LND-7330757468@CS Name : Unnamed Changed by : Marius

KISSsoft - Release 03-2011L File on: 09.11.2012 at: 22:55:27

Warning : Calculation not consistent. Results are probably not valid !

Important hint: At least one warning has occurred during the calculation: 1-> Contact interference! Notice: The length of the involute of gear 1 is too short. Some proposals: - Change tip form diameter of Gear 2 through Gear 2: Tip chamfer >= 0.0300 mm or Tip circle <= 164.7800 mm - Change reference profile of Gear 1 through: Smaller root radius or larger dedendum.

CALCULATION OF A HELICAL GEAR PAIR

Drawing or article number: Gear 1: 0.000.0 Gear 2: 0.000.0 Calculation method DIN 3990 Method B ------- GEAR 1 -------- GEAR 2 -Power (kW) Speed (1/min) Torque (Nm) Application factor Required service life Gear driving (+) / driven (-) 1. TOOTH GEOMETRY AND MATERIAL (Geometry calculation according ISO 21771) Center distance (mm) Centre distance tolerance Normal module (mm) Pressure angle at normal section () Helix angle at reference circle () Number of teeth Facewidth (mm) Hand of gear Accuracy grade Inner diameter (mm) Inner diameter of gear rim (mm) Material Gear 1: Gear 2: [a] [mn] [alfn] [beta] [z] [b] [Q-DIN3961] [di] [dbi] ------- GEAR 1 -------- GEAR 2 -112.000 ISO 286 Measure js7 2.7500 20.0000 12.0000 23 58 36.00 35.00 right left 8 8 0.00 0.00 0.00 0.00 steel, case-hardened core strength >=25HRC Jominy J=12mm<HRC28 steel, case-hardened core strength >=25HRC Jominy J=12mm<HRC28 ------- GEAR 1 -------- GEAR 2 -HRC 61 HRC 61 430.00 1500.00 1200.00 850.00 206000 0.300 0.00 4.80 20.00 430.00 1500.00 1200.00 850.00 206000 0.300 0.00 4.80 20.00 [P] [n] [T] [KA] [H] 725.0 38.2 + 2.900 1.25 800.00 287.5 96.3 -

18CrNiMo7-6, Case-carburized ISO 6336-5 Figure 9/10 (MQ), 18CrNiMo7-6, Case-carburized ISO 6336-5 Figure 9/10 (MQ),

Surface hardness Fatigue strength. tooth root stress (N/mm) [sigFlim] Fatigue strength for Hertzian pressure (N/mm) [sigHlim] Tensile strength (N/mm) [Rm] Yield point (N/mm) [Rp] Young's modulus (N/mm) [E] Poisson's ratio [ny] Average roughness, Ra, tooth flank (m) [RAH] Mean roughness height, Rz, flank (m) [RZH] Mean roughness height, Rz, root (m) [RZF]

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Tool or reference profile of gear 1 : Reference profile 1.25 / 0.38 / 1.0 ISO 53.2 Profil A Addendum coefficient [haP*] Dedendum coefficient [hfP*] Tip radius factor [rhoaP*] Root radius factor [rhofP*] Tip form height coefficient [hFaP*] Protuberance height factor [hprP*] Protuberance angle [alfprP] Ramp angle [alfKP] Tool or reference profile of gear 2 : Reference profile 1.25 / 0.38 / 1.0 ISO 53.2 Profil A Addendum coefficient [haP*] Dedendum coefficient [hfP*] Tip radius factor [rhoaP*] Root radius factor [rhofP*] Tip form height coefficient [hFaP*] Protuberance height factor [hprP*] Protuberance angle [alfprP] Ramp angle [alfKP] Summary of reference profile gears: Dedendum reference profile (module) [hfP*] Tooth root radius Refer. profile (module) [rofP*] Addendum Reference profile (module) [haP*] Protuberance height (module) [hprP*] Protuberance angle () [alfprP] Buckling root flank height (module) [hFaP*] Buckling root flank angle () [alfKP] Data for Grinding / Honing: Depth of immersion (module) [hgrind*] Radius at cutter head (module) [rgrind*] Type of profile modification: Tip relief (m)

