Report of cylindrical gear calculation according to DIN 3960 , DIN GWJ Technology - www.eAssistant.

eu
3990
Mani Kandan 30. Mai 2019 - 16:44
abc Pvt Ltd
Design
14 3rd road
100014 Delhi
Tel: 9885654524
Fax: 25468513 Version 5.24
manikandanvicky5@gmail.com Project: -
Filename: kcp 1.sgp

Contents
Input values
Geometry
Allowances and quality
Tool
Load capacity
Options
Results of calculation
Geometry
Test dimensions
Tolerances
Load capacity (general influence factors)
Load capacity (flank)
Load capacity (root)
Load capacity (Scuffing)
Efficiency of gearing
References

Input values
Geometry

Cylindrical gear pair

Normal module (mn): 36.0 mm

Pressure angle (αn): 25.0 °
Helix angle (β): 0.0 °

Gear 1 Gear 2
Comment: Piion Gear1
driving driven
No. of teeth (z): 17 180
Profile shift coefficient (x*): 0.1679 0.1679
Facewidth (b): 90.0 mm 90.0 mm
Addendum chamfer (hk): 0.0 mm 0.0 mm
Chamfer: 0.0 mm 0.0 mm
Inner / outer diameter: 0.0 mm 0.0 mm

Allowances and quality

Cylindrical gear pair

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Centre distance tolerance field: User-defined input

Centre distance allowance max. value (Aae): 105.0 µm
Centre distance allowance min. value (Aai): -105.0 µm
Tolerance standard DIN 3961 (August 1978)

Gear 1 Gear 2
Quality: 6 6
Backlash allowance sequence: cd cd
Tolerance sequence: 25 25
Upper tooth thickness -175.0 µm -780.0 µm
allowance (Asne):
Lower tooth thickness -255.0 µm -1030.0 µm
allowance (Asni):
Upper tooth space allowance (AWe): -158.6039 µm -706.9201 µm
Lower tooth space allowance (AWi): -231.1085 µm -933.497 µm

Tool
Gear 1 Gear 2
Tool: Hob Hob
Basic rack profile: User-defined input User-defined input
Tool tip radius coefficient (ρ*aP0): 0.25 0.25

Addendum coefficient (h*aP0): 1.25 1.25

Dedendum coefficient (h*fP0): 0.9974 1.0
Semi topping height (h*FfP0): 0.0 0.0

Semi topping angle (αKP0): 0.0 ° 0.0 °

Protuberance coefficient (p*rP0): 0.0 0.0

Allowance (q): 0.0 mm 0.0 mm
Angle of protuberance (αprP0): 0.0 ° 0.0 °

Load capacity

Min. safety for load capacity calculation

Min. safety flank: 1.1

Min. safety tooth root: 1.3
Min. safety scuffing (integral): 2.0
Min. safety scuffing (flash): 3.0

Cylindrical gear pair

Calculation method: DIN 3990 Method B

Endurance: 100000.0 h

Power

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Gear 1 Gear 2
Power (P): 550.0 kW 550.0 kW
Torque (T): 26260.5656 Nm 278053.0476 Nm
Rotational speed (n): 200.0 1/min 18.8889 1/min

Factors for load capacity calculation

Application factor (KA): 1.0

Face coefficient (KHβ): 1.5
No pitting permitted
Load stage in FZG test: 12
Relative structure factor (XW rel T): 1.0
Type of profile modification: without profile modification

Lubricant

Kind of lubrication: Oil splash lubrication

Description of lubricant: Standard ISO VG 100
Comment: Standard oil ISO viscosity class VG
100
Viscosity at 40°C: 100.0 mm²/s
Viscosity at 100°C: 11.01 mm²/s
Density: 0.9 g/cm³
Temperature of lubricant: 70.0 °C
Load stage in FZG test: 12

Material

Source of data Gear 1 DIN 743, DIN EN 10084, Datenbank FORMAT, Datenbank Stahlwissen
NaviMat 3.1, DIN EN 10083-1:1996-10, DIN 7190:2001-02, VDI 2230, DIN
3990 Edition 12/87 Part 5
Material quality Gear 1 MQ (according to DIN 3990 Part 5, edition 12/87)

Source of data Gear 2 DIN 743, DIN EN 10084, Datenbank FORMAT, Datenbank Stahlwissen
NaviMat 3.1, DIN EN 10083-1:1996-10, DIN 7190:2001-02, VDI 2230, DIN
3990 Edition 12/87 Part 5
Material quality Gear 2 MQ (according to DIN 3990 Part 5, edition 12/87)

