GEARCALC - Release 12-2006 GEARCALC demo version File Name : GEARCALC Tutorial 001 Changed by : jatan on: 12/21/06

at: 9:29 am

This KISSsoft demoversion may not be used for professional application ! Warning : Calculation not consistent. Results are probably not valid !

RESULTS FOR RESISTANCE CALCULATION FOLLOWING AGMA 2001-D04

INPUT DATA SUMMARY GEAR GEOMETRY DATA Number of teeth Net face width Outside diameter Normal diametral pitch (1/in) Normal module (mm) Normal pressure angle Standard helix angle Operating center distance Centre distance tolerance z1,z2 b1,b2 da1,da2 Pnd mn alfa(n) beta a a.e/i = = = = = = = = = Pinion 25 50.8000 68.5800 10.0000 2.5400 20.0000 0.0000 95.2500 0.0000 / 0.0000 0.00000 0.02400 0.00000 1.5708 1.4000 0.3500 0.0000 Gear 50 50.8000 132.0800

***Gear geometry data for mn = 1.0*** Profile shift coefficient X1,X2 = Thinning for backlash del.sn1, del.sn2 = Stock allow. per side for finishing Us1,Us2 = ***Tool geometry data for mn = 1.0*** Tool normal tooth thickness tce1,tce2 Tool addendum haP01*,haP02* Tool tip radius roaP01*,roaP02* Tool protuberance DELTA(o1),DELTA(o2) = = = =

0.00000 0.02400 0.00000 1.5708 1.4000 0.3500 0.0000

MATERIALS/HEAT-TREATMENT DATA Material (Pinion) = Steel, Grade 2, HB400(AGMA) AGMA 2001-C95; AGMA 2101-C95 Material (Gear) = Steel, Grade 2, HB350(AGMA) AGMA 2001-C95; AGMA 2101-C95 Material type = Heat-treatment = LOAD DATA Pinion Transmitted power (kW) P = 44.7417 Pinion speed (rpm) n(P) = 1750.0000 Required life (HRS) L = 20000 Reliability R = 99 % Driving: = PINION Number of contacts per revolution = 1 Reversed bending (0=No; 1=Yes) = 0 Spur gear loading type = TIP Stress cycle factors, Curve chosen, Figs. 17 & 18 = Upper DERATING FACTORS Overload (or application) factor Size factor Surface condition factor Rim thickness factor Load distribution factor Ko Ks Cf KB KH = = = = = 1.0000 0.0000 0.0000 0.0000 0.0000 Gear

1 0 (for general applications)

0.0000

Dynamic factor

Kv =

1.1442

GEOMETRY SUMMARY-1 Generating pitch dia Operating pitch dia Base dia Mean dia of pinion Root diameter (manufactured) Limit (SAP) (manufactured) Top of fillet (manufactured) PRESSURE ANGLES Standard transverse Operating transverse Standard normal Operating normal HELIX ANGLES Standard Operating Base PITCHES Transverse circular Normal circular Transverse base Normal base Axial DISTANCES ALONG LINE OF ACTION Start of active profile (SAP) Low single tooth contact (LPSTC) Pitch point High single tooth contact (HPSTC) End of active profile (EAP) Distance between interference points Active length of line of action Pinion addendum portion of Z Pinion dedendum portion of Z Dist. from pitch point to stress calc LENGTH OF CONTACT LINE Minimum Maximum Average RATIOS Contact length Transverse (profile) contact Axial (face) contact Total contact Gear ratio Load sharing (mN = F/Lmin) TRANSVERSE RADII OF CURVATURE At operating pitch point of pinion At operating pitch point of gear At point of stress calc of pinion At point of stress calc of gear TOOTH DEPTHS Operating addendum Operating dedendum Operating clearance Whole depth Working depth ds,Ds d,D db,Db dm dR,DR dc,Dc de,De alpha(t) alpha(wt) alpha(a) alpha(wn) = = = = = = = = = = = Pinion 0.0000 0.0000 0.0000 63.5000 0.0000/0.0000 0.0000/0.0000 0.0000/0.0000 Gear 0.0000 0.0000 0.0000 0.0000/0.0000 0.0000/0.0000 0.0000/0.0000