not topping

1.000 1.250 0.000 0.380 0.000 0.000 0.000 0.000

not topping 1.250 0.380 1.000 0.000 0.000 0.000 0.000 1.066 0.100

1.000 1.250 0.000 0.380 0.000 0.000 0.000 0.000

1.250 0.380 1.000 0.000 0.000 0.000 0.000 1.066 0.100

none (only running-in) [Ca] -0.00 oil bath lubrication Oil: ISO-VG 220 Mineral-oil base [nu40] [nu100] [FZGtestA] [roOil] [TS]

-0.00

Lubrication type Type of oil Lubricant base Kinem. viscosity oil at 40 C (mm/s) Kinem. viscosity oil at 100 C (mm/s) FZG-Test A/8.3/90 (ISO 14635-1) Specific density at 15 C (kg/dm) Oil temperature (C) Overall transmission ratio Gear ratio Transverse module (mm) Pressure angle at pitch circle () Working transverse pressure angle ()

220.00 17.50 12 0.895 70.000

[itot] [u] [mt] [alft] [alfwt] [alfwt.e/i] Working pressure angle at normal section () [alfwn] Helix angle at operating pitch circle () [betaw] Base helix angle () [betab] Reference centre distance (mm) [ad] Sum of profile shift coefficients [Summexi] Profile shift coefficient [x] Tooth thickness (Arc) (module) [sn*] Tip alteration (mm) Reference diameter (mm) Base diameter (mm) Tip diameter (mm) (mm) Tip diameter allowances (mm) Tip chamfer / tip rounding (mm) Tip form diameter (mm) (mm) Operating pitch diameter (mm) (mm) Root diameter (mm) Generating Profile shift coefficient Manufactured root diameter with xE (mm) Theoretical tip clearance (mm) Effective tip clearance (mm) [k*mn] [d] [db] [da] [da.e/i] [Ada.e/i] [hK] [dFa] [dFa.e/i] [dw] [dw.e/i] [df] [xE.e/i] [df.e/i] [c] [c.e/i]

------- GEAR 1 -------- GEAR 2 -0.000 2.522 2.811 20.410 17.672 17.700 / 17.644 17.320 11.809 11.267 113.863 -0.6350

0.0000 1.5708

-0.6350 1.1085

-0.117 64.663 60.603 69.929 69.929 / 69.919 0.000 / -0.010 0.000 69.929 69.929 / 69.919 63.605 63.615 / 63.595 57.788 -0.0350 / -0.0549 57.596 / 57.486 0.688 0.909 / 0.801

-0.117 163.063 152.826 164.837 164.837 / 164.827 0.000 / -0.010 0.000 164.837 164.837 / 164.827 160.395 160.420 / 160.370 152.696 -0.6825 / -0.7074 152.435 / 152.297 0.688 0.861 / 0.766

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Active root diameter (mm)