Gear 1 Gear 2
Material: 34CrNiMo6 hardened 34CrMo4 hardened
and tempered
Type of material: Tempering steel Tempering steel
Kind of treatment: hardened hardened
and tempered
Hardness: 238.0 HB 488.0 HB
Poisson's ratio (ν): 0.29 0.29

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E-Module: 210000.0 N/mm² 210000.0 N/mm²

Yield point (σS): 600.0 N/mm² 450.0 N/mm²

Density (ρ): 7.85 kg/dm³ 7.85 kg/dm³

Fatigue strength of contact stress (σHlim): 700.0 N/mm² 1155.0 N/mm²

Fatigue strength of nominal bending stress in the tooth 290.0 N/mm² 360.0 N/mm²
root (σFlim):

Roughness Tooth root (Rz): 16.0 µm 16.0 µm

Roughness Tooth flank (Rz): 4.0 µm 4.0 µm

Thermal contact coefficient (BM): 13.6 N/(mm K 13.6 N/(mm K

0.5 0.5
s ) s )

Options
Factor for minimal gear ring thickness: 2.0

Results of calculation
Geometry

Cylindrical gear pair

Normal circular pitch (pn): 113.0973 mm

Transverse pitch (pt): 113.0973 mm
Axial pitch (px): 0.0 mm
Circular pitch (pe): 102.501 mm
Transverse circular pitch (pet): 102.501 mm
Transverse pressure angle (αt): 25.0 °
Working transverse pressure angle (αwt): 25.4112 °
Helix angle base diameter (βb): 0.0 °
Helix angle on the pitch circle diameter (βw): 0.0 °
Transverse module (mt): 36.0 mm
Ratio (i): -10.5882
Gear ratio (u): 10.5882
Working centre distance (a): 3558.0 mm
Standard centre distance (ad): 3546.0 mm
Free from backlash centre distance (min.): 3556.6381 mm
Free from backlash centre distance (max.): 3556.9871 mm
Sum of profile shift coefficients (x*): 0.3359
Transverse contact ratio (εα): 1.4536
Overlap contact ratio (εβ): 0.0
Total contact ratio (εγ): 1.4536
Length of path of contact (gα): 148.9942 mm

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Beginning of path of contact (gf): 70.7625 mm

End of path of contact (ga): 78.2316 mm
Backlash pitch diameter min. value (jti): 857.0754 µm
Backlash pitch diameter max. value (jte): 1382.9246 µm
Backlash normal plane min. value (jni): 776.7741 µm
Backlash normal plane max. value (jne): 1253.3553 µm
Radial backlash min. value (jri): 902.0414 µm
Radial backlash max. value (jre): 1455.479 µm

Gear 1 Gear 2
Generating shift coefficient min. value (x*E Min): 0.1603 0.1372
Generating shift coefficient max. value (x*E Max): 0.1627 0.1447
Addendum modification (k): -0.0924 mm -0.0924 mm
Reference diameter (d): 612.0 mm 6480.0 mm
Pitch circle diameter (dw): 614.0711 mm 6501.9289 mm
Base diameter (db): 554.6604 mm 5872.8745 mm
Diameter at V-Circle (dv): 624.0888 mm 6492.0888 mm
Root diameter (df): 534.0888 mm 6402.0888 mm
Generated root diameter min. value (df Min): 533.542 mm 6399.88 mm
Generated root diameter max. value (df Max): 533.7135 mm 6400.4161 mm
Form diameter of dedendum (dFf): 559.6132 mm 6413.7072 mm
Form diameter of dedendum min. value (dFf min): 559.4429 mm 6411.5988 mm
Form diameter of dedendum max. value (dFf max): 563.2501 mm 6412.1103 mm
Diameter of active flank root (dNf): 567.9149 mm 6436.3404 mm
Diameter of active flank root min. value (dNf min): 567.0446 mm 6435.0867 mm
Diameter of active flank root max. value (dNf max): 568.8146 mm 6437.6007 mm
Tip diameter allowance max. value (Adae): 1800.0 µm 1800.0 µm
Tip diameter allowance min. value (Adai): -1800.0 µm -1800.0 µm
Tip diameter (da): 695.7168 mm 6563.904 mm
Tip diameter min. value (da Min): 693.9168 mm 6562.104 mm
Tip diameter max. value (da Max): 697.5168 mm 6565.704 mm
Form diameter of addendum (dFa): 695.7168 mm 6563.904 mm
Form diameter of addendum max. value (dFa max): 697.5168 mm 6565.704 mm
Form diameter of addendum min. value (dFa min): 693.9168 mm 6562.104 mm
Diameter of active flank tip (dNa): 695.7168 mm 6563.904 mm
Tip clearance (c): 9.0972 mm 9.0036 mm
Tip clearance min. value (cmin): 8.9286 mm 8.1862 mm
Tip clearance max. value (cmax): 11.2066 mm 10.282 mm
Sliding factor at tooth root (Kgf): -0.2522 -0.2789
Sliding factor at tooth point (Kga): 0.2789 0.2522

