A.

TECHNICAL DOCUMENTATION

1. Structural scheme, torques and rotations for each shaft

1.1. Structural scheme

M - electrical engine
P - power or electrical engine
n - electrical engine rotation
Tm - nominal torque of engine shaft
ic- ratio of the V-belt/chain drive
I - input shaft
TI -torque of input shaft
nI- rotation of input shaft
II - output shaft
TII - torque of output shaft
nII - rotation of output shaft
A, B, C, D - the bearings

P = 15 kW
n = 1440 rot/min
ic = 1,15
ir = 5
Lh = 10500 h

1.2. Torques and rotations for each shaft

Engine

n 1440rot / min
Tm 9,55 106

P
15
9,55 106
99479,1666Nmm
n
1440

Input shaft (I)

nI

n 1440

1252,1739rot / min
ic
1,15

TI Tm ic 99479,1666 1,15 114401,0416Nmm

Output shaft (II)

n II

n I 1252,1739

250,4347rot / min
ir
5

TII TI ir 114401,0416 5 572005,208Nmm

2.

Predimensioning of the gear

2.1. PROJECT DATA
Input shaft (I) rotation speed
n I 1252 ,1739 rot / min
Input shaft (I) torque
TI 114401 ,0416 Nmm
Gearing ratio
ir 5
Minimum lifetime
Lh 10500 h
Working conditions of the gear
Moderate shocks
K A 1,35

Stress cycle of the gears teeth

Contact and bending: pulsating cycle
Nr. of stress cycles of the teeth flank, for a full rotation
x1, 2 1 - general use speed reducers
Reference rack profile
n = 20; h*an = 1,0; c*u = 0,25; *fn = 0,38
2.2. STEEL CHOSEN, TREATMENT APPLIED AND THE LIMIT
STRESSES
Material: 17MnCr10
Steel treatment: cemented steel
Superficial hardness: 60 HRC
Inside hardness: 300 HB
r1.2 = 590 MPa
02 1,2= 1000 Mpa
Limit stresses, contact stress Hlim1,2 and bending stress
Flim1,2
Hlim1,2 = 1500MPa
Flim1,2= 500MPa

2.3. PREDIMENSIONING CALCULUS

Teeth nr. of the input shaft (pinion) z1, and z2 for the driven
gear
a 2
2
z1 max w
cos 50
cos14 16,1715
5 1
mn u dat 1

z 2 z1 u dat 16 5 80

We choose:z1 = 16 teeth and z2 = 80 teeth

Real gearing ratio

z 2 80

5
z1 16

u
u
u dat

1 1 0 0.03

Factors for contact calculus

The elasticity factor of the gear material zE
1

zE

1
1 22

E2
E1
2
1

1 2 0,3
E1 E 2 2,06 105 MPa
Z E 189,8 MPa

Contact area factor zH

z H 2,49 cos 2,49 cos14 2,4527

Covering factor z
1

1
0,8451
1,4

= 1,4 for inclined teeth

Inclination factor of the teeth z
Z

1
cos

1
cos14

0,9850

Factors for bending calculus

Number of teeth for the equivalent wheels
z1
16

17,5148
3
cos cos3 14
z2
80

87,5744
3
cos cos3 14

z n1
zn2

Displacement coefficient of the profile in the normal

plane
x n1, 2 0

Shape factor of the teeth YFa 1,2

YFa1 YFa ( z n1 , xn1 ) YFa (17,5148;0) 2,93
YFa 2 YFa ( z n 2 , xn 2 ) YFa (87,5744;0) 2,21

Correction factor of stress at the base of the teeth YSa

1,2

YSa1 YSa ( z n1 , xn1 ) YSa (17,5148;0) 3,23

YSa 2 YSa ( z n 2 , xn 2 ) YSa (87,5744;0) 2,29

Covering factor Y
Y 0,25

0.75

cos2 0,25

0.75
cos2 14 0.7543
1.4

1,4
Inclination factor of the teeth Y
Y 1

120

14
0,8833
120

Load correction factors

The application factor KA
K A 1,35

The dynamic factor Kv

K v 1,10

The factors of uneven distribution of loads on the

width of the teeth, KH for contact stress and KFfor
bending stress
K H 1,50
K F 1,50

