Spur gearing, gearing [mm/ISO] Spur gearing, HelicalHelical gearing [mm/ISO] i ii Check lines:10.

0; Project information Date 06/06/2012 Pinion Gear Project No. 111-111

Author John Doe File name Gear1_02.xls Project Name Spur Gear Basic Info

Spur gearing: Beta=0; mn=2.75; b1=35; b2=34; z1=18; z2=45; n1=9000; n2=3600; i=2.5; P=51.76 [kW] Project Notes Comments

? 1.0 Options of basic input parameters 1.1 Transferred power 1.2 Speed (Pinion / Gear) 1.3 Torsional moment (Pinion / Gear) 1.4 Transmission ratio / from table 1.5 Actual transmission ratio / deviation 2.0 2.0 Material identification according standard : 2.1 Material of the pinion : 2.2 Material of the gear : 2.3 Loading of the gearbox, driving machine - examples 2.4 Loading of gearbox, driven machine - examples 2.5 Type of gearing mounting 2.6 Accuracy grade - ISO1328 |Ra max|v max 2.7 Coefficient of one-off overloading 2.8 Desired service life 2.9 Coefficient of safety (contact/bend) 2.10 Automatic design 3.0

Input section Pw [kW] n [/min] Mk [Nm] i i

ANSI F...Alloy structural steel Gr. 4340 (A322-82) (Rm=965 MPa) face hardened F...Alloy structural steel Gr. 4340 (A322-82) (Rm=965 MPa) face hardened A...Continuous A...Continuous Double-sided symmetrically supported gearing - type 1 4....(Ra max.= 0.4 / v max.= 60)

51.764 9000.0 54.93 2.50 2.50

51.403 3600.0 136.36 0.00% [/min] [Nm]

Options of material, loading conditions, operational and production parameters

KAS Lh SH / SF 1.30

2.00 1250 1.60 [h]

Parameters of the cutting tool and tooth profile

1. DIN 867 (a=20deg, ha0=1.25, hf0=1.0, ra0=0.38, d0=0, anp=0deg, ca=0.25)

3.1 Standardized tool 3.2 Addendum of tool 3.3 Dedendum of tool 3.4 Fillet radius of tool 3.5 Root fillet radius of tool 3.6 Chamfer of root 3.7 Chamfer of root 3.8 Protuberance hight 3.9 Protuberance angle 3.10 Min. unit head clearance 3.11 Unit head clearance
4.00 3.00 2.00 1.00 0.00 -6.00 -4.00 -2.00 -1.00 -2.00 -3.00 -4.00 0.00 2.00

ha0* hf0* ra0* rf0* cha* chb*

1.250 1.000 0.380 0.000 0.000 0.000 0.000 0.000 0.2500 0.2500

1.250 1.000 0.380 0.000 0.000 0.000 0.000 0.000 0.2500 0.2500

[modul] [modul] [modul] [modul] [modul] [modul] [modul] [] [modul] [modul]

d0* anp
ca*min ca*

4.00

6.00

-4.00

4.0

Design of a module and geometry of toothing

4.1 Number of teeth Pinion / Gear 4.2 Normal pressure angle 4.3 Base helix angle 4.4 Setting of the ratio of the width of the pinion to its diameter 4.5 The ratio of the pinion width to its diameter 4.6 Module / Standardized value 4.7 Reference diameter Pinion / Gear 4.8 Recommended width of gearing 4.9 Face width (Pinion / Gear) 4.10 Working face width 4.11 The ratio of the pinion width to its diameter 4.12 Working center distance 4.13 Approximate weight of the gearing 4.14 Minimum coefficient of safety

18 20 0 0.7 2.75 49.50 35.00 34 0.71 86.625 3.698 1.30

45 [] [] < 1.1 [mm] 123.75 34.00 < 1.1 [mm] [kg] 3.08 [mm] [mm] [mm] [mm]

a
b

y d / max
mn d1/d2 b1/b2 bw

29.2 - 54.5

y d / max
aw m SH / SF
80 60 40 20 0 -50 -20 0 -40 -60 -80

50

100

150

200

250

4.15 Normal backlash 4.16 - Recommended min. | max. value 4.17 - Selected normal backlash 5.0 Correction of toothing (Addendum modification) -0.222 -0.056 0.259 x Sx 0.0000 0.0000 1.6328 0.6817 -6.9524 0.5924 9.8725 1.30 3.08 1.50 3.36 0
6.0 5.0 4.0 3.0 2.0 1.0 0.0

