DIN 3990 MDesign 2016 Esempio Spur Gear, Gear Rack

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Spur Gear, Gear Rack
With the following program based on the standard calculations DIN 3960, the geometry of spur gears can be calculated.
This module has different operations and possibilities for calculation profile shift.
These possibilities are the following:
Automatic calculation and distribution of the total profile shift coefficient according to DIN 3992 (DIN 3993)
Input of centre distance
Input of total profile shift
Input of profile shift
With the following program the strength examination (pitting load capacity, root load capacity, corrosion load capacity) of spur gears will
be calculated. Therefore the calculation base DIN 3990 and also the international ISO 6336 can chose by the user.
With this program standard gauges for spur gears will be calculated.
The application of the number of teeth thickness, spherical dim.-roll diameter DM, deviations of center distance and deviations of teeth
thickness are optional.
Groundwork calculations
Geometry of the spur gear pair and the gear
The standard calculations for this module are described by DIN 3960, edition March 1987.
The following DIN specifications will also be utilized:
DIN 780 Module sequence for spur gears
DIN 867 edition February 1986 (basic profile)
DIN 3960 edition March 1987 (concept and dimension determination for spur gear pairs with involute gearing)
DIN 3960 supplement 1, edition July 1980
DIN 3992 edition March 1964 (profile displacement for spur gears with outer gearing)
DIN 3993 edition August 1981, part 1 - 4 (geometric design of cylindrical inner gear pairs).
Strength examination of spur gears
The standard calculations for this module are described by the following DIN specifications:
DIN 3990 Part 1 edition December 1987 (general influence factors)

DIN 3990 Part 2 edition December 1987 (calculation of the pitting load capacity)
DIN 3990 Part 3 edition December 1987 (calculation of the root load capacity)
DIN 3990 Part 4 edition December 1987 (calculation of the corrosion load capacity)
DIN 3990 Part 5 edition December 1987 (fatigue stress values and material qualities)
DIN 3990 Part 6 edition December 1994 (operational stability)
DIN 3990 Part 11 edition February 1989 (application standards for industrial gears)
DIN 3961 edition August 1961 (ground tolerances)
DIN 3962 Part 1 edition August 1978 (tolerances for deviation of individual determined dimensions)
DIN 3962 Part 2 edition August 1978 (tolerances for flank line deviations)
DIN 50 150, edition December 1976 1976 (conversion table for Vickers - Rockwell- Brinell hardness and ultimate strength)
ISO 6336 Part 1 edition September 2006 (Basic principles, influence factors)
ISO 6336 Part 2 edition September 2006 (Calculation of surface durability (pitting))
ISO 6336 Part 3 edition September 2006 (Calculation of tooth bending strength)
ISO 6336 Part 6 edition September 2006 (Calculation of service life under variable load)
ISO 6336-1 Technical Corrigendum 1
ISO 1328 Part 1 edition August 2005 (Definitions and allowable values of deviations)
Gauge Design for Spur Gears

The standard calculations for this program are described by DIN 3960, edition March 1987.
The following DIN specifications will also be utilized:
DIN 3961 edition August 1978 (tolerances for spur gearing)
DIN 3962 supplement 1 edition August 1978 (tolerances for deviation of individual determined dimensions)
DIN 3964 edition November 1980 (axis position and Axis position tolerances of housing for spur gears)
DIN 3967 edition August 1978 (flank play, tooth thickness dimension, tooth thickness tolerances)
DIN 3977 edition February 1981 (dimension diameter for the radial or diametric standard gauge of the tooth thickness of spur gears
(cylinder gears))
05/13/2016 11:45:34 Page 1/17
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Input data:
Calculation method
Spur gear
Calculation variants
All
Calculation standard
DIN 3990
Type of toothing
External toothing
Spur gear geometry