0.0000 0.0000 20.0000 Division by zero: ZPP[0].dw/ZR[0].d 0.0000 Division by zero: ZPP[0].dw/ZR[0].d 0.0000 0.0000 0.0000 0.0000 0.0000 -----0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 -0.0000 -0.0000 0.0000 0.0000 0.0000 0.0000 Division by zero: ZP[0].L.E/ZP[0].L.i 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 34.2900/ 34.2900 0.0000/ 0.0000 0.0000/ 0.0000 34.2900/ 34.2900 34.2900/ 34.2900 66.0400/ 66.0400 0.0000/ 0.0000 0.0000/ 0.0000 66.0400/ 66.0400 66.0400/ 66.0400

beta = beta(w) = beta(b) = p pn pb pN px C1 C2 C3 C4 C5 C6 Z Za Zb Zc = = = = = = = = = = = = = = =

Lmin = Lmax = Lavg = mL mp mF mt mG mN RP RG R1 R2 a1,a2 b1,b2 c1,c2 ht1,ht2 hK = = = = = = = = = = = = = = =

TRANSVERSE CIRCULAR TOOTH THICKNESSES (manufactured) Topland to1,to2 = Division by zero: ZR[0].da/ZR[0].d/Division by zero: ZR[0].da/ZR[0].d Division by zero: ZR[1].da/ZR[1].d/Division by zero: ZR[1].da/ZR[1].d Operating tr1,tr2 = Division by zero: (ZR[0].BPmm.sn+ZR[0].As.E)/cos(ZS.Geo.beta)/ZR[0].d/Division by zero: (ZR[0].BPmm.sn+ZR[0].As.i)/cos(ZS.Geo.beta)/ZR[0].d Division by zero: (ZR[1].BPmm.sn+ZR[1].As.E)/cos(ZS.Geo.beta)/ZR[1].d/Division by zero: (ZR[1].BPmm.sn+ZR[1].As.i)/cos(ZS.Geo.beta)/ZR[1].d Generating tg1,tg2 = -0.0610/-0.0610 -0.0610/-0.0610 Base tb1,tb2 = Division by zero: (ZR[0].BPmm.sn+ZR[0].As.E)/cos(ZS.Geo.beta)/ZR[0].d/Division by zero: (ZR[0].BPmm.sn+ZR[0].As.i)/cos(ZS.Geo.beta)/ZR[0].d Division by zero: (ZR[1].BPmm.sn+ZR[1].As.E)/cos(ZS.Geo.beta)/ZR[1].d/Division by zero: (ZR[1].BPmm.sn+ZR[1].As.i)/cos(ZS.Geo.beta)/ZR[1].d NORMAL CIRCULAR TOOTH THICKNESSES (manufactured) Topland tno1,tno2 = 0.0000/0.0000 0.0000/0.0000 Operating tnr1,tnr2 = Division by zero: (ZR[0].BPmm.sn+ZR[0].As.E)/cos(ZS.Geo.beta)/ZR[0].d/Division by zero: (ZR[0].BPmm.sn+ZR[0].As.i)/cos(ZS.Geo.beta)/ZR[0].d Division by zero: (ZR[1].BPmm.sn+ZR[1].As.E)/cos(ZS.Geo.beta)/ZR[1].d/Division by zero: (ZR[1].BPmm.sn+ZR[1].As.i)/cos(ZS.Geo.beta)/ZR[1].d Generating tng1,tng2 = -0.0610/-0.0610 -0.0610/-0.0610 Base tnb1,tnb2 = Division by zero: (ZR[0].BPmm.sn+ZR[0].As.E)/cos(ZS.Geo.beta)/ZR[0].d/Division by zero: (ZR[0].BPmm.sn+ZR[0].As.i)/cos(ZS.Geo.beta)/ZR[0].d Division by zero: (ZR[1].BPmm.sn+ZR[1].As.E)/cos(ZS.Geo.beta)/ZR[1].d/Division by zero: (ZR[1].BPmm.sn+ZR[1].As.i)/cos(ZS.Geo.beta)/ZR[1].d LEAD L1,L2 = 0.0000 0.0000/ 0.0000 0.0000/ 0.0000 0.0000/ 0.0000 0.0000