The factors of uneven distribution of loads in the

frontal plane, KH for contact stress and KFfor
bending stress

1,4
k H k F

1,4870 1,4
2
cos cos 2 14

The allowable stress limits, HP1,2 for contact and FP1,2 for
bending stress
ZL lubricating factor
ZV speed factor
ZR roughness factor of the active flanks
Z L Z V Z R 0,85 - for unrectified teeth
ZW = 1,0 material couple factor
Zx= 1 size factor
The durability factors, ZN1 for the pinion and ZN2 for
driven gear
N L1 60n1 LH 1 60 1252,1739 10500 1 7,88 108
N L 2 60n2 LH 2 60 250,4347 10500 1 1,57 108

z N1 1
z N 2 1,08
Minimum safety coefficient
S H min 1 - cylindrical gear, for industrial transmissions
Contact stress limit

z
1500 1
HP1 H lim N 1 Z L Z V Z R Z W Z X
0,85 1 1 1275MPa
S H min
1

HP min( HP1 , HP2 )

z
1500 1,08
HP2 H lim N 2 Z L Z V Z R Z W Z X
0,85 1 1 1377MPa
S H min

HP min(1275;1377) 1275MPa

Correction factor for bending on the standard testing

gear
YST 2,0
Relative sensibility factor of the stress concentrator
from the base of the teeth, Y 1 for the pinion and Y 2
for the driven gear
Y 1, 2 =1

Relative factor of the transition area at the base of the

teeth, Y 1 for the pinion and Y 2 for the driven gear
Y 1, 2 1
Yx= 1 size factor
The durability factors, YN1 for the pinion and YN2 for
driven gear
YN 1 1

YN 2 1
Minimum safety coefficient
S F min 1,5 - for standard industrial transimissions
Bending stress limit

Y Y
500 2 1 1 1 1
FP1 F lim 1 ST N 1 Y 1YR1Yx
666,666MPa
S F min

FP 2

1,5

F lim 2YST YN 2
S F min

Y 2YR 2Yx

500 2 1 1 1 1
666,666MPa
1,5

Distance between axes at predimensioning

Width coefficientsa, d
a 0,3
d = u 1 a 5 1 0,3 0,9
2

Distance between the axes from the strength

condition at contact
T1 k A kV k H k H
a wH (u 1)3
(Z E Z H Z Z ) 2
2
2a u HP
(5 1)3

114401,0429 1,35 1,10 1,5 1,4870

(189,8 2,4527 0,8451 0,985) 2
2 0,3 5 12752

136,086mm

Distance between axis from the strength condition at

bending
a wF 3

Y Y
T1 z1 (u 1) 2
k a k v k F k F Y Y Fa Sa
2 a cos
FP

114401,0429 165 1

1,35 1,1 1,50 1,4870 0,7543 0,8833 0,0141

2 0,3 cos14
2

152,1478mm
YFa YSa

FP

Y Y
Y Y
max( Fa1 Sa1 , Fa 2 Sa 2 ) 0,0141

FP1

FP 2

Defining the distance between the axis at

predimensioning aw
aw= max (awH,awF) = max (136,086;152,1478) =
152,1478 mm
We use from STAS 6055 the following a w = 160 mm
The preliminary width of the gears
b2 a aW 0,3 160 48 mm
b1 b2 b 48 2 50 mm
b 1...3; b 2

3. Dimensioning (including geometrical) calculus, using computer software

INPUTS
Table 3.1
PARAMETER
Inputs
Power
Lifetime
Functioning factor
Type of engine
Type of load
Rotation at pinion
Center distance
Helical angle
Width factor