0.056 jn 0.0000

0.223

[mm] [mm]

5.1 Types 5.2 - Permissible undercutting of teeth (min. value) 5.3 - Preventing undercutting of teeth (min. value) 5.4 - Prevents tapering of teeth (min. value) 5.5 Pinion addendum modification coefficient setting 5.6 Addendum modification coefficient Pinion / Gear 5.7 Sum of addendum modification coefficients | min. value 5.8 Transverse / Total contact ratio 5.9 Unit tooth thickness on the tip diameter 5.10 Specific sliding on tooth root 5.11 Specific sliding on tooth tip 5.12 Sum of all specific slidings 5.13 Safety coefficient for surface durability 5.14 Safety coefficient for bending durability 5.15 Display of tooth and tool turn for:
0 -1 -2 -3 -4 -5 -6 -7 7 6 5 4 3 2 1 0 Gear

-0.689 -0.622 -1.488 0.0000 > -1.29 1.6328 0.7688 -1.4535 0.8743

S= S= S=

-0.911 -0.678 -1.230 [modul] [modul]

ea/eg
sa*

JA1/JE2 JE1/JA2 Sum|J|

SH SF

[]

0.0 8 6 4 2 0 -2 -4 -6 -8 -2.0 -1.0 -2.0 -3.0 -4.0 -5.0 0.0 2.0 4.0 6.0 8.0 10.0

Results section 6.0 Basic dimensions of gearing

6.1 Number of teeth Pinion / Gear 6.2 Face width (Pinion / Gear) 6.3 Normal module 6.4 Transverse module 6.5 Circular pitch 6.6 Transverse circular pitch 6.7 Base circular pitch 6.8 Center distance (pitch) 6.9 Center distance (production) 6.10 Center distance (working) 6.11 Pressure angle 6.12 Transverse pressure angle 6.13 Pressure angle at the pitch cylinder 6.14 Transverse pressure angle at the pitch cylinder 6.15 Helix angle 6.16 Base helix angle 6.17 Tip diameter 6.18 Reference diameter 6.19 Base diameter 6.20 Root diameter 6.21 Operating pitch diameter 6.22 Addendum 6.23 Dedendum 6.24 Tooth thickness on the tip diameter 6.25 Tooth thickness on the tip diameter 6.26 Tooth thickness on the pitch diameter 6.27 Tooth thickness on the pitch diameter 6.28 Tooth thickness on the root diameter 6.29 Unit tooth thickness on the tip diameter 6.30 Unit correction 6.31 Total unit correction 6.32 Addendum modification coefficient 7.0 Supplemental parameters of gearing 7.1 Number of teeth 7.2 Virtual number of teeth of a helical gear Minimum number of teeth: 7.3 7.4 7.5 8.0 - Permissible undercutting - Without undercutting - Without tapering Qualitative indices of gearing

z b mn mt p pt ptb a av aw

18 35 2.75 2.7500 8.639 8.639 8.118 86.6250 86.6250 86.6250 20.00 20.0000 20.0000 20.0000 0.00 0.0000 55.0000 49.5000 46.5148 42.6250 49.5000 2.7500 3.4375 1.8746 1.8746 4.3197 4.3197 4.3550 0.6817 0.0000 0.0000 0.0000 18 18.000 14 17 22

45 34 [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [] [] [] [] [] [] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [modul] [modul] [modul] 0.0000 45 45.000 14 17 22 [modul] 129.2500 123.7500 116.2870 116.8750 123.7500 2.7500 3.4375 2.1142 2.1142 4.3197 4.3197 5.8217 0.7688

a at awn awt
b bb da d db df dw ha hf sna sta sn st sb sa* dY x1+x2 x z zn zmin1 zmin2 zmin3