[dNf] 60.923 156.371 [dNf.e/i] 60.938 / 60.911 156.400 / 156.347 Root form diameter (mm) [dFf] 60.982 155.955 (mm) [dFf.e/i] 60.923 / 60.891 155.807 / 155.731 Reserve (dNf-dFf)/2 (mm) [cF.e/i] 0.023 / -0.006 0.335 / 0.270 Addendum (mm) [ha = mn * (haP*+x)] 2.633 0.887 (mm) [ha.e/i] 2.633 / 2.628 0.887 / 0.882 Dedendum (mm) [hf = mn * (hfP*-x)] 3.438 5.184 (mm) [hf.e/i] 3.534 / 3.589 5.314 / 5.383 Roll angle at dFa () [xsi_dFa.e/i] 32.986 / 32.967 23.158 / 23.148 Roll angle to dNa () [xsi_dNa.e/i] 32.986 / 32.967 23.158 / 23.148 Roll angle to dNf () [xsi_dNf.e/i] 6.025 / 5.781 12.464 / 12.370 Roll angle at dFf () [xsi_dFf.e/i] 5.889 / 5.591 11.372 / 11.224 Tooth height (mm) [H] 6.071 6.070 Virtual gear no. of teeth [zn] 24.447 61.649 Normal tooth thickness at tip cyl. (mm) [san] 2.101 2.403 (mm) [san.e/i] 2.031 / 1.983 2.311 / 2.257 Normal spacewidth at root cylinder (mm) [efn] 0.000 0.000 (mm) [efn.e/i] 0.000 / 0.000 0.000 / 0.000 Max. sliding velocity at tip (m/s) [vga] 0.826 0.693 Specific sliding at the tip [zetaa] 0.624 0.746 Specific sliding at the root [zetaf] -2.931 -1.657 Sliding factor on tip [Kga] 0.342 0.287 Sliding factor on root [Kgf] -0.287 -0.342 Pitch on reference circle (mm) [pt] 8.832 Base pitch (mm) [pbt] 8.278 Transverse pitch on contact-path (mm) [pet] 8.278 Lead height (mm) [pz] 955.722 2410.081 Axial pitch (mm) [px] 41.553 Length of path of contact (mm) [ga, e/i] 14.330 (14.387 / 14.249) Length T1-A, T2-A (mm) [T1A, T2A] 3.115( 3.057/ 3.186) 30.884(30.884/30.871) Length T1-B (mm) [T1B, T2B] 9.167( 9.167/ 9.157) 24.832(24.775/24.900) Length T1-C (mm) [T1C, T2C] 9.654( 9.638/ 9.671) 24.345(24.304/24.386) Length T1-D (mm) [T1D, T2D] 11.393(11.335/11.464) 22.606(22.606/22.593) Length T1-E (mm) [T1E, T2E] 17.445(17.445/17.435) 16.555(16.497/16.622) Length T1-T2 (mm) [T1T2] 33.999 (33.942 / 34.057) Diameter of single contact point B (mm) [d-B] 63.316(63.316/63.310) 160.694(160.658/160.735) Diameter of single contact point D (mm) [d-D] 64.746(64.705/64.796) 159.374(159.374/159.366) Addendum contact ratio [eps] 0.941( 0.943/ 0.938) 0.790( 0.795/ 0.783) Minimal length of contact line (mm) [Lmin] 59.982 (mm) Transverse contact ratio Transverse contact ratio with allowances Overlap ratio Total contact ratio Total contact ratio with allowances 2. FACTORS OF GENERAL INFLUENCE Nominal circum. force at pitch circle (N) ------- GEAR 1 -------- GEAR 2 -0.0 0.0 0.0 0.0 0.00 0.0 0.0 0.0 2.45 0.0 0.0 0.000 0.000 0.000 0.000 0.000 [eps_a] [eps_a.e/m/i] [eps_b] [eps_g] [eps_g.e/m/i] 1.731 1.738 / 1.730 / 1.721 0.842 2.573 2.580 / 2.572 / 2.564

[Ft] Axial force (N) [Fa] Radial force (N) [Fr] Normal force (N) [Fnorm] Tangent.load at p.c.d.per mm (N/mm) (N/mm) [w] Only as information: Forces at operating pitch circle: Nominal circumferential force (N) [Ftw] Axial force (N) [Faw] Radial force (N) [Frw] Circumferential speed pitch d.. (m/sec) [v] Running-in value (m) [yp] Running-in value (m) [yf] Correction coefficient [CM] Gear body coefficient (bs= 8.75 mm) [CR] Reference profile coefficient [CBS] Material coefficient [E/Est] Singular tooth stiffness (N/mm/m) [c'] Meshing stiffness (N/mm/m) [cg] The formula for c' and cg at w*KA < 25 is imprecise! Therefore the factors KV, KHb or KHa are to high. Reduced mass (kg/mm) [mRed] Resonance speed (min-1) [nE1] Nominal speed (-) [N] Subcritical range Running-in value (m) [ya] Bearing distance l of pinion shaft (mm) [l] Distance s of pinion shaft (mm) [s] Outside diameter of pinion shaft (mm) [dsh]

