 3-1 Symbols Used in Gear Rating Equations Symbol Unis int Used Paragraph Cc Operating Center in (mm) Eq 4.2 42 Application Factor for Pittng Resistance raat 7. C_ Mes Allgnment Correction Factor 4626.2. G—Suttace Condition Factor Eqat 4a Gy Hardness Ratio Factor Ea4i 10. c, Life Factor for Pitting Resistance ‘Eq 4.1 9. Gq Load Distribution Factor for Pitting Resistance Ea4t 6. Gq Mesh Aligiment Factor eq62 62d Gre Lead Correction Factor E462 6.24 Gag Face Load Distribution Factor Fq 6.1 6.2. Gu Transverse Load Distribution Factor Ea6i 6. g Elastic Coefficient Tib/in?] °-8 ((MPa} +5) Eq 4.1 42 Py Pinion Proportion Fastor F462 62d Com Pinion Proportion Modifier Fq62 624 Gq Reliability Factor for Piling Resistance raat t Ch Size Factor for Pitng Resistance East 42 Gop Service Factor for Pting Resistance Eqizt 12 Cp Temperature Fastor for Piting Resistance Fgtt 42 , Dynamic Factor for Piting Resistance Fas 5. 4” Operating Pitch Diameter of Pinion in(mm) Egat 42 F Net Face Width of Narrower Member in (mm) Eq 4.1 42 Sp ‘Surface Finish of Pinion ‘micro in (um) Eq 10.4 10,2, Hy Brinell Hardness Fig 8-3 8.2 Hyg Brinell Hardness of Gear Eq 10.2 10.1 Hyp Brinell Hardness of Pinion Fq 10.2 10.1 ‘4, Minimum Effective Case Depth in (mm) Fig8-1 8.4 1 Geometry Factor for Piting Resistance Fq4t ta J Geometry Factor for Bending Strength Eq 4.4 13.2 K, Application Factor for Bending Strength asd 7. A, Life Factor for Bending Strength Fate 9 K,, Load Distribution Factor for Bending Strengin Bas 6. Ky Reliability Factor for Bending Strength Fass K. Size Factor for Bending Strength Fass 44 Kyp Service Factor for Bending Strength Bq i22 12. Kp Temperature Factor for Bending Strength Eq 4.4 44 K, Dynamic Factor for Bending Strength Bats. m Metric Module in Plane of Rotation (mm) Eq 4.4 44 mp Face Contact Rati Bit Bd mg Gear Ratio (always 2 1.0) Eq 4.2 42 ‘ANSUAGMA 2 6004-F88AGMA BOO4-F MH 0687575 OO022)7 SOb mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers e@ Table 3-1 (cont) Symbols Used in Gear Rating Equations Symbot Description Units Fa'Usea__Bavseras 'm, Normal Metric Module at Standard Pitch Diameter (mm) Baas 9. ny Pinion Speed pm Egat 4.2 Ziq Allowable Transmitted Power for Pitting Resistance hp (kW) Eq 4. 42 2y Allowable Transmitted Power for Bending Strength hp (kW) Eg 4.64.4 F —_Diametral Pitch in Plane of Rotation in? Eq 44 44 Faq Notmal Diametral Pitch at Standard Pitch Diameter in" Eq 4.5 44 2 Axial Pitch in (mm) Eq 13.1013. Q, Transmission Accuracy Level Number Eqs3 52 S’ Bearing Span in (mm) Fig6-2— 6.2.4 5, Pinion Offset in (mm) Fig6-2, 6.241 Syq Allowable Contact Stress Number Ibfin? (MPa) Eq 4.1 8. 4, Allowable Bending Stress Number Ibfin? (MPa) Eq 4.4 8. % Pitch Line Velocity at Operating Pitch Diameter f/min (m/s) Eq 5.1 52 Yz —_Helix Angle at Standard Pitch Diameter degrees Eq4s 4a 4. Rating Formulas np tae SL oH ‘The formulas in this Standard are based on * amy AGMA Standard 218, Rating the Pleting Resis- tance and Bending Strength of Spur and Helical where Involute Gear Teeth, which contains the funda- faq = allowable transmitted power for imental gear rating formulas. piling resistance, hp (kW) 4.1. Pitting Resistance. ‘The intent of the pitting np = pinion speed, rpm resistance formula is to determine the maximum F = net face width of narrower load at which destructive pitting of the teeth does not occur during their design life. The ratings for Haier 0 (rm) FOr cal Bed by Hers lor contact prevate peween two tearing, the net face width is the curved surfaces, modified for the effect of load Total face width minus the gap sharing between adjacent teeth. with, measured paral t0 the ‘The pitting of gear teeth is considered to be a ands of rotation, fatigue phenomenon. Initial pitting and destruc- 2 = geometry factor for pitting tive pitting are illustrated and discussed in ANSI/ resistance (see Section 13) AGMA 110, Nomenclature of Gear Tooth Failure , = dynamic factor for pitting Modes. resistance (see Section 5) 4.2. Pitting Resistance Power Rating. The pi Cy = size