Basic data
Normal modulus
mn = 4,5
mm
Helical angle
: 12
Centre distance
a:0
mm
Driving element
Pinion
Input of geometry
z1, z2
Number of teeth (pinion)
z1 = 25
Number of teeth (wheel)
z2 = 63
Translation ratio
i = 2,52
Pinion
Tooth width
Wheel
b = 75
70
Input method for tooth-tip height modification
No input
Tip edge modification
No
mm
Addendum modification according to DIN 3992/3993

Input methode profile shift coefficients
Input of x1 and x2
Profile shift coefficient (pinion)
x1 = -0,257
Profile shift coefficient (wheel)
x2 = -0,257
Basic gear rack
Pinion
Tip clearance factor
c P * = 0,25
Root fillet radius factor
f P * : 0,45
Wheel
0,25
0,45
p = 20
Pressure angle
Tooth-tip thickness factor
san * = 0,25
Pinion
Tooth-tip height factor

Residual fillet undercut
Wheel
haP * = 1
spr : 0
mm
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Cutter data
Pinion
Wheel
Number of cutter teeth
z0 : 0
Basic gear rack profile shift coefficient
x0 : 0
Spur Gear Calculation - Strength

Drive data
Load case
Nominal load
Pinion
Number of meshed teeth

Application factor
Dynamic factor
Performance
Wheel
nZE = 1
1
KA = 1
Kv : 0
P = 15
kW
Rotation speed (pinion)
n1 = 3000
1/min
Required lifetime
Lh = 10000
Lubrication
Viscosity class for 40
oil = 32
cSt
Viscosity class for 100
oil = 1
cSt
Density for 15C
oil = 885
kg/m
Oil temperature
oil = 30
Force level (according to FZG-test)

Type of oil distribution
3
Splash lubrication
Material selection
Pinion - materials (strength values) according to
MDESIGN database
International materials
no
Material designation
Material number
16MnCr5
1.7131
Material group
Casehardening steel
Heat treatment / State
trial hardened
Standard dimension
d Nm = 16
mm
Standard dimension
d Np = 16
mm
Ultimate strength for d Nm

Yield point for d Np
RmN = 1000
N/mm
RpN = 695
N/mm
Tooth root strength
Flim = 430
N/mm
Surface durability (pitting)
Hlim = 1500
N/mm
Type of Material
Modulus of elasticity
E = 210000
Poisson's ratio
= 0,3
Hardness scale
HB
Hardness
N/mm
=0
Density
= 7850
kg/m
Linear expansion factor
= 12
10^-6/K
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Temperature
T = 20
Wheel - materials (strength values) according to
MDESIGN database
International materials
no
Material designation
16MnCr5
Material number
1.7131
Material group
Casehardening steel
Heat treatment / State
trial hardened
Standard dimension
d Nm = 16
mm
Standard dimension
d Np = 16
mm
Ultimate strength for d Nm
RmN = 1000
N/mm
Yield point for d Np

Tooth root strength
RpN = 695
N/mm
Flim = 430
N/mm
Surface durability (pitting)
Hlim = 1500
N/mm
Type of Material
Modulus of elasticity
E = 210000
Poisson's ratio
= 0,3
Hardness scale
N/mm
HB
Hardness
=0
Density
= 7850
kg/m
Linear expansion factor
= 12
10^-6/K
Temperature
T = 20
Spur gear calculation material

Structure factor
Pinion
Wheel
XW = 1
= 50
50
N/(s*K)
Heat capacity
c M = 485
485
N*m/(kg
*K)
Root roughness
Rz = 1,6
1,6
Tooth flank roughness
Rz = 1,6
1,6
Thermal conductivity
Data width load factor

Tooth modification
No
Face load factor (root stress)
KF : 0
Face load factor (contact stress)
KH : 0
Face load factor (scuffing load)
KB : 0
Bearing span
Eccentricity (pinion)
Shaft diameter at pinion
Factor
Type of helical toothing
l = 200
mm
s:0
mm
d sh = 30
mm
K' = 0.48
Simple
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Transverse load factors