0.000

0.00000 0 0.000 0.0 0.000 0.000 0.000

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Load according DIN 3990/1 Figure 6.8 (0:6.8a, 1:6.8b, 2:6.8c, 3:6.8d, 4:6.8e) Without support effect Tooth trace deviation (active) (m) from deformation of shaft (m) Tooth without tooth trace modification Position of Contact pattern: favorable from production tolerances (m) Tooth trace deviation, theoretical (m) Running-in value (m) Dynamic factor Face load factor flank Tooth root Scuffing

[-] [Fby] [fsh*B1] [fma*B2] [Fbx] [yb] [KV] [KHb] [KFb] [KBb] [KHa] [KFa] [KBa] [Kbg] [NL] 0.000

4 0.00 0.00 0.00 0.00 0.0 1.000 0.000 0.000 0.000 1.000 0.000 0.000 0.000 0.000

Transverse load factor - flank - Tooth root - Scuffing Helix angle coefficient scuffing Number of load cycles (in mio.) 3. TOOTH ROOT STRENGTH

------- GEAR 1 -------- GEAR 2 -Calculation of Tooth form coefficients according method: B (Calculate tooth form factor YF with manufacturing addendum mod. xE.e) Tooth form factor [YF] 0.00 0.00 Stress correction factor [YS] 0.00 0.00 Working angle () [alfen] 0.00 0.00 Bending lever arm (mm) [hF] 0.00 0.00 Tooth thickness at root (mm) [sFn] 0.00 0.00 Tooth root radius (mm) [roF] 0.00 0.00 (hF* = 0.000/0.000 sFn* = 0.000/0.000 roF* = 0.000/0.000 dsFn = 0.00/ 0.00 alfsFn = 0.00/ 0.00) Contact ratio factor [Yeps] Helical load factor [Ybet] Effective facewidth (mm) [beff] Nominal shear stress at tooth root (N/mm) [sigF0] Tooth root stress (N/mm) [sigF] Permissible bending stress at root of Test-gear Support factor [YdrelT] Surface factor [YRrelT] Size coefficient (Tooth root) [YX] Finite life factor [YNT] [YdrelT*YRrelT*YX*YNT] Alternating bending coefficient [YM] Stress correction factor [Yst] Limit strength tooth root (N/mm) [sigFG] Permissible tooth root stress (N/mm) [sigFP=sigFG/SFmin] Required safety [SFmin] Safety for Tooth root stress [SF=sigFG/sigF] Transmittable power (kW) [kWRating] 4. SAFETY AGAINST PITTING (TOOTH FLANK) Zone factor [ZH] Elasticity coefficient (N^.5/mm) [ZE] 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) [sigH] Lubrication factor Speed factor Roughness factor Material mating factor Finite life factor [ZL] [ZV] [ZR] [ZW] [ZNT] [ZL*ZV*ZR*ZNT] Small amount of pitting permissible (0=no, 1=yes) ------- GEAR 1 -------- GEAR 2 -0.000 0.000 0.000 0.000 35.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000 0.000 0.000 0 0.00 0.00 0.00 0.000 0.000 0.000 0.000 0.000 0.000 0 0.000 0.000

36.00 0.00 0.00 0.000 0.000 0.000 0.000 0.000 1.000 0.00 0.00 1.40 0.00 0.00

35.00 0.00 0.00 0.000 0.000 0.000 0.000 0.000 1.000 0.00 0.00 1.40 0.00 0.00

0.00

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Size coefficient (flank) [ZX] Limit strength pitting (N/mm) [sigHG] Permissible surface pressure (N/mm) [sigHP=sigHG/SHmin] Safety for surface pressure at operating pitch circle [SHw] Required safety [SHmin] Transmittable power (kW) [kWRating] Safety for stress at single tooth contact [SHBD=sigHG/sigH] (Safety regarding nominal torque) [(SHBD)^2] 4b. MICROPITTING ACCORDING TO ISO/TR 15144-1:2010

