KISSsoft Release

03/2014

XBS 4.17 Arsynx Turbosystemz

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:
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Composting i4.5 p18g81a600
Gajanan Avantkar
on: 13.12.2016

at: 00:03:32

CALCULATION OF A CYLINDRICAL SPUR GEAR PAIR

Drawing or article number:
Gear 1:
0.000.0
Gear 2:
0.000.0
Calculation method

DIN 3990:1987 Method B

------- GEAR 1 -------- GEAR 2 --

Power (kW)
Speed (1/min)
Torque (Nm)
Application factor
Required service life
Gear driving (+) / driven (-)

[P]
[n]
[T]
[KA]
[H]

32.987
9.5
33333.3

2.1
150000.0
1.50
40000.00
-

1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to
DIN 3960:1987)
------- GEAR 1 -------- GEAR 2 -Center distance (mm)
[a]
600.000
Centre distance tolerance ISO 286:2010 Measure h7
Normal module (mm)
[mn]
12.0000
Pressure angle at normal section ()
[alfn]
20.0000
Helix angle at reference circle ()
[beta]
0.0000
Number of teeth
[z]
18
81
Facewidth (mm)
[b]
250.00
240.00
Hand of gear
Spur gear
Accuracy grade
[Q-DIN 3961:1978]
6
8
Inner diameter (mm)
[di]
0.00
0.00
Inner diameter of gear rim (mm)
[dbi]
0.00
0.00
Material
Gear 1:

18CrNiMo7-6, Case-carburized steel, case-hardened

ISO 6336-5 Figure 9/10 (MQ), core strength >=30HRC
Gear 2:
34 CrNiMo 6 (1), Through hardened steel, alloyed, through hardened
ISO 6336-5 Figure 5/6 (MQ)
------- GEAR 1 -------- GEAR 2 -Surface hardness
HRC 61
HBW 240
Fatigue strength. tooth root stress (N/mm)
[sigFlim]
500.00
290.00
Fatigue strength for Hertzian pressure (N/mm)
[sigHlim]
1500.00
700.00
Tensile strength (N/mm)
[Rm]
1200.00
1200.00
Yield point (N/mm)
[Rp]
850.00
1000.00
Young's modulus (N/mm)
[E]
206000
206000
Poisson's ratio
[ny]
0.300
0.300
Mean roughness, Ra, tooth flank (m)
[RAH]
0.60
1.05
Mean roughness height, Rz, flank (m)
[RZH]
4.80
8.00
Mean roughness height, Rz, root (m)
[RZF]
20.00
20.00

1/8

Gear reference profile1 :

Reference profile
1.40 / 0.39 / 1.0 ISO 53.2:1997 Profil D
Dedendum coefficient
[hfP*]
Root radius factor
[rhofP*]
Addendum coefficient
[haP*]
Tip radius factor
[rhoaP*]
Protuberance height factor
[hprP*]
Protuberance angle
[alfprP]
Tip form height coefficient
[hFaP*]
Ramp angle
[alfKP]
not topping
Gear reference profile2 :
Reference profile
1.40 / 0.39 / 1.0 ISO 53.2:1997 Profil D
Dedendum coefficient
[hfP*]
Root radius factor
[rhofP*]
Addendum coefficient
[haP*]
Tip radius factor
[rhoaP*]
Protuberance height factor
[hprP*]
Protuberance angle
[alfprP]
Tip form height coefficient
[hFaP*]
Ramp angle
[alfKP]
not topping

1.400
0.390
1.000
0.000
0.000
0.000
0.000
0.000

1.400
0.390
1.000
0.000
0.000
0.000
0.000
0.000

Summary of reference profile gears:

Dedendum reference profile
Tooth root radius Reference profile
Addendum Reference profile
Protuberance height factor
Protuberance angle ()
Tip form height coefficient
Ramp angle ()

[hfP*]
[rofP*]
[haP*]
[hprP*]
[alfprP]
[hFaP*]
[alfKP]