Transverse load factor (root stress)
KF : 0
Transverse load factor (contact stress)
KH : 0
Transverse load factor (scuffing load)
KB : 0
General input
Pinion
Gearing quality
Design
Wheel
Disk
Disk
Inner diameter of rim
di : 0
mm
Tooth modification, base relief
Ca : 0
Loading type
Pulsating
=0
Stress ratio
Pulsating
0
Minimal root safety
SFmin = 1
Minimal flank safety
SHmin = 1
Minimal scuffing load safety
SBmin = 1
Standard gauge spur gear

General data
Pinion
Deviation of teeth thickness (DIN 3967)

Tolerances of teeth thickness (DIN 3967)
Number of teeth dimension
Spherical dimension- and roll diameter
Wheel
24
24
k:0
DM : 0
Deviation of centre distances (DIN 3964)
mm
Free input deviations
Pinion
Wheel
Upper deviation of teeth thickness
A sne : 0
Lower deviation of teeth thickness
A sni : 0
q:0
mm
Upper deviation of centre distances
A ae : 0,01
Lower deviation of centre distances
A ai : 0
Machining allowance
Results:
General data
Effective number of teeth ratio
2,52
Effective translation ratio
2,52
Transverse pressure angle
20,41
Pressure angle at pitch cylinder
wt
18,455
Ground lead
11,267
Zero centre distance
ad
202,423
mm
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Centre distance
200,001
mm
Profile shift coefficient (pinion)
x1
-0,257
Profile shift coefficient (wheel)
x2
-0,257
Sum profile shift coefficient
xs
-0,514
Length of path of contact
21,695
mm
Length of recess path
ga
7,844
mm
Length of approach path
gf
13,851
mm
Transverse contact ratio
1,602
Overlap ratio
1,029
Total contact ratio
2,631
Number of teeth
25
63
Virtual number of teeth of helical gear
zn
26,573
66,963
Reference diameter
115,013
289,834
mm
Base diameter
db
107,793
271,638
mm
Pitch diameter
dw
113,637
286,365
mm
Root diameter
df
101,45
276,271
mm
V-circle diameter
dv
112,7
287,521
mm
Tip diameter
da
121,482
296,302
mm
Theoretical tip diameter
d a th
121,7
296,521
mm
Tip utility diameter
d Na
119,534
296,302
mm
Root form circle diameter
d Ff
108,156
280,469
mm
Root form diameter
d Nf
108,11
280,664
mm
Interference utility
cF
-0,023
0,097
mm
Specific sliding at point A
-4,677
0,824
Specific sliding at point E
0,424
-0,737
Tooth thickness on the tip cylinder
san
3,651
3,774
mm
Tooth depth
10,016
10,016
mm
Addendum
ha
3,234
3,234
mm
Dedendum
hf
6,782
6,782
mm
Root fillet radius factor
f P*
0,45
0,45
Root fillet radius
2,025
2,025
mm
Theoretical bottom clearance
1,125
1,125
mm
Actual topland play
c tat
1,125
1,125
mm
Tooth tip height modification
-0,1092
-0,1092
mm
Normal base pitch
p en
13,285
mm
Transverse base pitch
p et
13,546
mm
Normal pitch on base cylinder
p bn
13,285
mm
Transverse pitch on base cylinder
p bt
13,546
mm
Geometrical data
Note:
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Condition for running without interference(c F1 > 0) is not met

Cutter data of gear rack
Cutter data pinion type cutter
Number of teeth
z0
Profile shift coefficient
x0
0
0
Topland height factor
haP0*
1,25
1,25
Root height factor
hfP0*
Reference diameter
d0
mm
Base diameter
d b0
mm
Tip diameter
d a0
11,25
11,25
mm
Deddendum diameter (generation)
d fE
101,45
276,271
mm
Centre distance
a0
56,241
143,724
mm
Zere centre distance
ad0
57,507
144,917
mm
Pressure angle at pitch cylinder
wt0
16,602
19,091
Transverse tangential load

at reference cylinder
Ft
830,277
Transverse tangential load

at pitch cylinder
Ftw
840,333
Radial load at pitch cylinder
Frw
280,446
Axial load at pitch cylinder
Faw
176,481
Tooth load at pitch cylinder
Fw
903,302
Moment (pinion)
T1
47,746
N*m
Moment (wheel)
T2
120,321
N*m
Results of calculation strength