0.000 0.00 0.00 0.00 1.00 0.00 0.00 0.00

0.000 0.00 0.00 0.00 1.00 0.00 0.00 0.00

Calculation did not run. (Lubricant: Load stage micropitting test is unknown 5. STRENGTH AGAINST SCUFFING Calculation method according DIN3990 0.000 13.795 0.00 1.000 0.00 35.000 0.000 0.000 0.790 0.00 0.00 0.00 0.000 0.00 0.000 0.000 0.00 0.000 2.000 0.000 0.00 0.00 0.00 0.000 0.00 0.000 0.000 0.000 0.000 0.00 1.800 0.000 0.000 13.795 0.00

Lubrication coefficient (for lubrication type) [XS] Relative structure coefficient (Scuffing) [XWrelT] Thermal contact factor (N/mm/s^.5/K) [BM] Relevant tip relief (m) [Ca] Optimal tip relief (m) [Ceff] Effective facewidth (mm) [beff] Applicable circumferential force/facewidth (N/mm) [wBt] Flash factor (K*N^-.75*s^.5*m^-.5*mm) [XM] Pressure angle factor (eps1: 0.000, eps2: 0.941) [Xalfbet] Flash temperature-criteria Tooth mass temperature (C) [theM-B] theM-B = theoil + XS*0.47*theflamax [theflamax] Scuffing temperature (C) [theS] Coordinate gamma (point of highest temp.) [Gamma] [Gamma.A]= -0.677 [Gamma.E]= 0.807 Highest contact temp. (C) [theB] Geometry factor [XB] Load sharing factor [XGam] Dynamic viscosity (mPa*s) [etaM] Coefficient of friction [mym] Required safety [SBmin] Safety factor for scuffing (flash-temp) [SB] Integral temperature-criteria Tooth mass temperature (C) theM-C = theoil + XS*0.70*theflaint Integral scuffing temperature (C) Contact ratio factor Dynamic viscosity (mPa*s) Averaged coefficient of friction Geometry factor Meshing factor Tip relief factor Integral tooth flank temperature (C) Required safety Safety factor for scuffing (intg.-temp.) Safety referring to transferred torque 6. MEASUREMENTS FOR TOOTH THICKNESS Tooth thickness deviation Tooth thickness allowance (normal section) (mm) [As.e/i] 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] [theM-C] [theflaint] [theSint] [Xeps] [etaOil] [mym] [XBE] [XQ] [XCa] [theint] [SSmin] [SSint] [SSL]

------- GEAR 1 -------- GEAR 2 -DIN3967 cd25 DIN3967 cd25 -0.070 / -0.110 0.000 0.000 0.000 / 0.000 0.000 -0.095 / -0.145 0.000 0.000 0.000 / 0.000 0.000 0.000 0.000 0.000 0.000 / 0.000 0.000

Theoretical diameter of ball/pin (mm) [DM] 0.000 Eff. Diameter of ball/pin (mm) [DMeff] 0.000 Theor. dim. centre to ball (mm) [MrK] 0.000 Actual dimension centre to ball (mm) [MrK.e/i] 0.000 / 0.000 Diameter of contact point (mm) [dMMr.m] 0.000 Diametral measurement over two balls without clearance (mm)

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Actual dimension over balls (mm) Theor. dimension over two pins (mm) Actual dimension over rolls (mm)

[MdK] [MdK.e/i] [MdR] [MdR.e/i]

0.000 0.000 / 0.000 0.000 0.000 / 0.000 0.000 0.000 / 0.000 0.000 4.320 4.250 / 4.210 112.000 0.000 0.018 0.011 0.018 / / / /

0.000 0.000 / 0.000 0.000 0.000 / 0.000 0.000 0.000 / 0.000 0.000 3.048 2.953 / 2.903 /112.000 0.000 -0.018 -0.011 -0.018