OPERATING CIRCULAR BACKLASH (manufactured) Transverse (only through Center dist. tol.) = Transverse (total) B = Normal (total) Bn = PROFILE SHIFT COEFFICIENTS FOR MANUFACTURING Theoretical, no backlash x1,x2 = Manufacturing xg1,xg2 = NOTE:

0.0000 0.0000/ 0.0000

0.0000 0.0000/ 0.0000

All dims in mm, all angles in degrees. All geometry data, which are not declared as 'manufacturing', are for the theoretical (no backlash) tooth meshing situation.

GEOMETRY SUMMARY-2 PITTING Helical Minimum Pitting RESISTANCE GEOMETRY FACTOR DATA overlap factor C(beta) = length of contact Lmin = resistance geometry factor I = 0.0000 0.0000 0.0000 Pinion 0.000 1.8902 1.8683 0.4365 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Gear 0.000 1.9199 2.0914 0.3952 0.0000 0.0000 0.0000 0.0000

BENDING STRENGTH GEOMETRY FACTOR DATA Load angle alpha(L) Height of Lewis parabola h Tooth thickness at critical section t Radius at curvature of fillet curve ro Loaded at tip (No load sharing) (h, t, ro for mn = 1.0) Diameter of the critical point F DFpoint Helical factor Ch Helix angle factor K(beta) Stress correction factor Kf Tooth form factor Y Bending strength geometry factor J = = = = = = = = = =

LOAD / MATERIAL SUMMARY Pitch line velocity (m/s) vt Transmitted tangential load (N) Wt Torque transmitted by pinion (Nm) T(1) Torque transmitted by gear (Nm) T(2) Contact load factor for pitting resist. K Unit load factor for bending strength U(L) MATERIALS/HEAT TREATMENT DATA Modulus of elasticity (N/mm) EP,EG Poisson's ratio mu(P),mu(G) Surface hardness Allowable contact stress sac(P), sac(G) Allowable bending stress sat(P), sat(G) Yield point (N/mm) sigs DERATING FACTOR SUMMARY Overload (or application) factor Ko = Size factor Ks = Surface condition factor Cf = Rim thickness factor KB = Load distribution factor Km = Transmission accuracy grade number Av = Dynamic factor Kv = Combined derating factor pitting Ko*Kv*Km*Ks*Cf = Combined derating factor bending Ko*Kv*Km*Ks*KB = 1.0000 0.0000 0.0000 0.0000 0.0000 7 1.1442 0.0000 0.0000 = = = = = = Division by zero: ZPP[0].dw/ZR[0].d Division by zero: ZR[0].d/ZPP[0].dw 244.1 488.3 0.0 0.0

= = = = =

206843 0.3000 1199 394 1211.00

206843 0.3000 1079 359 1049.00

0.0000

Km CALCULATED USING AGMA2001/2101 METHOD (CHAPTER 15) Gear unit type: Commercial enclosed gear unit Mesh alignment factor KHma = 0.0000 Mounting procedure: Without contact improvement at assembly Mesh alignment correction factor KHme = 0.0000 Gearing: Without longitudinale flanc correction Lead correction factor KHmc = 0.0000 Pinion proportion factor KHpf = 0.0000 Pinion proportion modifier KHpm = 0.0000 Large offset pinion (s1/s >= 0.175) Face load distribution factor KHbeta = 1.2324 NOTE: Transverse load distribution factor KHalpha = 1.0 STRENGTH SUMMARY Stress cycle factor (Contact) Surface condition factor Hardness ratio factor Surface finish [mm/1000] Temperature factor Reliability factor Allow. contact stress No. (N/mm) Z(N) Z(R) Z(W) f(p) K(T) K(R) sigHP = = = = = = = Pinion 0.0000*a* 0.0000 0.0000 16.0000 0.0000 1.0000 0 0.0000*a* 1.0000 0 Gear 0.0000*a* 0.0000 0.0000 16.0000 0.0000 0 0.0000*a* 1.0000 0