Forces, moment, speed
Line load
11,861
N/mm
Peripheral speed at reference cylinder
18,066
m/s
Peripheral speed at pitch cylinder
vw
17,85
m/s
Rotation speed (pinion)
n1
Rotation speed (wheel)
n2
Number of loading cycle (pinion)
NL1
Number of loading cycle (wheel)
NL2
3000
1/min
1190,476
1/min
1800000000
714285714
Note:
The lineload is < 100 N/mm so the risk of bad load distribution and vibrations is available !
General factors
Hekix slope deviation
fH
10
10
Transverse pitch deviation
fpe
Profile form deviation
ff
10
10
10
Effective meshing slope deviation
fpe eff
9,287
Effective profile form deviation
ff eff
9,25
Flank line deviation
fx
10,271
Manufacturing - flank line deviation
fma
10
Flank line deviation through pinion def.
fsh
0,204
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Reduced mass / tooth width
mred
0,035
kg/mm
Individual spring rigidity
c'
1,469
N/(mm*m)
Meshing spring rigidity
2,132
N/(mm*m)
Resonance velocity (pinion)
nE1
2965,243
1/min
Resonance velocity (gear)
nE2
1176,684
1/min
Basic velocity
NR
1,012
Dynamic factor
Kv
2,016
Face load factor (root stress)
KF
1,326
Face load factor (contact stress)
KH
1,389
Face load factor (scuffing load)
KB
1,389
Transverse load factor (root stress)
KF
1,165
Transverse load factor (contact stress)
KH
1,165
Transverse load factor (scuffing load)
KB
1,165
Helix angle factor
KB
1,245
Zone factor
ZH
2,587
Elasticity factor
ZE
191,646
Contact ratio factor
0,79
Helix angle factor
0,989
Work hardening factor
ZW
Lubricant factor
ZL
0,922
Velocity factor
Zv
1,017
Roughness factor
ZR
1,071
Life factor for contact stress
ZNT
1,019
Size factor
ZX
Single pair tooth contact factor
ZB
Pitting stress limit
HG
1507,76
1536,617
N/mm
Allowable flank pressure
HP
1507,76
1536,617
N/mm
Contact stress
265,68
265,68
N/mm
Safety factor for pitting
SH
5,675
5,784
Attainable lifetime
Lh
fat. strength
Overlapping factor (root stress)
0,7
Helix angle factor
0,9
Deep tooth factor
Y DT
Rim thickness factor
YB
Tooth form factor
YF
1,494
1,362
Stress correction factor
YS
1,71
1,874
Relativ notch sensitivity factor
Y relT
0,946
0,966
Relativ survace factor
Y RrelT
1,024
1,024
Size factor
YX
Life factor for tooth root stress
Y NT
Mean stress influence factor
YM
Pitting load capacity
ZD =
1,000
fat. strength
Root load capacity
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Tooth root stress limit
FG
833,799
850,981
N/mm
Allowable root stress
FP
833,799
850,981
N/mm
Tooth root stress
17,629
17,624
N/mm
Safety factor for tooth breakage
SF
47,297
48,284
Attainable lifetime
Lh
Angle factor
0,95
Lubricant factor
XS
Load distribution factor
0,333
Flash factor
XM
50,235
Geometry factor
XB
0,264
Tangential line force at weigth
w Bt
48,194
N/mm
Scuffing temperature
99,42
Corrosion safety factor
SB
25,759
Flash factor
XM
50,235
Geometry factor (pinion tip)
XBE
0,264
Pitch factor
XQ
Tip relief factor
XCa
Contact ratio factor
0,337
Mass temperature
31,535
Integral temperature
int
34,823
Scuffing integral temperature
intS
99,42
Corrosion safety factor
SintS
2,855
Scuffing load safety factor
SSL
14,394
fat. strength
fat. strength
Scuffing load capacity
Flash temperature calculation way
Integral calculation way
Ultimate strength for pinion
Rm
684,7
N/mm
Ultimate strength for gear
Rm
545,7
N/mm
Yielding point for pinion
Re
475,9
N/mm
Yielding point for gear
Re
379,3
N/mm
(for d eff =
(for d eff =
107,79
mm
271,64
mm
(for d eff =
(for d eff =
107,79
mm
271,64
mm
Results check gauge