1.400
0.390
1.000
0.000
0.000
0.000
0.000

1.400
0.390
1.000
0.000
0.000
0.000
0.000

Type of profile modification:

none (only running-in)
Tip relief (m)

[Ca]

2.0

8.5

Lubrication type
Type of grease
Lubricant base
Kinem. viscosity
base oil at
Kinem. viscosity
base oil at
FZG-Test A/8.3/90
Specific density at 15 C (kg/dm)
Grease temperature (C)

Grease lubrication
Grease: Arcanol TEMP90
Mineral-oil base
40 C (mm/s)
[nu40]
100 C (mm/s) [nu100]
step
[FZGtestA]
[roOil]
0.900
[TS]
70.000

130.00
15.50
0

------- GEAR 1 -------- GEAR 2 -[itot]

-4.500
[u]
4.500
[mt]
12.000
[alft]
20.000
[alfwt]
21.519
[alfwt.e/i]
21.519 / 21.502
Working pressure angle at normal section ()
[alfwn]
21.519
Helix angle at operating pitch circle ()
[betaw]
0.000
Base helix angle ()
[betab]
0.000
Reference centre distance (mm)
[ad]
594.000

Overall transmission ratio

Gear ratio
Transverse module (mm)
Pressure angle at pitch circle ()
Working transverse pressure angle ()

2/8

Sum of profile shift coefficients

Profile shift coefficient
Tooth thickness (Arc) (module) (module)

[Summexi]
[x]
[sn*]

0.5184
0.4450
1.8948

0.0734
1.6242

Tip alteration (mm)

[k*mn]
-0.221
-0.221
Reference diameter (mm)
[d]
216.000
972.000
Base diameter (mm)
[db]
202.974
913.381
Tip diameter (mm)
[da]
250.239
997.319
(mm)
[da.e/i]
250.239 / 250.139
997.319 / 997.219
Tip diameter allowances (mm)
[Ada.e/i]
0.000 / -0.100
0.000 / -0.100
Tip form diameter (mm)
[dFa]
250.239
997.319
(mm)
[dFa.e/i]
250.239 / 250.139
997.319 / 997.219
Active tip diameter (mm)
[dNa]
250.239
997.319
Active tip diameter (mm)
[dNa.e/i]
250.239 / 250.139
997.319 / 997.219
Operating pitch diameter (mm)
[dw]
218.182
981.818
(mm)
[dw.e/i]
218.182 / 218.156
981.818 / 981.704
Root diameter (mm)
[df]
193.081
940.161
Generating Profile shift coefficient
[xE.e/i]
0.4256/ 0.4164
0.0379/ 0.0230
Manufactured root diameter with xE (mm) [df.e/i]
192.614 / 192.394
939.310 / 938.952
Theoretical tip clearance (mm)
[c]
4.800
4.800
Effective tip clearance (mm)
[c.e/i]
5.454 /
5.156
5.193 /
4.963
Active root diameter (mm)
[dNf]
206.819
959.474
(mm)
[dNf.e/i]
206.867 / 206.746
959.527 / 959.358
Root form diameter (mm)
[dFf]
204.492
948.946
(mm)
[dFf.e/i]
204.330 / 204.257
948.274 / 947.994
Reserve (dNf-dFf)/2 (mm)
[cF.e/i]
1.305 /
1.208
5.766 /
5.542
Addendum (mm)
[ha=mn*(haP*+x)]
17.119
12.660
(mm)
[ha.e/i]
17.119 / 17.069
12.660 / 12.610
Dedendum (mm)
[hf=mn*(hfP*-x)]
11.460
15.919
(mm)
[hf.e/i]
11.693 / 11.803
16.345 / 16.524
Roll angle at dFa ()
[xsi_dFa.e/i] 41.315 / 41.266
25.122 / 25.106
Roll angle to dNa ()
[xsi_dNa.e/i] 41.315 / 41.266
25.122 / 25.106
Roll angle to dNf ()
[xsi_dNf.e/i] 11.276 / 11.098
18.441 / 18.407
Roll angle at dFf ()
[xsi_dFf.e/i]
6.636 /
6.454
15.988 / 15.922
Tooth height (mm)
[H]
28.579
28.579
Virtual gear
no. of teeth
[zn]
18.000
81.000
Normal tooth thickness at tip cylinder (mm)
[san]
5.961
9.687
(mm)
[san.e/i]
5.834 /
5.672
9.412 /
9.236
Normal spacewidth at root cylinder (mm) [efn]
0.000
7.992
(mm)
[efn.e/i]
0.000 /
0.000
8.078 /
8.116
Max. sliding velocity at tip (m/s)
[vga]
0.040
0.024
Specific sliding at the tip
[zetaa]
0.554
0.554
Specific sliding at the root
[zetaf]
-1.242
-1.242
Mean specific sliding
[zetam]
0.554
Sliding factor on tip
[Kga]
0.372
0.226
Sliding factor on root
[Kgf]
-0.226
-0.372
Pitch on reference circle (mm)
[pt]
37.699
Base pitch (mm)
[pbt]
35.426
Transverse pitch on contact-path (mm)
[pet]
35.426
Length of path of contact (mm)
[ga, e/i]
53.331 ( 53.522 / 53.121)
Length T1-A, T2-A (mm)
[T1A, T2A] 19.849( 19.658/
19.973) 200.238( 200.238/
Length T1-B (mm)
[T1B, T2B] 37.754( 37.754/
37.669) 182.332( 182.141/
Length T1-C (mm)
[T1C, T2C] 40.016( 39.981/
40.016) 180.071( 179.914/
Length T1-D (mm)
[T1D, T2D] 55.274( 55.083/
55.399) 164.812( 164.812/
Length T1-E (mm)
[T1E, T2E] 73.180( 73.180/
73.094) 146.906( 146.715/
Length T1-T2 (mm)
[T1T2]
220.086 ( 219.895 / 220.086)
Diameter of single contact point B (mm) [d-B]
216.564( 216.564/ 216.504) 983.486(
983.345/
983.550)