Stress cycle factor (Root) Y(N) = Reverse loading factor = Allow. bending stress No. (N/mm) sigFP = *a* NOTE: Based on life (HRS) L = 20000 Curve chosen, Figs. 17 & 18 = Upper STRESS SUMMARY Elastic coefficient Contact stress No. [N/mm]^.5 (N/mm) Z(E) = sigH = sigF1 = sigF2 =

(for general applications)

0.0 0.0 0.0 0.0

Pinion bending stress No. (N/mm) Gear bending stress No. (N/mm)

NOTE: Materials with HB > 400: Yield strength is not checked. RESULTING SAFETY FACTORS Safety factor (Bending) Safety factor (Contact) ZPP[0].Flanke.sigHP/ZP[0].Flanke.sigH ZPP[1].Flanke.sigHP/ZP[0].Flanke.sigH SERVICE FACTORS Service factor for bending Service factor for contact Service factor for gear set KSF = CSF = SF = 0.00 0.00 0.00 0.00 0.00 SF = SH = 0.00 Division by zero: Division by zero: 0.00

POWER RATING CALCULATION

(Calculation of the transmittable power) Allow. transmitted power for pitting (W) Allow. transmitted power for bending (W) Allowable transmitted power (W) Life factor for pitting resistance Life factor for bending resistance Durability (Pitting) life (HRS) Durability (Pitting) life (CYCS/10^6) Bending fatigue life (HRS) Bending fatigue life (CYCS/10^6) *a* NOTE: *b* NOTE: Z(N) Y(N) L(C) N(C) L(T) N(T) Paz = Pay = Pa = = = = = = = Pinion 0.00 0.00 0.00 0.000 *b* 0.000 *b* 20000.0 0.0 20000.0 0.0 0.000 *b* 0.000 *b* 20000.0 0.0 20000.0 0.0 Gear *a* 0.00 0.00

Based on allowable stresses at life (HRS) L = 20000 Pitting and Bending Life calculated for general applications (Upper portion in fig. 17 and 18)

MANUFACTURING DATA
Tooth thickness dimensions Thinning for backlash Normal circular tooth thickness Span measurement Number of teeth spanned Diameter of span contact point Measurement over 1 ball Measurement over 2 balls Ball or roll diameter Diameter of ball/roll contact point Normal chordal thickness Normal chordal height *a* NOTE: *c* NOTE: NOTE: As sn Wk k dWk MrK MdK DM dMM 'sn ha = = = = = = = = = = = Pinion 0.0610/ 0.0610 -0.0610/ -0.0610 0.0000/ 0.0000 3.0000 0.0000 0.0000/ 0.0000 0.0000/ 0.0000 4.3891 0.0000 0.0000/ 0.0000 0.0000 Gear 0.0610/ 0.0610 -0.0610/ -0.0610 0.0000/ 0.0000 6.0000 0.0000 0.0000/ 0.0000 0.0000/ 0.0000 *c* 4.3891 0.0000 0.0000/ 0.0000 *a* 0.0000

Tooth thickness measured at generating pitch diameter When measuring over 2 balls, the two balls must be in the same transverse plane. All dims in mm.

Tolerances Following AGMA 2000-A88: Accuracy grade (Quality) Pitch Variation Allowable Runout Radial Tolerance Profile Tolerance Tooth Alignment Tolerance Composite Tolerance, Tooth-to-Tooth Composite Tolerance, Total NOTE: End report All dims in 1/1000 mm.

Q-AGMA2000 VpA VrT VphiT VpsiT VqT VcqT

= = = = = = =

11 0.0 0.0 0.0 0.0 0.0 0.0

11 0.0 0.0 0.0 0.0 0.0 0.0

lines:

335