Symbol

Value

15
10500

P , kW
Lh , ore

1,35

KA
Electric asynchronous
Pulsating
n1 , rot / min
a w , mm
, grade
a

1252,1739
140
14
0,3

Teeth number of pinion

Teeth number of wheel
Materials
Steel
Type
Superficial hardness
Inside hardness
Recomanded limit contact stress
Limit contact stress

HRC
HB
MPa
H lim 1, 2 , MPa

1500

Recomanded limit bending stress

Limit bending stress

MPa
F lim 1, 2 ,MPa

500

Machining information
Profile roughness
Root roughness
Functioning conditions
Minimal safety coeficients
For contact stress
For bending stress

16
80

z1
z2
Cemented steel
17MnCr10

60
300

0,80
Ra , m

1,60

S H m in
S F m in

1
1,5

DIMENSIONING CALCULATION - RESULTS

Table 3.2
Gear

Parameter

Pinion
Wheel
GEAR PARAMETERS
a w 160 mm
a 158,71450 mm
mn 3,60715 mm
14
b 13,14006

Center distance
Reference center distance
Normal module
Helix angle
Helix angle on base circle
Frontal pressure angle
Gearing angle

Frontal
Normal

t 20 ,56171
wt 21,48788
wn 20 ,89850

Total addendum correction coefficient,

in normal plane
Contact degree

x sn 0,29533

Helical

1,40
1,08

Total

2,51

Frontal

v 3,04 m / s
8
50 180 cSt

Speed on pitch circle

Precission
Lubricant viscosity
Rougness

Ra 0,8 m

Active profile

Ra 1,6 m
PINION AND WHEEL PARAMETERS
d a1 55 ,0399 mm
d a 2 236 ,9223 mm

Fillet (root)
Addendum diameters
Dedendum diameters

d f 1 41,5776 mm

d f 2 223 ,4600 mm

Pitch diameters
Rolling circle diameters

d1 46 ,3776 mm
d w1 54 ,5454 mm

d 2 231,8880 mm
d w2 265 ,4545 mm

Base circle diameters

d b1 43,4231 mm

d b 2 217 ,1155 mm

Numbers of teeth
Width
Normal addendum correction coefficient

z1 16 dini
b1 38,7mm
x n1 0,45

z 2 80 dini
b2 36 ,7mm

Frontal addendum correction coefficient

xt1 0,4366

xt 2 0,15008

Minimum normal addendum correction

coefficient

x n m in1 0,041

x n m in 2 3,795

x n 2 0,1546

10

Teeth width on the addendum circle, on

normal plane

s an1 1,35 mm

s an 2 2,46 mm

Minimum teeth width on the addendum

circle, on the normal plane

s an m in1 1,20 mm

s an m in 2 1,20 mm

Teeth number

EQUIVALENT GEAR PARAMENTERS

z n1 16 ,30

z n1 81,50

Addendum diameters

d n1 48,9050 mm

d n 2 244 ,5251 mm

Dedendum diameters

d bn1 45,9556 mm

d bn 2 229 ,7784 mm

Pitch diameters

d an1 57 ,5673 mm

d an 2 249 ,5594 mm

Center distance

a wn 147 ,5754 mm

Contact degree

n 1,51

Functioning factor
Dynamic factor

CALCULUS FACTORS
K A 1,35
K v 1,10

Teeth width stress repartition factor

K H 1,49

K F 1,49

Frontal stress repartiton factor

K H 1,31

Gear material elasticity factor

Contact degree factor
Helix angle factor
Teeth form factor

Z E 189 ,80
Z H 2,45