factor for pitting resistance, ting resistance power rating formula is’ ssi 1 value of unity (1.0) Cm = load distribution Factor for pitting npF Ic, (2 ex} a Fac ® tele se resistance (see Section 6) 126000 Sm Ep CK Sp eR = surface condition factor, assign a e ean) value of unity (1.0) ANSI/AGMA, 3 6004-F88 Coptic by he Ait Gear Horfatre an Aig 08 16:48:38retin Geo Manto AGMA GOO4-F MM Ob87575 C0022 442 Mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Cq = application factor for pitting resistance (see Section 7) allowable contact stress number, Ib/in? (MPa) (see Section 8) Cp = elastic coefficient , [lb/in?] 5 (IMPa] 5) G = 2300.0 (191) for meet gears C__ = life factor for pitting resistance (see Section 9) hardness ratio factor (eee Section 10) Cp = temperature factor for pitting resistance, assign a value of unity (4.0) Ga = Fellabltty factor for piting resistance (see Section 11) a ‘operating pitch diameter of pinion, in (mm) 2c a- 2c : mati (Eq 4.2) where C= operating center distance, in (mm) mg = gear ratio (never less than 1.0) Substituting the unity values. the power rating formulas become: ac" eo Goel eT | ea 43 126 000 6, C, Ce - npF_ ily (4 4e¢ CoCH ae" Torx GO? Oy Cg CR (Eq 4.3M) CAUTION: The ratings of both pinion and gear teeth must be calculated 10 evaluate differences in material properties and num- ber of tooth contact cycles under load. The pliting resistance power rating is based on the lower of the values. The C,y value is applied only to the gear. 4.3 Bending Strength. The intent of the strength rating formula is to determine the maximum load which can be transmitted for the design life of the gear drive without causing cracking or breakage in the root fillet. ANSI/AGMA, ‘The bending strength of gear teeth is a fatigue phenomenon related to the stress at the tooth root filet. Typical cracks and fractures are flustrated in ANSI/AGMA 110.04-1980, Nomenclature of Gear Tooth Failure Modes. ‘The strength ratings determined by this Stan- dard are based on plate theory modified to con- sider: (1) The compressive stress at the roots caused by the radial component of tooth loading. (2) Non-uniform moment distribution resull- ‘ng from the inclined angle of the load lines on the teeth, (For helical, double helical. or herringbone gearing.) (3) Stress concentration at the tooth root fil- Jets. (4) The load sharing between adjacent teeth. 4.4 Bending Strength Power Rating. The bend- ing strength power rating formula is: ated ky Fd fae By a 44 fe 126 000K, K, 2X, kk, "144 gee Fe TOKO? K Km Ky Ky kp (Eq 44M) where Tyg = allowable tranemited power for ending strength, hp (kW) np = pinion speed, rpm d= operating pitch diameter of pinion, in (mm) (see Eq 4.2) Ky = dynamic factor for bending strength (see Section 5) , = application factor for bending strength (see Section 7) F = not face width, in (mm) For herringbone or double helical searing, the net face width is the total face width minus the gap width, measured parallel to the axis of rotation. K,, = load distribution for bending strength (see Section 6) J = geometry factor for bending strength (see Section 13) K; = site factor for bending strength assign a value of unity (1.0) 6004-F88AGNA GOOU-F MM 0687575 0002219 385 me Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Sy = allowable bending stress number, Ib/int (MPa) (vee Section 8) life factor for bending strength (Gee Section 9) = reliability factor for bending strength (see Section 11) ‘p= temperature factor for bending surength, asign a value of unity (2.0) = Giamesral pitch in plane of rotation, in? for spur gears (Eq 4.5) ” (Eq 4.5M) for helical gears Py =P, 4cosy, (Ea 46) ” aq 4.6M, cosy, OA46M) where mm = motie module in plane of rotation, e P,q_ = normal diamewal pitch at sandard pitch diameter, in my = normal metric module at standard pitch diameter, mm helix angle at standard pitch diameter ‘Substituting the unity values, the power rating Formulas become: Pp fat FS Stk © 126 000 5 Py Km Kp mp4 Ky rms 91x G0"K kK, CAUTION: The rating of both pinion and