8.1 Transverse contact ratio / overlap ratio 8.2 Total contact ratio 8.3 Coefficient of gear unloading 8.4 Resonance speed 8.5 Resonance ratio 8.6 Approximate weight of the gearing 8.7 Efficiency of the gearing 8.8 Recomended lubricant viscosity 9.0 Coefficients for safety calculation Common for the gearing 9.1 Stiffness of a tooth pair 9.2 Meshing stiffness per unit face width 9.4 Application factor 9.5 Dynamic factor 9.6 Number of cycles For pitting safety calculation 9.7 Face load factor (contact stress) 9.8 Transverse load factor (contact stress) 9.9 Total factor of additional loads 9.10 Elasticity factor 9.11 Zone factor 9.12 Helix angle factor 9.13 Contact ratio factor 9.14 Work hardening factor 9.15 Lubricant factor 9.16 Peripheral speed factor 9.17 Roughness factor affecting surface durability 9.18 Life factor for contact stress 9.19 Single pair tooth contact factor For bending safety calculation 9.20 Face load factor (root stress) 9.21 Transverse load factor (root stress) 9.22 Total factor of additional loads 9.23 Helix angle factor 9.24 Contact ratio factor 9.25 Notch sensitivity factor 9.26 Size factor 9.27 Tooth-root surface factor 9.28 Alternating load factor 9.29 Production technology factor 9.30 Life factor for bending stress 9.31 Form factor (bending) 9.32 Stress correction factor 9.33 Tip factor, equal (YFa YSa) 10.0 Safety coefficients 10.1 Safety coefficient for surface durability 10.2 Safety coefficient for bending durability 10.3 Safety in contact in one-time overloading 10.4 Safety in bending in one-time overloading 10.5 Variability coefficient for calculation of probability of a failure 10.6 Probability of a failure 10.7 Nominal contact stress 10.8 Contact stress 10.9 Pitting stress limit 10.10 Permissible contact stress 10.11 Nominal tooth-root stress 10.12 Tooth-root stress 10.13 Tooth-root stress limit 10.14 Permissible bending stress

ea | eb eg
Cdi/df nE1 N m m v50

1.6328 1.6328 0.00

0.0000 0.00

25938.02 0.35 3.6982 99.30% 74 74

[ /min] [kg] [mm2/sec]

c'

11.673 17.213 1.000 1.227 6.75E+08 2.70E+08

cg
KA KV NK KHb KHa KH ZE ZH Zbeta Zeps ZW ZL ZV ZR ZN ZB/ZD KFb KFa KF Ybeta Yeps Ydelta YX YR YA YT YN YFa YSa YFS SH SF SHst SFst vH/vF P SigmaH0 SigmaH SigmaHG SigmaHP SigmaF0 SigmaF SigmaFG SigmaFP 778.44 0.850 3.139 1.505 4.723 1.30 3.08 2.18 4.65 0.08 0.989 1.000 0.987 0.977 1.028 1.020 0.850 1.088

1.007 1.267 1.567 189.81 2.495 1.000 0.888 1.000 0.977 1.028 1.020 0.905 1.000 1.007 1.987 2.455 1.000 0.709 0.995 1.000 0.987 1.000 1.000 0.850 2.568 1.650 4.238 1.50 3.36 2.37 5.03 0.1 1.51 571.48 715.31 1075.94 827.65 71.35 175.16 588.11 367.57 1010.05 776.96 77.24 189.64 584.86 365.54 [%] [MPa] [MPa] [MPa] [MPa] [MPa] [MPa] [MPa] [MPa]
n=; YN=0.85 Automatic n=; ZN=0.85 Mineral oil

11.0

Check dimensions of gearing zw zw W dt dt M 3 3 20.9892 4.8125 4.8125 56.2589 6 6 46.3842 4.8125 4.8125 130.5638 [mm] [mm] [mm] [mm]

11.1 Number of measured teeth 11.2 Number of measured teeth 11.3 Chordal dimension 11.4 Pin/Ball diameter 11.5 Pin/Ball diameter 11.6 Dimension over pins/balls 12.0 Force conditions (forces acting on the toothing)