3/8

200.113)
182.417)
180.071)
164.687)
146.992)

Diameter of single contact point D (mm)

970.955)
Addendum contact ratio
0.566)

[d-D]

Minimal length of contact line (mm)

[Lmin]

Transverse contact ratio

Transverse contact ratio with allowances
Overlap ratio
Total contact ratio
Total contact ratio with allowances

[eps_a]
[eps_a.e/m/i]
[eps_b]
[eps_g]
[eps_g.e/m/i]

[eps]

231.126( 230.944/ 231.245) 971.039(

0.936(

0.937/

0.934)

0.569(

240.000
1.505
1.511 /1.505 /1.500
0.000
1.505
1.511 /1.505 /1.500

2. FACTORS OF GENERAL INFLUENCE

------- GEAR 1 -------- GEAR 2 -Nominal circum. force at pitch circle (N)
[Ft]
308642.0
Axial force (N)
[Fa]
0.0
Radial force (N)
[Fr]
112336.5
Normal force (N)
[Fnorm]
328449.9
Tangent.load at p.c.d.per mm (N/mm) (N/mm)
[w]
1286.01
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N)
[Ftw]
305555.6
Axial force (N)
[Faw]
0.0
Radial force (N)
[Frw]
120478.9
Circumferential speed reference circle (m/s)
[v]
0.11
Circumferential speed operating pitch circle (m/s)
[v(dw)]
0.11
Running-in value (m)
[yp]
4.3
Running-in value (m)
[yf]
5.3
Correction coefficient
[CM]
0.800
Gear body coefficient
[CR]
1.000
Reference profile coefficient
[CBS]
0.900
Material coefficient
[E/Est]
1.000
Singular tooth stiffness (N/mm/m)
[c']
13.323
Meshing stiffness (N/mm/m)
[cg]
18.373
Reduced mass (kg/mm)
[mRed]
0.17070
Resonance speed (min-1)
[nE1]
5504
Resonance ratio (-)
[N]
0.002
Subcritical range
Running-in value (m)
[ya]
4.3
Bearing distance l of pinion shaft (mm) [l]
500.000
Distance s
of pinion shaft (mm)
[s]
50.000
Outside diameter of pinion shaft (mm)
[dsh]
172.800
Load according to Figure 6.8,
DIN 3990-1:1987
[-]
(0:6.8a, 1:6.8b, 2:6.8c, 3:6.8d, 4:6.8e)
Coefficient K' according to Figure 6.8,
DIN 3990-1:1987
[K']
-0.60
With support effect
Tooth trace deviation (active) (m)
[Fby]
7.66
from deformation of shaft (m)
[fsh*B1]
10.55
(fsh (m) =21.10, fHb5 (m) = 8.00)
Tooth trace: width-crowned
[Cbeta = 0.5*(fma+fsh)]
Position of Contact pattern: optimal
from production tolerances (m)
[fma*B2]
11.00
Tooth trace deviation, theoretical (m) [Fbx]
11.00
Running-in value (m)
[yb]
3.34