Specific sliding at tooth root (ζf): -1.2698 -0.6885

0.4077 0.5594

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Specific sliding at tooth point (ζa):

Test dimensions
Gear 1 Gear 2
No. of the teeth for span measurement (k): 3 26
Measurement diameter (span measurement) (dM): 620.4234 mm 6504.0191 mm
Span measurement nominal value (Wk): 277.9876 mm 2794.9258 mm
Span measurement min. value (Wk min): 277.7565 mm 2793.9923 mm
Span measurement max. value (Wk max): 277.829 mm 2794.2189 mm
Diameter of ball or pin (DM): 69.0 mm 63.0 mm
Measurement diameter (measurement over balls) (dM): 624.4839 mm 6492.2455 mm
Radial single-ball measurement nominal value (MrK): 364.0217 mm 3291.1747 mm
Radial single-ball measurement min. value (MrK min): 363.8076 mm 3290.0988 mm
Radial single-ball measurement max. value (MrK max): 363.8748 mm 3290.3601 mm
Measurement over balls nominal value (MdK): 725.232 mm 6582.3493 mm
Measurement over balls min. value (MdK min): 724.8056 mm 6580.1976 mm
Measurement over balls max. value (MdK max): 724.9395 mm 6580.7202 mm
Measurement over pins nominal value (MdR): 725.232 mm 6582.3493 mm
Measurement over pins min. value (MdR min): 724.8056 mm 6580.1976 mm
Measurement over pins max. value (MdR max): 724.9395 mm 6580.7202 mm
Transverse tooth thickness (st): 62.1858 mm 62.1858 mm
Transverse tooth thickness min. value (st min): 61.9308 mm 61.1558 mm
Transverse tooth thickness max. value (st max): 62.0108 mm 61.4058 mm
Transverse tooth thickness at V-circle (svt): 57.4167 mm 56.63 mm
Transverse tooth thickness at V-circle min. value (svt min): 57.1567 mm 55.5981 mm
Transverse tooth thickness at V-circle max. value (svt max): 57.2383 mm 55.8486 mm
Chordal tooth thickness at V-circle nominal value (svn): 57.3358 mm 56.6293 mm
Chordal tooth thickness at V-circle min. value (svn min): 57.0865 mm 55.6016 mm
Chordal tooth thickness at V-circle max. value (svn max): 57.1647 mm 55.851 mm
Chordal height (hv): 37.1346 mm 36.0311 mm
Circular normal space width at V-Circle (evt): 57.9146 mm 56.6783 mm
Normal chordal tooth thickness at reference diameter nominal 62.0788 mm 62.1848 mm
value (sn):
Normal chordal tooth thickness at reference diameter min. 61.8295 mm 61.1571 mm
value (sn min):
Normal chordal tooth thickness at reference diameter max. 61.9077 mm 61.4065 mm
value (sn max):
Normal chordal tooth thickness at tip diameter nominal 15.6484 mm 22.2162 mm
value (san):
Normal chordal tooth thickness at tip diameter min. value (san 14.0288 mm 20.2794 mm
min):

Normal chordal tooth thickness at tip diameter max. value (san 16.7658 mm 22.318 mm
max):

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Chordal height at reference diameter (ha): 43.4381 mm 42.1012 mm

Circular normal space width at reference diameter (et): 50.9116 mm 50.9116 mm
Tooth depth (h): 80.814 mm 80.9076 mm