12.1 Tangential force 12.2 Normal force 12.3 Axial force 12.4 Radial force 12.5 Bending moment 12.6 Peripheral speed on the pitch diameter 12.7 Specific load / Unit load 13.0 Parameters of the chosen material 13.1 Density 13.2 Young's Modulus (Modulus of Elasticity) 13.3 Tensile Strength, Ultimate 13.4 Tensile Strength, Yield 13.5 Poison's Ratio 13.6 Contact Fatigue Limit 13.7 Bending Fatigue Limit 13.8 Tooth Hardness - Side 13.9 Tooth Hardness - Core 13.10 Base Number of Load Cycles in Contact 13.11 Wohler Curve Exponent for Contact 13.12 Base Number of Load Cycles in Bend 13.13 Wohler Curve Exponent for Bend 14.0 Calculation of gearing for the given axis distance

Ft Fn Fa Fr Mo v | vmax wt | wt* Ro E Rm Rp0.2 SHlim SFlim VHV JHV NHlim qH NFlim qF Additions section 0.00 23.33 65.27 7870 206 965 750 0.3 1160 705 600 300

2219.28 2361.71 0.00 807.75 0.00 < 60 23.74 7870 206 965 750 0.3 1160 705 600 300 1.00E+08 10 3.00E+06 9

[N] [N] [N] [N] [Nm] [m/s] [N/mm | MPa] [kg/m^3] [GPa] [MPa] [MPa] [MPa] [MPa] [HV] [HV]

1.00E+08 10 3.00E+06 9

14.1 Required axis distance / Standardized 14.2 List of solutions 14.3 Combination of the teeth number 14.4 Number of teeth Pinion / Gear 14.5 Transmission ratio / Deviation 14.6 A. Change of the addendum modification 14.7 Base helix angle 14.8 Total unit correction 14.9 Distribution of correction 14.10 Type of distribution of corrections to the pinion and gear 14.11 Press the button for transmitting values in to calculation 14.12 B. By a change of the helix angle 14.13 Base helix angle 14.14 Total unit correction 14.15 Press the button for transmitting values in to calculation 15.0 Power, warming-up, gearbox surface 15.1 Ambient air temperature 15.2 Maximum oil temperature 15.3 Coefficient of heat dissipation 15.4 Power losses

aw [mm] ID. z1/z2 i b Sum x x

250 z1 51 2.5294 0.0000 0.94259

According to Meritt

86.63 z2 i 129 1.16% [] [modul] [modul] b Sum X

5. | 51 | 129 | 2.529 | 8.110 | 0.9426

0.7132

0.2294

b Sum x

8.1096 0.0000

[] [modul]

20.00 60.00 10.00 0.36

[C] [C] [W/m2/K] [kW]

15.5 Gearbox surface (min.) 16.0 16.1 16.2 17.0 Preliminary design of shaft diameters (steel) Recommended shaft diameter for: - Main power-transmitting shafts - Small, short shafts Approximate module calculation from the existing gear z da u b mn DA DB 46.51 36.15

0.90

[m2]

62.96 48.93 20 33.50 0.00 10.00 1.50

[mm] [mm]

17.1 Number of teeth 17.2 Tip diameter 17.3 Distance between teeth edges 17.4 Helix angle 17.5 Module of tooth 18.0 19.0 Auxiliary calculations Graphical output, CAD systems
DXF File Automatic Pinion

[mm] [mm] [] [mm]

19.1 2D drawing output to: 19.2 2D Drawing scale 19.3 Detail:

a [] 19.4 Detailed drawing of tooth and wheel 19.5 Number of drawn teeth 19.6 Number of points of tooth tip 19.7 Number of points of tooth flank 19.8 Rolling (turning) of a tool between the bite 19.9 Number of tooth copies in the picture of engagement check 19.10 Text description (Information for BOM) Row 1 (BOM attribute 1) Row 2 (BOM attribute 2) Row 3 (BOM attribute 3) Row 1 (BOM attribute 1) Row 2 (BOM attribute 2) Row 3 (BOM attribute 3) 19.11 Table of parameters
Table of pinion parameters

30 3 5 30 0.5 20 Pinion Spur gear - Pinion []

b [] a [modul]

30 1

Drawing without axes

z1=18, mn=2.75, beta=0 Material: Gr. 4340 (A322-82) Gear Spur gear - Gear z2=45, mn=2.75, beta=0 Material: Gr. 4340 (A322-82)