gear teeth must be calculated to evaluate differences in geometry factors, number of Toad cycles, and material properties. The bending strength power rating is the lower of the two values. ANSVAGMA Coptic by he Siete an Aig 08 16:48:38 or Monit 5. Dynamic Factors, C, and K, ‘The dynamic factors, C, and K,, account for internally generated gear tooth loads which are induced by non-conjugate meshing action of the gear teeth. Tooth loads caused by dynamic forces generated by the prime mover and/or the driven equipment are accounted for by the application factor. Even if the input torque and speed are constant, significant vibration of the gear masses, and therefore dynamic tooth forces, can exist These forces result from the relative displace- ments between the gears as they vibrate in re- sponse to an excitation known as transmission er ror. The ideal kinematics of a gear provide uni- form relative angular motion. The transmission er- ror is defined as the departures from uniform rela tive angular motion. It is influenced by all the de- viations from the ideal gear tooth form. 5.1 Resonance. When an excitation frequency coincides with a natural frequency, the resonant response is limited only by the damping, and high dynamic loads may result. The dynamic factors, Gy and Ky» do not apply to resonance. 5.2 Approximate Dynamic Factors. igure 5-1 shows dynamic factors which can be used in the absence of specific knowledge of the dynamic loads. The curves of Fig 5-1 and Eqe 5-1 through 5-4 are based on empirical data Choice of curves Q, = 5 through Q, = 11 should be based on transmission error. When transmission error is unavailable, itis reasonable to-use pitch (spacing) and profile accuracy. Q, is the transmission accuracy level number. 9, be the same as the quality number from AGMA 2000-A88, Gear Classification and Inspection Handbook, when mamfacturing techniques. en- sure equivalent transmission accuracy or when the pitch (spacing) and profile eccuracy are within the AGMA 2000-A88 tolerances for the selected ‘quality number. If the mating gears are of differ- ent quality numbers, use the quality number of the less accurate gear 28 Q, Due to the approximate nature of the empiri cal curves and the lack of measured tolerance val- ues at the design stage of the job, the dynamic factor curve should be selected based on the ex- perience with the manufacturing methods and op- erating considerations of the design. 6004-F88AGNA GOOW-F MM ObS7575 O002220 OTO Gear Power Rating for Cyli ‘The empirical curves for Fig S=1 are gener ated by the following equations for values of Q, (Eq 5.1) .¥ (Bq 5.1M conf gam) een 50 +56 (1.0 B) (€a 5.2) pitchline velocity at operating pitch diameter (42-0,) 007 4 Q, = transmission accuracy level number ‘The following equation must be used for values of 2, when 0,< 6 (45.3) (Bq 5.4) (Bq 5.4m) "1000 \drical Grinding Mills. Kilns, Coolers and Dryers 6. Load Distribution Factors, Gy, and Ky, The load distribution factor modifies the rat- ‘ng equations to reflect the non-uniform distribu- tion of the load along the lines of contact. The amount of non-uniformity of the load distribu- tion fs influenced by: (Q) Geer tooth manufacturing accuracy, (ead, profile, spacing, and runout) (2) Tooth crowning and end relief. @) Alignment of the axes of rotation of the pitch cylinder of the mating gear elements (4) Elastic deflections of gear elements, shafts, bearings, mountings, and foundations which support the gear elements, (5) Hertzian contact and bending deforma- tions at the tooth surface. (6) Bearing clearances. (7) Thermal expansion and distortion due to operating or ambient temperature conditions (es- pecially important for wide face gearing) "1500 2000 ft/enin ——_ . os os rt 7 10 mie PITCHLINE VELOCITY, V, Fig 5-1 Dynamic Factors, C, and Ky 1.0 2 Ss 2 z SF 08 Q g = 06 2 5 500 & 26 ANS/AGMA retin Geo Manto an Aig 08 16:48:38 6004-F88cot byt an Aig 08 16:48:38 retin Geo Manto AGHA BOD4-F MH 0b67575 OO0e22) T37 Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Bearing clearances and thermal expansion and distortion are beyond the scope of thie Stan- dard. The remaining influences are handled in the remainder of this Section. ‘The load distribution factors are defined as: m= Km = Cm X Cot (Eq 6.1) where Gap ~ face load distibution factor mi Gy = tansverse load distribution factor ‘mt NOTE: Maximum value of Cy OF Kyq 18 2.0. See 6.2.1 item 4 for explanation. 