Z 1,02
-

K F 1,31

Y 0,88

YFa1 3,00

YFa 2 2,23

Bending stress correction factor

Lubrication factor
Speed factor

Z L 1,04
Z v 0,97

Roughness factor
Sensibility relative factor

Z R 0,97
-

Durability factor
Minimum safety coeficients

Limit stress

Z N 1 1,02

YSa1 1,58
YSa 2 1,87
-

YR 1,00
Y 1 0,994
Y 2 1,003
YN 1 1,00

Z N 2 1,15

YN 2 1,00

S H m in 1,00

S F m in 1,50

STRESS AND MATERIALS

H lim 1, 2 1250 MPa

11

 F lim 1, 2 450 MPa

Permissible stress
Actual stress
Width coefficient

HP 1 1248 ,4MPa

HP 2 1372 ,4 MPa

FP 1 602 ,3MPa

FP 2 600 ,5MPa

H 1 1229 ,9 MPa

H 2 1229 ,9MPa

F 1 312 ,1MPa

F 2 325 ,3MPa

Preliminary
Final

a 0,30
a rec 0,23

4. Gear forces calculus

4.1. CALCULUS OF FORCES
Tangential force Ft
Ft1

2T1 2 114401,0429

4194,7091N
d w1
54,54

Ft1 Ft 2 4194,709N

Radial force Fr
F
4194,709
Fr1 t1 tg wn
tg 20,8985 1650,710N
cos
cos14
Fr 2 Fr1 1650,710N
Axial force Fa
Fa1 Ft1 tg 4194,7091 tg14 1045,8584N
Fa1 Fa 2 1045,8584N

4.2. ESTABLISHING THE DIRECTION OF FORCES

12

5. Shaft calculus
5.1. PREDIMENSIONING CALCULUS

at1 15 for input shaft

at 2 30 for output shaft
dI 3

16 TI 3 16 114401,0416

33,8664mm
atI
15

d II 3

16 TII 3 16 572005,208

45,9638mm
atII
30

5.2. CHOOSING THE BEARING MOUNTINGS FOR INPUT AND

OUTPUT SHAFTS

Input
Shaft
Output
Shaft

Symbol

d[mm]

D[mm] B[mm] Cr[kN] Cor[kN]

6207

35

80

21

61

48

6209

45

90

25

93

78

13

5.3. CHECKING THE INPUT SHAFT FOR COMPOSITE STRESS

Horizontal plane
[H]
Fa1
Fr1

RAH

RBH

M B 0
R AH (l1 l2 ) Fr1l2 Fa1
R AH

d w1
0
2

d w1
54,5454
1650,710 83 1045,8584
2
2
997,182N
(l1 l2 )
83 83

Fr1 l2 Fa1

RBH Fr1 R AH 1650,710 997,182 653,528N

Vertical plane
[V]

Ft1

RAV

RBV

l1

M B 0
R AV (l1 l 2 ) Ft1 l 2 0
R AV

Ft1 l 2 4194,7091 83

2097,3545N
l1 l 2
83 83

R BV Ft1 R AV 4194,7091 2097,3545 2097,3546N

14

Determining the reactions in the 2 bearings

B

l1

Mih
Miv
Mt
T

M iV max R AV l1 2097,354 83 174080,382Nmm

M iH max R AH l1 997,182 83 82766,106Nmm

- Torsion
16 T1 16 114401 ,0416
1

14 ,8239 MPa
d 13
(34 ) 3
- Bending
32 M iH M iV
2

d13

32 (82766 ,106 ) 2 (174080 ,382 ) 2

(34 ) 3

49 ,9536 MPa

6. Design of the key assemle between the wheel and the output shaft

15

We choose from STAS 1004-81: b=18; h=11

4Tm
4 99479 ,1666
lc

6,029
d h as
60 11 100
as 65 ... 100 MPa
To fix the wheel on the output shaft we choose the parallel type
18X11X25STAS 1004 81.
l = lc + b = 6,029 + 18 = 24,029mm
l = 25 mm STAS 1004-81

7. Checking of the bearing mountings of the input shaft

FA

Co

X=1
Y=0
FA

FR

FA1
R AH R AV
2

FA
e P FR
FR

FA
e P X FR Y FA
FR
Cnec P L C
60 n I Lh
L
mil rot
10 6
p

16