4/8

971.039/
0.574/

Dynamic factor

[KV]

1.001

Face load factor - Tooth root

- Scuffing

flank
[KFb]
[KBb]

[KHb]
1.044
1.050

Transverse load factor - flank

- Tooth root
- Scuffing

[KHa]
[KFa]
[KBa]

1.000
1.000
1.000

Helical load factor scuffing

[Kbg]

1.000

Number of load cycles (in mio.)

[NL]

22.680

1.050

5.040

3. TOOTH ROOT STRENGTH

Calculation of Tooth form coefficients according method: B
(Calculate tooth shape coefficient YF with addendum mod. x)
------- GEAR 1 -------- GEAR 2 -Tooth form factor
[YF]
1.39
1.51
Stress correction factor
[YS]
2.03
1.97
Working angle ()
[alfFen]
24.32
20.87
Bending lever arm (mm)
[hF]
13.70
16.40
Tooth thickness at root (mm)
[sFn]
26.22
27.92
Tooth root radius (mm)
[roF]
5.82
6.05
(hF* =1.142/
1.366sFn* =2.185/
2.326 roF* =
0.485/ 0.504 dsFn =197.084/ 945.148 alfsFn =
30.00/30.00)
Contact ratio factor
Helical load factor
Effective facewidth (mm)
Nominal stress at tooth root (N/mm)
Tooth root stress (N/mm)

[Yeps]
[Ybet]
[beff]
[sigF0]
[sigF]

1.000
1.000
250.00
290.56
455.24

Permissible bending stress at root of Test-gear

Support factor
[YdrelT]
0.998
Surface factor
[YRrelT]
0.957
size factor (Tooth root)
[YX]
0.930
Finite life factor
[YNT]
1.000
[YdrelT*YRrelT*YX*YNT]
0.888
Alternating bending coefficient
[YM]
1.000
Stress correction factor
[Yst]
2.00
Yst*sigFlim (N/mm)
[sigFE]
1000.00
Permissible tooth root stress (N/mm) [sigFP=sigFG/SFmin]
634.03
Limit strength tooth root (N/mm)
[sigFG]
887.65
Required safety
[SFmin]
1.40
Safety for Tooth root stress
[SF=sigFG/sigF]
1.95
Transmittable power (kW)
[kWRating]
45.94

240.00
318.07
498.35

0.999
0.957
0.958
1.000
0.915
1.000
580.00
379.23
530.92
1.40
1.07
25.10

4. SAFETY AGAINST PITTING (TOOTH FLANK)

Zone factor
Elasticity coefficient (N^.5/mm)

5/8

[ZH]
[ZE]

------- GEAR 1 -------- GEAR 2 -2.397

189.812

Contact ratio factor

[Zeps]
Helix angle factor
[Zbet]
Effective facewidth (mm)
[beff]
Nominal flank pressure (N/mm)
[sigH0]
Surface pressure at operating pitch circle (N/mm)
[sigHw]
Single tooth contact factor
[ZB,ZD]
Flank pressure (N/mm)
[sigHB, sigHD]