Tolerances
Gear 1 Gear 2
Profile form deviation (ff): 32.0 µm 32.0 µm
Profile slope deviation (fHα): 20.0 µm 20.0 µm
Total profile deviation (Ff): 36.0 µm 36.0 µm
Single pitch deviation (fp): 22.0 µm 28.0 µm
Tooth to tooth pitch deviation (fu): 28.0 µm 36.0 µm
Cumulative pitch deviation (Fp): 63.0 µm 100.0 µm
Variation of tooth thickness (Rs): 28.0 µm 45.0 µm
Runout (Fr): 50.0 µm 71.0 µm
Helix deviation (Fβ): 14.0 µm 14.0 µm
Helix slope deviation (fHβ): 10.0 µm 10.0 µm
Helix form deviation (fβf): 10.0 µm 10.0 µm
Total radial composite deviation (F´´i): 56.0 µm 80.0 µm
Radial composite deviation (f´´i): 25.0 µm 32.0 µm
Single flank pitch deviation (F´i): 80.0 µm 110.0 µm
Single flank pitch step (f´i): 40.0 µm 45.0 µm

Load capacity (general influence factors)

Cylindrical gear pair

Carried width (tooth root) (b*): 0.0

Nominal circumferential force at pitch cylinder (Ft): 85818.8419 N
Axial force on the reference diameter (Fa): 0.0 N
Radial force on the reference diameter (Fr): 40017.9832 N
Normal tooth force on the reference diameter (Fn): 94690.6151 N
Circumferential force on the pitch circle
diameter (Ftw): 85529.4023 N
Axial force on the pitch circle diameter (Faw): 0.0 N
Radial force on the pitch circle diameter (Frw): 40632.917 N
Normal tooth force on the pitch circle
diameter (Fnw): 94690.6151 N
Circumferential speed (v): 6.4088 m/s
Running-in allowance (yα): 4.8571 µm
Running-in allowance (yf): 4.8571 µm
Running-in allowance (yp): 3.5643 µm
Layout value of the profile correction (Cay): 6.1944 µm
Correction coefficient (CM): 0.8
Gear body coefficient (CR): 1.0
Basic rack profile coefficient (CBS): 1.0725

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Single spring stiffness (c´): 15.8327 N/(mm µm)

Meshing spring stiffness (cγ): 21.2188 N/(mm µm)
Reduced mass (mred): 1.4199 kg/mm
Reference speed (N): 0.0921
Sub-critical range
Resonance speed (nE1): 2171.5023 1/min
Dynamic coefficient (Kv): 1.0451

Gear 1 Gear 2
Number of load changes (NL): 1200.0 Mio. 113.3333 Mio.
Number of contacts (q): 1.0 1.0

Load capacity (flank)

Cylindrical gear pair

Zone factor (ZH): 2.2639

Elasticity coefficient (ZE): 191.0274 (N/mm²)
0.5

Overlap factor (Zε): 0.9213

Helix angle factor (Zβ): 1.0
Lubrication coefficient (ZL): 0.9354
Speed coefficient (Zv): 0.9746
Roughness factor (ZR): 1.145
Transverse coefficient (KHα): 1.0
Nominal contact stress at pitch point (σH0): 520.2938 N/mm²

Gear 1 Gear 2
Limited life factor (ZN): 1.0 1.0
Endurance factor (static strength) (ZNT): 1.6 1.6
Size factor (ZX): 1.0 0.9
Single contact factor (ZB,D): 1.0977 1.0
Work hardening factor (static) (ZW): 1.136 1.0
Work hardening factor (dynamic) (ZW): 1.136 1.0

Existing contact stress (σH): 715.0429 N/mm² 651.4306 N/mm²

Allowable contact stress (static strength) (σHP stat): 1272.8471 N/mm² 1848.0 N/mm²

Allowable contact stress (fatique strength) (σHP dauer): 830.4596 N/mm² 1085.1425 N/mm²

Safety flank (stat. strength): 1.7801 2.8368

Safety flank (dyn. strength): 1.1614 1.6658

Load capacity (root)

Cylindrical gear pair

Face coefficient (KFβ): 1.3241

Transverse coefficient (KFα): 1.0
Helix factor (Yβ): 1.0

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Overlap factor (Yε): 0.766

Stress correction coefficient (YST): 2.0

Max. possible normal tooth force at target safety

(static) (FN max): 1335929.7513 N
Max. transmissible moment at target safety
(static) (Tmax): 370493.6422 Nm
Max. possible normal tooth force at target safety
(dynamic) (FN max): 322458.9954 N
Max. transmissible moment at target safety
(dynamic) (Tmax): 89427.6122 Nm