6.1 Transverse Load Distribution Factor, Gay+ The transverse load distribution factor accounts for the non-uniform distribution of load among the gear teeth which share the total load. Stan- dardized procedures to evaluate the influence of me have not been established. Since the evaluation of the transverse load distribution factor is beyond the scope of this Standard, a value of unity may be used. 6.2 Face Load Distribution Factor, Gy. ‘The face load distribution factor accounts for the non— uniform distribution of load across the gearing face width. The magnitude of the face load distri- ‘bution factor is defined as the peak load intensity divided by the average load intensity across the face width, ‘The following two methods of determining the face load distribution factor may be used. These two methods will result in significantly different re~ sults in some cases. When using the analytical approach, the calculated load capacity of the gears should be compared with past experience since it may be necessary to re-evaluate other rat- ing factors to arrive at a rating consistent with past ‘oxperienes. 621 Empirical Method. The empirical method requires a minimum amount of informa- tion, and is recommended as an appropriate method for gear designs which meet all of the fol- lowing requirements: (1) Net face width to pinion pitch diameter ratio less than or equal to 2.0. (2) Gear elements are mounted betwes ANSIAGMA, bearings (not overhung). (3) Face width equal to or less than 40 inches. (4) Contact across full face width of the nar- rower member when loaded (limiting Gp OF Ky ‘to @ maximum value of 2.0). NOTE: Designs falling outside the above ranges require special analysis. ‘This method will give results similar to those obtained in previous AGMA Standards. Sng =19 + Cnel Cop Com * Ena &) cea 52) where Gag * lt correction factor me Gy = Pinion proportion factor Sym = Pinion proportion modifier Gnq ~ mesh alignment factor Cz = mesh alignment correction factor ‘The lead correction factor, Cy.» modifies peak load intensity when lead modification is ap- plied. Gre = 1-0 for gear with unmodified leads Ge ~ 0-8 for gear with leads properly modified NOTE: For wide face gears, when methods for careful lead matching or lead correc- tions to compensate for deflection are em- ployed, it may be desirable to use the ana- lytical approach of 6.2.2 to determine the load distribution factor. The pinion proportion factor, Cpy» accounts for deflections due to load (see Fig 6-1). ‘These deflections are normally higher for wide face width or higher F/d ratios. ‘The factor can be evaluated using the follow- ing equations: when 1.0.1.7 then use (# pp/ gq) *1-7 to calculate Cyy ins, Coolers and Dryers 10.2 Surface Hardened/Through Hardened Values. When surface hardened pinions (48 HIRC cor harder) are run with through hardened gears (180 to 365 BHN), @ work hardening effect is achieved. The Cy; factor varies with surface finish of the pinion, Jp . und the mating gear hardness. Typical values are shown in Fig 10-2 oF can be calculated as follows: Cyt 1.0 +B (450 Hy) (&q 10.3) where B= 0.000 75 (¢)" 2-12 Up) (Eq 10.4) € = base of natural or Napierian logarithm = 2.718 28 surface finish of pinion, tp = iieroinches, rms (root mean square) 14 7 Fr 112 fle 18 °é Fis 4 . 