Chordal tooth thickness (no backlash) (mm) ['sn] 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] Backlash free center distance (mm) [aControl.e/i] Backlash free center distance, allowances (mm) [jta] Centre distance allowances (mm) [Aa.e/i] Circumferential backlash from Aa (mm) [jt_Aa.e/i] Radial clearance (mm) [jr] Circumferential backlash (transverse section) (mm) [jt] Torsional angle for fixed gear 1 () Normal backlash (mm) [jn] 7. GEAR ACCURACY According DIN 3961: Accuracy grade Profile form deviation (m) Profile slope deviation (m) Total profile deviation (m) Helix form deviation (m) Helix slope deviation (m) Total helix deviation (m) Normal base pitch deviation (m) Single pitch deviation (m) Difference between adjacent pitches (m) Total cumulative pitch deviation (m) Cumulative circular pitch deviation over

0.000 / 0.000 0.0000 /0.0000 0.000 / 0.000

------- GEAR 1 -------- GEAR 2 -8 16.00 12.00 20.00 11.00 17.00 20.00 15.00 15.00 19.00 53.00 33.00 37.00 22.00 44.00 18.00 58.00 25.00 18.00 50.00 31.36 12.24 65.00 8 16.00 12.00 20.00 11.00 17.00 20.00 16.00 16.00 20.00 62.00 39.00 43.00 25.00 51.00 22.00 66.00 25.00 20.00 56.00 31.36 11.90 72.00

[Q-DIN3961] [ff] [fHa] [Ff] [ffb] [fHb] [Fb] [fpe] [fp] [fu] [Fp] z/8 pitches (m) [Fpz/8] Concentricity deviation (m) [Fr] Tooth Thickness Variation (m) [Rs] Total radial composite deviation (m) [Fi"] Radial tooth-to-tooth composite deviation (m) [fi"] Total tangential composite deviation (m) [Fi'] Tangential tooth-to-tooth composite deviation (m) [fi'] According DIN 58405 (Precision Mechanics): Tooth-to-tooth composite error (m) [fi"] Composite error (m) [Fi"] Axis alignment error (m) [fp] Flank direction error (m) [fbeta] Concentricity deviation (m) [Trk, Fr]

Tolerance for alignment of axes (recommendation acc. ISO/TR 10064, Quality 8) Maximum value for deviation error of axis (m) [fSigbet] 26.03 Maximum value for inclination error of axes (m) [fSigdel] 52.07 8. ADDITIONAL DATA Maximal possible centre distance (eps_a=1.0) [aMAX] Torsional stiffness (MNm/rad) [cr] Mean coeff. of friction (acc. Niemann) [mum] Wear sliding coef. by Niemann [zetw] Power loss from gear load (kW) [PVZ] Weight - calculated with da (g) [Mass] Moment of inertia (System referenced to wheel 1): calculation without consideration of the exact tooth shape single gears ((da+df)/2...di) (kgm) [TraeghMom] System ((da+df)/2...di) (kgm) [TraeghMom] 9. DETERMINATION OF TOOTHFORM Data for the tooth form calculation : Calculation of Gear 1 113.983 0.000 0.000 0.000

0.0

0.0

0.00 0

0.00 0

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Tooth form, Gear 1, Step 1: automatic (final treatment) haP*= 1.002, hfP*= 1.250, rofP*= 0.380 Calculation of Gear 2 Tooth form, Gear 2, Step 1: automatic (final treatment) haP*= 1.016, hfP*= 1.250, rofP*= 0.380

REMARKS: - Specifications with [.e/i] imply: Maximum [e] and Minimal value [i] with consideration of all tolerances Specifications with [.m] imply: Mean value within tolerance - For the backlash tolerance, the center distance tolerances and the tooth thickness deviation are taken into account. Shown is the maximal and the minimal backlash corresponding the largest resp. the smallest allowances The calculation is done for the Operating pitch circle.. - Details of calculation method: cg according to method B KV according to method B KHb, KFb according method C KHa, KFa according to method B End report lines: 495

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