Gear 1 Gear 2
Effective facewidth (btr): 90.0 mm 90.0 mm

Angle of load application (αFen): 26.2615 ° 25.4352 °

Root fillet radius at 30° tangent (ρF): 15.7977 mm 10.9578 mm

Chord of tooth root thickness (sFn): 78.0231 mm 92.3986 mm

Bending moment arm (hFe): 40.3946 mm 47.2346 mm

Existing stress in the tooth root (σF): 109.9169 N/mm² 116.0144 N/mm²

Nominal stress in the tooth root (σF0): 79.4342 N/mm² 83.8407 N/mm²

Allowable stress in the tooth root (stat. strength) (σFP stat): 1517.8142 N/mm² 2321.2883 N/mm²

Allowable stress in the tooth root (fatigue strength) (σFP dauer): 478.7419 N/mm² 567.761 N/mm²

Form factor (YF): 1.4182 1.1908

Stress correction coefficient (YS): 2.1146 2.6582
Limited life factor (YN): 1.0 1.0
Endurance factor (static strength) (YNT): 2.5 2.5
Relative notch sensitivity factor (Yδ Rel T): 0.9993 1.0144
Relative surface factor (YR Rel T): 0.9717 0.9717
Size factor (YX): 0.85 0.8
1) 1.0 1.0
Technology factor (YT):
Mode of operation: swelling swelling
2) 1.0 1.0
Mode of operation factor (YA):
Safety root (stat. strength): 13.8087 20.0086
Safety root (dyn. strength): 4.3555 4.8939

Load capacity (Scuffing)

Mass temperature at FZG test (approximation) (ϑMT): 203.05 °C
Flash temperature at FZG test (approximation) (ϑfla int T): 150.3538 °C
Flash temperature at FZG test (approximation) (ϑfla max T): 225.5308 °C
Angular factor (Xα β): 1.0648
Face coefficient (KB β): 1.5
0.7661

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Transverse coefficient (KB α):

Decisive circumferential force (wBt): 1145196480.405 N/mm

Integral temperature method

Scuffing integral temperature (ϑint S): 428.5808 °C

Contact ratio factor (Xε): 0.2819
Decisive tip relief (Ca): 3.8782 µm
Tip relief factor (XCa): 1.0204
Mesh factor (XQ): 1.0
Geometry factor for pinion tooth tip (XBE): 0.2528
Flash factor (XM): 50.8808 K N
-0.75
s
0.5 -0.5
m mm
Helix factor (KB γ): 1.0
Average on-site friction coefficient (µmC): 0.0564
Flash temperature at the tip mesh point E of the pinion (ϑfla
E): 48.8514 K
Average flash temperature above mesh (ϑfla int): 13.7703 K
Lubrication factor (XS): 1.0
Mass temperature (ϑM): 79.6392 °C
Integral temperature (ϑint): 100.2947 °C
Scuffing safety (integral temperature) (Sint S): 4.2732

Flash temperature method

Scuffing contact temperature (ϑS): 428.5808 °C

Coordinate of maximum contact temperature (Γmax): -0.5371
Distribution factor (XΓ max): 0.3333
Geometry factor (XB max): 0.3972
Flash factor (XM max): 50.8808 K N
-0.75
s
0.5 -0.5
m mm
Average on-site friction coefficient (µmy max): 0.0838
Mass temperature (ϑM): 88.2284 °C
Maximal flash temperature (ϑfla max): 38.7838 K
Maximal contact temperature (ϑB max): 127.0122 °C
Scuffing safety (flash temperature) (SB): 6.2895

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A B C D E
127.5
125
122.5
120
117.5
115
112.5
110
107.5
105
102.5
100
97.5
95
92.5
90
87.5
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 0.6
Coordinate over line of action # [-]

Efficiency of gearing
See G.Niemann, H.Winter: Maschinenelemente Vol.
II, 2nd Edition 1989, Springer-Verlag, Chap. 21.11
Average coefficient of friction (µm): 0.0295
Grade of tooth losses (Hv): 0.1225
Tooth friction losses (PVz): 1.9853 kW
Efficiency of gearing (ηz): 99.639 %

References

1)
Influence of the technology factor according to:
Linke, Heinz: Stirnradverzahnungen
Carl Hanser publishing company, 1st Edition 1996
Page 320 (Equation 6.5/36)

2)
Influence of the mode of operation factor according to:
Linke, Heinz: Stirnradverzahnungen
Carl Hanser publishing company, 1st Edition 1996
Page 320 (Equation 6.5/36) and Page 321 (Table 6.5/7)

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