18 g 3 Ee g Q = = 1.08 14 2 Bp & a & 2 x 1.08 13 9 a" 3 6 42 © 1.04 = WHEN i 1.02 TBP 24.2, Hea USE Cy = 1,00 a 0 2 4 6 8 10 12 14 16, 18 20 SINGLE REDUCTION GEAR RATIO Fig 10-1 Hardness Ratio Factor, Cj; (fhrough Hardened) ANSI/AGMA 14 6004-F88cot byt an Aig 08 16:48:38 retin Geo Manto AGHA G004-F MM 0687575 0002229 228 mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Surface Finish of Pinion, fp, 1.46 ‘microinches (rms) 114 5 16 = rms & 112 5 32 z ims S110 5 = 1.08 ee a Z 1.08 € = 128 * 4.04 rms 1.02 — 1.00, 180200, 250 300 350 ‘400 BRINELL HARDNESS, Haq, Fig 10-2 Hardness Ratio Factor, C}; (Surface Hardened) 11, Reliability Factors, Cy and Kp ‘The reliability factors account for the effect of the normal statistical distribution of failure found in material testing. The allowable stress numbers given in Table 8-1 and Table 8-2 are based upon 2 statistical probability of one failure in 100 at 107 cycles. When gear equivalent horsepower require- ‘ments are established using service factors, reli- ability factors Cp and Kp should be assigned a value of unity when determining the gear tooth power rating, 12, Service Factors Cop and Ks ‘The historical method of selecting open or semi-enclosed gears involves the use of a service factor. When the service factor method is used, an equivalent horsepower to be transmitted must be determined. This is done by multiplying the specified transmitted horsepower or prime mover nameplate horsepower, at base speed, by the serv ice factors. Manufacturer and user must have 2 ANSUAGMA, contractual agreement which should dictate horse- power selected for rating the gear set. Cop is the pitting resistance service factor and Kgp is the bending strength service factor. It is necessary ‘that the gear set selected have an allowable trans- mitted power equal to or greater than the appro priate equivalent horsepower. ‘The table of service factor values, C5p and Kgp- shown in Appendix A, has been developed from the experience of manufacturers and users cf gear sets for use in common applications with electric motor prime movers, and has been found to be generally satisfactory for the listed applica- tion when gears are rated using AGMA Stan- dards. It'is recommended that service factors for special applications be agreed upon by the user and the gear manufacturer when variations of the table may be required. Some of the operational characteristics that affect the selection of the proper service factors are: 15 6004-F8scot byt an Aig 08 16:48:38 retin Geo Manto AGMA GOO4-F MM 0687575 0002230 THT am Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers (1) Prime Mover. Different types of prime movers are electric motors, steam or gas turbines, and internal combustion engines having single or multiple cylinders. (2) Starting Conditions. Starting conditions where high peak loads or where frequent starts and stops occur require special load analysis. (3) Systems Conditions. An essential phase in the design of any system of rotating machinery is, the analysis of the dynamic response of the 5ys- tem. The dynamic loads imposed on a gear drive are the result of the dynamic behavior of the total system and not of the gear drive alone. There fore, the dynamic analysis must consider the com- plete system including prime mover, gear drive, driven equipment, couplings, and foundations. ‘The dynamic response of a system to an excitation force produces relative motion between adjacent elements of the system and imposes additional loads on the components of that system. These dynamic loads are superimposed on the nominal running load. ‘The resultant load may be signifi- cantly greater than the nominal running load and could lead to premature failure of individual sys+ tem components. In a gear drive, these failures could consist of tooth breakage, severe surface destruction of the gear teeth, shaft breakage or ‘bearing failure, (4) Ambient Conditions. Ambient conditions involving oxiremes of temperature and environ- ment require special analysis. (5) Lubrication. Special analysis is required when the manufacturer's lubrication recommen- dations cannot be followed, (©) Misalignment and Distortions. Abnormal misalignment between the shafts of the gear drive and the shafts of the connected machinery, oF Jack of rigidity of the gear drive foundation re- ‘quire special analysis. (7) Overloads. Loads which are