Case centre distance
200,001
mm
Maximum case centre distance
amax
200,001
mm
Minimum case centre distance
amin
200,001
mm
Theoretical backlash
jt
0,396
mm
Maximum theoretical backlash
jt max
0,429
mm
Minimum theoretical backlash
jt min
0,363
mm
Upper deviation of teeth thickness
A sne
-125
-230
Lower deviation of teeth thickness
A sni
-150
-270
Tolerance of teeth thickness
T sn
25
40
Fluctuation of teeth thickness
Rs
14
18
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Nominal teeth thickness (theoretical)
snth
6,227
6,227
mm
Nominal teeth thickness
sn
6,227
6,227
mm
Maximum nominal teeth thickness
sn max
6,102
5,997
mm
Minimum nominal teeth thickness
sn min
6,077
5,957
mm
Base tangent length (theoretical)
W k th
34,099
89,788
mm
Base tangent length
Wk
34,099
89,788
mm
Maximum base tangent length
W k max
W k min
33,981
89,572
mm
Minimum base tangent length
33,958
89,534
mm
Number of teeth dimension
Measure roller diameter
DM
Radial gauge spheres/roller
Mrk
61,165
148,419
mm
Maximum radial gauge spheres/roller
Mrk e
61,182
148,447
mm
Minimum radial gauge spheres/roller
Mrk i
61,147
148,391
mm
Diametral gauge spheres
Mdk
122,103
296,748
mm
Diametral gauge roller
MdR
122,329
296,838
mm
max. Diametral gauge spheres
Mdk e
122,137
296,804
mm
min. Diametral gauge spheres
Mdk i
122,068
296,693
mm
max. Diametral gauge roller
MdRe
122,364
296,894
mm
min. Diametral gauge roller
MdRi
122,294
296,783
mm
Factor of deviation of base tangent length A w

Factor of deviation radial spheres/roller
A mr
0,94
0,94
1,39
1,391
Factor of deviation diametral roller
A md
2,78
2,782
Factor of deviation diametral spheres
A md
2,774
2,781
7,5
7,5
mm
Specific sliding accord. to DIN 3960

External toothing
Kg
5,2
1,114
3,9
Kg1
A
0,442
0,341
0,246
2,6
E
1,3
0
-0,246
-0,341
-0,442
-1,3
2
Kg2
-2,6
-3,9
-1,114
-5,2
6,331
18,994
31,657
44,320
56,983
x1
x2
xs
= -0,257
= -0,257
= -0,514
ga
gf
g
= 7,844
= 13,851
= 21,695
Kga1
Kga2
Kgf1
Kgf2
=
=
=
=
0,246
0,341
0,341
0,246
spec. sliding: pinion