0.912
1.000
240.00
1119.05
1404.81
1.02
1.00
1437.27
1404.81

Lubrication coefficient at NL
Speed coefficient at NL
Roughness coefficient at NL
Material pairing coefficient at NL
Finite life factor

[ZL]
0.971
[ZV]
0.883
[ZR]
0.979
[ZW]
1.000
[ZNT]
1.062
[ZL*ZV*ZR*ZNT]
0.891
Small amount of pitting permissible (0=no, 1=yes)
0
Size factor (flank)
[ZX]
0.991
Permissible surface pressure (N/mm) [sigHP=sigHG/SHmin]
1325.25
Limit strength pitting (N/mm)
[sigHG]
1325.25
Required safety
[SHmin]
1.00
Safety for surface pressure at operating pitch circle
[SHw]
0.94
Safety for stress at single tooth contact[SHBD=sigHG/sigHBD]
(Safety regarding nominal torque)
[(SHBD)^2]
0.85
Transmittable power (kW)
[kWRating]
28.05

0.979
0.914
0.985
1.135
1.190
1.048
0
1.000
833.08
833.08
1.00
0.59
0.92
0.35
11.60

0.59

6. MEASUREMENTS FOR TOOTH THICKNESS

------- GEAR 1 -------- GEAR 2 -Tooth thickness deviation
DIN 3967 b26
DIN 3967 b26
Tooth thickness allowance (normal section) (mm)
[As.e/i] -0.170 / -0.250 -0.310 /
Number of teeth spanned
Base tangent length (no backlash) (mm)
Actual base tangent length ('span') (mm)
Diameter of contact point (mm)

[k]
[Wk]
[Wk.e/i]
[dMWk.m]

3.000
95.242
95.082 /95.007
224.125

-0.440

10.000
350.759
350.467 /350.345
978.289

Theoretical diameter of ball/pin (mm)

[DM]
23.966
20.285
Eff. Diameter of ball/pin (mm)
[DMeff]
25.000
22.000
Theor. dim. centre to ball (mm)
[MrK]
132.636
503.805
Actual dimension centre to ball (mm)
[MrK.e/i]
132.487 /132.416 503.416 /503.253
Diameter of contact point (mm)
[dMMr.m]
227.561
976.664
Diametral measurement over two balls without clearance (mm)
[MdK]
265.272
1007.424
Actual dimension over balls (mm)
[MdK.e/i]
264.973 /264.832 1006.647 /1006.320
Diametral measurement over rolls without clearance (mm)
[MdR]
265.272
1007.424
Actual dimension over rolls (mm)
[MdR.e/i]
264.973 /264.832 1006.647 /1006.320
Dimensions over 3 rolls without clearance (mm)
[Md3R]
0.000
1007.239
Actual dimensions over 3 rolls (mm)
[Md3R.e/i]
0.000 /0.000 1006.462 /1006.135

6/8

Chordal tooth thickness (no backlash) (mm)

Actual chordal tooth thickness (mm)
['sn.e/i]
Reference chordal height from da.m (mm) [ha]
Tooth thickness (Arc) (mm)
[sn]
(mm)
[sn.e/i]

['sn]
22.525 /22.445
17.693
22.737
22.567 /22.487

22.695
19.179 /19.049
12.732
19.491
19.181 /19.051

19.489

Backlash free center distance (mm)

[aControl.e/i]
599.383 /599.112
Backlash free center distance, allowances (mm)
[jta]
-0.617 /
-0.888
dNf.i with aControl (mm)
[dNf0.i]
205.941
957.996
Reserve (dNf0.i-dFf.e)/2 (mm)
[cF0.i]
0.805
4.861
Centre distance allowances (mm)
[Aa.e/i]
0.000 /-0.070
Circumferential backlash from Aa (mm)
[jtw_Aa.e/i]
0.000 /-0.055
Radial clearance (mm)
[jrw]
0.888 /0.547
Circumferential backlash (transverse section) (mm)
[jtw]
0.697 /0.430
Torsional angle for fixed
gear 1 () 0.0822 / 0.0507
Normal backlash (mm)
[jnw]
0.655 /0.404

7/8