in excess of the nominal design load are considered overloads. Overloads can be momentary, periodic, quasi- steady state, or vibratory in nature. Depending ‘upon the magnitude and the number of stress cy cles accurnmulated, overload can cause a fatigue or yield condition. Applications involving high torque motors, in- termittent operation, extreme repetitive shock, oF where high energy loads must be absorbed. as when stalling, require special analysis, (8) Brake Equipped Applications. Applica- tions involving a working brake require spe% analysis. ANSUAGMA (9) Overspeeds. Overspeeds contributing to increased transmitted or dynamic loads require special analysis, (10) Reliability Requirement and Life Re- quirement. Applications requiring a high degree of dependability or unusually long life should be given careful consideration. The service factor in- cludes the application factors, Cand Ky , the life factors, C, and Ky, and the reliability factors, Cy and Kz. The service factors are defined as: for pitting resistance @ Ge = Gla (Eq 12.1) for bending strength Ky Sr 7 lip (Eq 12.2) 13, Geometry Factors, J and J ‘The geometry factors, J and J, evaluate the effect of tooth proportions on stress. 13.1 Pitting Resistance Geometry Factor, 1. The geometry factor, Z, evaluates the radii of cur- vature of the contacting tooth profiles based on the pressure angle, helix angle, and gear ratio, Effects of modified tooth proportions and load sharing are considered. The method for caleulat- ing the J {actor can be found in AGMA 218. In this Standard, the face contact ratio for helical gears must be greater than 1.0. The ‘method to calculate the face contact ratio is: K mpet aad (Eq 13.1) where mp = face contact ratio (= 0 for spur gears) P, = axial pitch, in (mm) NOTE: For herringbone or double helical ‘pearing the face contact ratio should be evaluated by considering F to be half the net face width. 13.2 Bending Strength Geometry Factor, J. The geometry factor. J, evalutes the shape of the tooth, the position at which the most damaging Joad 1s applied, siress concentration due to ge0- metric shape, and the sharing of load between ‘oblique lines of contact in helical gears. Both the tangential (bending) and radial (compressive) components of the tooth load are included. The method for calculating the J factor can be found in AGMA 218. 16 6004-F88AGMA GOO4-F MM Ob87575 0002231 9ab Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Appendix A Service Factors, Cop and Kgp [This Appendix is provided for informational purposes only. and should not be construed as a part of AGMA Standard 6004-F88, Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dry- Al. Purpose. The table of service factors shown in this Appendix has been developed from the ex- perience of manufacturers and users of gears for cylindrical grinding mills, kilns, coolers and dryers with electric motor prime movers, and has been found to be generally satisfactory for the listed ap- Standards. It is suggested that service factors for special applications be agreed upon by the user and the gear manufacturer when variations of the table may be required. See Section 12 of AGMA. {6005-F88 for some of the operation characteris- tics that affect selection of proper service factors. plications when gears are rated using AGMA Table A-t Minimum Service Factors (24 Hours Per Day Duty Cycle) Coolers 4.00* 4st Dryers 1.00" 1st uns 1.00° 1.75* Grinding Mills: e Ball 1s 2.25 ‘Autogenous 43 24 Rod 1.65 25 ‘* When the gear speed is less than 1.5 rpm, use service factors from the Table above. When the gear speed is greater than 1.5 rpm, the durability and strength service factors given in the Table should be multiplied by the following value: [(0.07 rpm of gear) + 0.9] The minimum resultant service factor need not be greater than 1.4 for durability and 2.25 for strength NO Combination Ball-Rod Mills require the appropriate service factor to be applied to the horsepower demand for each portion of the mill 7 6004-FaR ANSI/AGMA, Coptic by he Ait Gear