A
E
= -4,677
= 0,424
spec. sliding: gear

A
E
= 0,824
= -0,737
[mm]
Meshing Line
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Tooth profile (evolvent) pinion
da1
d1
dw1
df1
Tooth profile (evolvent) gear
da2
d2
dw2
df2
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Gap of tooth (envelope curve, evolvent) pinion
da1
d1
dw1
df1
Gap of tooth (envelope curve, evolvent) gear
da2
d2
dw2
df2
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Side view pinion
df1 d1 da1
Side view gear
df2 d2 da2
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Front view pinion
df1 d1da1
Front view gear
df2 d2da2
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Gear wheel (evolvent) pinion
Gear wheel (evolvent) gear
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Pinion, Pitting Bearing Capacity Diagram

material :
HG
[N/mm]
16MnCr5
load cycle [-]
3000
static
102
0,00
103
0,01
104
0,06
0,56
10
2400
time strength
1800
106
5,56
107
55,56
108
555,56
10
5555,56
1010
fatigue strength
1200
lifetime [h]
55555,56
600
0
102
103
104
105
106
107
108
109
1010
load cy cle
Gear, Pitting Bearing Capacity Diagram

material :
HG
[N/mm]
16MnCr5
load cycle [-]
3000
2400
time strength
0,00
103
0,01
0,14
105
1,40
106
14,00
107
140,00
1400,00
109
14000,00
1010
140000,00
10
1800
fatigue strength
1200
102
10
static
lifetime [h]
600
0
102
103
104
105
106
107
108
109
1010
load cy cle
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Pinion, Root Bearing Capacity Diagram

material :
FG
[N/mm]
16MnCr5
load cycle [-]
3000
102
0,00
103
0,01
104
0,06
0,56
10
2400
static
1800
106
5,56
107
55,56
108
555,56
10
time strength
lifetime [h]
5555,56
1010
55555,56
1200
fatigue strength
600
0
102
103
104
105
106
107
108
109
1010
load cy cle
Gear, Root Bearing Capacity Diagram

material :
FG
[N/mm]
16MnCr5
load cycle [-]
3000
102
0,00
103
0,01
0,14
10
2400
static
105
1,40
106
14,00
107
140,00
1400,00
109
14000,00
1010
140000,00
10
1800
time strength
lifetime [h]
1200
fatigue strength
600
0
102
103
104
105
106
107
108
109
1010
load cy cle
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DIN 3990 MDesign 2016 Esempio Spur Gear, Gear Rack

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DIN 3990 MDesign 2016 Esempio Spur Gear, Gear Rack

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test version

Module version : 16.0

Spur Gear, Gear Rack

DIN 3990 Part 1 edition December 1987 (general influence factors)

Gauge Design for Spur Gears

05/13/2016 11:45:34 Page 1/17

Module version : 16.0

Spur Gear, Gear Rack

Spur gear geometry

Number of teeth (pinion)

Number of teeth (wheel)

Input method for tooth-tip height modification

Tip edge modification

Addendum modification according to DIN 3992/3993

Profile shift coefficient (pinion)

Profile shift coefficient (wheel)

Basic gear rack

Tip clearance factor

Root fillet radius factor

Tooth-tip height factor

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Module version : 16.0

Spur Gear, Gear Rack

Number of cutter teeth

Basic gear rack profile shift coefficient

Spur Gear Calculation - Strength

Number of meshed teeth

Rotation speed (pinion)

Viscosity class for 100

Density for 15C

Force level (according to FZG-test)

Heat treatment / State

Ultimate strength for d Nm

Tooth root strength

Surface durability (pitting)

Linear expansion factor

05/13/2016 11:45:34 Page 3/17

Module version : 16.0

Spur Gear, Gear Rack

Wheel - materials (strength values) according to

Heat treatment / State

Ultimate strength for d Nm

Yield point for d Np

Surface durability (pitting)

Linear expansion factor

Spur gear calculation material

Tooth flank roughness

Data width load factor

Face load factor (root stress)

Face load factor (contact stress)

Face load factor (scuffing load)

05/13/2016 11:45:34 Page 4/17

Module version : 16.0

Spur Gear, Gear Rack

Transverse load factors

Transverse load factor (contact stress)

Transverse load factor (scuffing load)

Inner diameter of rim

Tooth modification, base relief

Minimal root safety

Minimal flank safety

Minimal scuffing load safety

Standard gauge spur gear