Horfatre an Aig 08 16:48:38AGMA GOOU-F MM 0687575 OOD2232 Al? mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers ‘THTS PAGE IS INTENTIONALLY LEFT BLANK ANSI/AGMA, 18 6004-F88 Coptic by he Ait Gear HorfatreAGHA LOO4-F MMH Ob87575 0002233 759 a Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers Appendix B Illustrative Examples [This Appendix is provided for informational purposes only, and should not be construed as a part of AGMA Standard 6004-F88, Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Drj- ers.) BL. Purpose. This Appendix provides several example power rating calculations, using the methods described in Standard 6004-F88. B2. Example 1 Application : Ball Mill 3750 hp at 200 rpm Pinion Cgp ahs Kspo 2.25 Given Daa Np =21 Jp = 32 1ms d= 21.149 inches Ny = 295 @ Hap = 55 HRC D = 297.090 inches 2, Hyg= 245 BAN np = 200 mpm Modified leads ¥ = 68" 5, = 0.0 inches dy = 25° S = 40.0 inches F = 28.0 inches Fy = 0.993 Pitting resistance power rating Using Eq 4.1 pteF ty (“= ‘9° 136 000 G; Gm Cy Ga \ Gp Caleulated values 1 = 0.2683 Sacq= 108 $70 C, = 1.00 Gy = 1.00 Cy = 0.7843 Cy = 1.1074 C, = 1.00 (fot gear only) Gn = 173818 G = 2300.0 G = 1.00 Cp = 100 @ re TE ANSUAGMA Substituting these values into Eq 4.1, the results Fue 6 484 hp Roc = 6600 hp The required minimum component power must be equal to or greater than the application power multiplied by the service factor. Required Aye = 3750 bp (1.5) = 5625 hp Bending strength power rating Using Eq 4.6 pet ky FOF ye & 126 000 Ky Py K, Ky, Kp Kp Calculated values Ky = 1.00 A, = 1.00 Jp = 0.5819 Ky = 1.00 K, 217318 gp = 55000 Ky = 0.7843 Kp = 1.00 K, = 1.00 Sarg = 33990 Ig = 9.7069 Substituting these values into Eq 4.6, the results are: Pap 713 720 hp Fayg 730 300 np Required Fa, = 3750 hp (2.25) = 8438 hp 6004-F88 Coptic by he Ait Gear Horfatre an Aig 08 16:48:38AGHA BOO4-F MM 0687575 0002234 69S mm Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers B3. Example 2 Application: Ball Mill 3500 hp at 200 rpm Pinion esp =1.50 Kgp®?25 Given Dat Np =21 225° d = 21.149 inches F = 28.0 inches Myp=350BEN fp = 125 rme 2, =8 N= 285 np = 200 mm D = 297.080 inchs ¥ 68° Hy gz 245 BHN Unmodified leads 54, = 0.0 inches S = 40.0 inches Py= 0.993 Pitting resistance power rating Using Eq 4.1 npF 126 000 C, Cy Cy Cy 1c, Ros Calculated values 1 = 0.2683 SacG = 108 570 1.00 cy = 1.00 G, = 0.7843 Cy = 1.059 (for gear only) C, = 1.00 Cp = 2300.0 Gy = 19148 Gp = 1.00 @ ~ 100 Gq = 100 Seep = 143 850 ANSUAGMA ‘Substituting these values into Eq 4.1, the results Fagp = 8548 Dp Bog = 5459 bp Required %-=3500 hp (1.8) = 5250 hp Bending strength power rating Using Eq 4.6 npak, a" 126 000 K, Calculated values K, = 1.00 K, = 0.7843 Jo = 0.7089 @ Jp = 0.5819 Ky = 1.00 Kp = 4.9148 Kp = 1.00 Ky = 1.00 fag = 33.990 fup = 42615 ‘Substituting these values into Eq 4.6, the results Ep = 9615 hp Pag = 9316 bp Required fa; =3500 hp (2.25) =7875 hp 20 6004-F88 Coptic by he Ait Gear HorfatreAGHA BOO4-F MM Ob87575 OODz235 Se) am Gear Power Rating for Cylindrical Grinding Mills. Kilns, Coolers and Dryers @ meme Application: Kiln Substituting these values into Eq 4.1, the results 150 hp at 16.68 spm Pinion are: Pacp = 247 hp Pag 158 hp Required P,, = 150 (1.0) = 150 hp Given Data Bending strength power rating Np =16 F = 18.5 inches Using Eq 4.6 4 = 16.2468 Ng = 222 “ G mpdK, Fo J 4, Ky 126 000 Ky Fy Kykm Ky Xp Hyp = 265BHN D = 225.4247 inches 2, -8 Hyg = 180 BHN np = 16.68 cpm 5, = 0.0 inches Calculated values vy =10° S = 30.0 inches e oy = 20 Fy = 0.985 k= 1.00 Jp = 0.5485 Ky = 1.9573 Pitting resistance power rating Ky = 1.00 Using Bq 4.1 k= 0936 2 0 npF ICy ( Sac ax) fap = 35 88 6" 126 000 C,C CCX C, CrC, mCp Ca Cp CrCR. Substicuting these values into Eq 4.6, the results re: Calculated values Rup = 421 hp 1 = 0.2873 cy = 1.000 : a Bag = St hp cy = 1.00 Cy = 1.083 Ge. naga (Gor gear only) Required £, = 150 hp. (1.75) = 262.5 hp v ” Cp = 2300.0 1.00 Gp + 1.00 1.1573 Gq = 1:00 G = 100 Seg = 96720 @ Syep = 115 290 ANSIAGMA a coors |B Coptic by he Ait Gear Horfatre