BS Gear Stranded

Licensed Copy: University of Manchester Library, The University of Manchester Library, 04/02/2013 16:37, Uncontrolled Copy, (c) The
British Standards Institution 2012
BRITISH STANDARD
Spur and helical

gears
Part 3: Method for calculation of
contact and root bending stress
limitations for metallic involute gears
UDC 621.833.1
BS 436-3:1986
(Reprinted,
incorporating
Amendment No. 1)
Licensed Copy: University of Manchester Library, The University of Manchester Library, 04/02/2013 16:37, Uncontrolled Copy, (c) The British Standards Institution 2012
BS 436-3:1986
Committees responsible for this

British Standard
The preparation of this British Standard was entrusted by the Machinery and
Components Standards Committee (MCE/-) to Technical Committee MCE/5
upon which the following bodies were represented:
Association of Consulting Engineers
British Clock and Watch Manufacturers Association
British Gear Manufacturers Association
British Horological Institute
British Railways Board
Engineering Equipment and Materials Users Association
Federation of Manufacturers of Construction Equipment and Cranes
Gauge and Tool Makers Association
Institution of Mechanical Engineers
Institution of Production Engineers
Lloyds Register of Shipping
Machine Tool Industry Research Association
Milling Cutter Association
Ministry of Defence
National Coal Board
Society of Motor Manufacturers and Traders Limited
This British Standard, having

been prepared under the
direction of the Machinery
and Components Standards
Committee was published
under the authority of the
Board of BSI and comes
into effect on
30 September 1986
BSI 06-1999
The following BSI references
relate to the work on this
standard:
Committee reference MCE/5
Draft for comment 84/73219 DC
ISBN 0 580 15227 8
Amendments issued since publication

Amd. No.
Date of issue
Comments
5797
May 1988
Indicated by a sideline in the margin
BS 436-3:1986
Contents
Page
Committees responsible
Inside front cover
Foreword
ii
Section 1. General
1
Scope and field of application
1
2
Definitions and symbols
2
3
Guide to using the calculation procedure
7
Section 2. Contact stress calculations
4
Basic equations for contact stress calculations
8
5
Nominal tangential force for contact stress, FHt
8
6
Zone factor for contact stress, ZH
9
7
Contact ratio factor for contact stress, Z&
9
8
Elasticity factor for contact stress, ZE
10
9
Basic endurance limit for contact stress, BH lim
10
10 Material quality for contact stress, ZM
12
11 Lubricant influence, roughness and speed factors for contact
stress, ZL, ZR and Zv
13
12 Work hardening factor for contact stress, ZW
13
13 Size factor for contact stress, ZX
13
14 Life factor for contact stress, ZN
13
15 Application factor, KA
16
16 Dynamic factor, Kv
18
17 Load distribution factors, KH and KH
22
18 Minimum demanded and actual safety factors on contact stress,
SH min and SH
26
Section 3. Bending stress calculations
19 Basic equations for tooth root bending stress
27
20 Nominal tangential force for bending stress, FFt
28
21 Geometry factors for bending stress, YF, YS, Y
28
22 Basic endurance limit for bending stress BF0
31
23 Material quality factor for bending stress, YM
32
24 Sensitivity factor for bending stress, YB
33
25 Surface condition factor for bending stress, YR
34
26 Size factor for bending stress, YX
34
27 Life factor for bending stress, YN
36
28 Load factors for bending stress, KF and KF
36
29 Minimum demanded and actual safety factors on tooth root
stress, SF min and SF
36
Appendix A Variable duty calculations
39
Appendix B Gearing equations
41
Appendix C Design guidance on tooth modifications
42
Appendix D Typical residual stresses
44
Appendix E Tooth and mesh stiffness c9 and c*
45
Appendix F Definition of material quality
46
Appendix G Examples of calculations
47
Appendix H Equations of graphs
52
Figure 1 Yield strength for contact stress, BHY
10
Figure 2 Values of BHD
11
Figure 3 Values of ZG2
12
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Page
12
14
14
15
16
17
21
21
24
25
29
32
35
35
37
Figure 4 Casedepth factor, Zc

Figure 5 Combined speed and lubricant factors, ZLZv
Figure 6 Roughness factor, ZR
Figure 7 Values of ZW
Figure 8 Life factor for contact stress, ZN
Figure 9 Constituent parts of typical gear load
Figure 10 Kv350 for helical gears, & W1
Figure 11 Kv350 for spur gears
Figure 12 Constant K for calculation of fsh
Figure 13 Values of qy
Figure 14 Dimensions of the basic rack of the gearing
Figure 15 Values of BF0
Figure 16 Values of YR
Figure 17 Values of YX
Figure 18 YN for through hardened steel
Figure 19 YN for thick case surface hardened steel and
cast iron
37
Figure 20 YN for thin case surface hardened steel, grey cast
iron and bronze
38
Figure 21 Typical S/N curve
39
Figure 22 Height and length of end relief
42
Figure 23 Height of crowning
43
Table 1 Value of ZE for some material combinations
10
Table 2 Limiting casedepth
11
Table 3 Values of ZM
13
Table 4 Values of application factor, KA
16
Table 5 Examples of prime mover with different working
characteristics
16
Table 6 Examples of driven machines with different working
characteristics
17
Table 7 Values of X
19
Table 8 Auxiliary value, A
23
Table 9 Minimum and maximum values of KH!
26
Table 10 Value of YM
33
Table 11 Values of 9
33
Table 12 Default values for contact stress S/N curve
parameters
40
Table 13 Typical values of residual stress, BR
44
Table 14 Change in residual stress due to post-hardening
operations
45
Table 15 Variable duty calculation example
52
Table 16 Values of Kv350 at discontinuities
55
Table 17 Kv350 termination points
55
55
56
Publication referred to
Inside back cover
ii
BSI 06-1999
BS 436-3:1986
Foreword
This Part of BS 436 has been prepared under the direction of the Machinery and
Components Standards Committee. It is a general application standard for spur
and helical external and internal gears.
The standard follows the principles developed by the International Organization
for Standardization (ISO) in that the stress levels in the tooth flank and in the
tooth root are calculated and compared with basic permissible stress levels
derived from tests on simple test specimens.
Modifying factors used to calculate stress levels are based on the ISO proposals
but have been adjusted to avoid the step functions which occur in these proposals.
This Part of BS 436 together with BS 436-1 Basic rack form pitches and accuracy
(diametrical pitch series) and BS 436-2 Basic rack form, modules and accuracy
(1 to 50 metric module) supersede BS 436:1940 which is therefore withdrawn.
BS 436-1 is retained solely for the purpose of supplying replacement gears
designed in accordance with the imperial system of units.
To assist in the data processing of the calculations given in this standard,
FORTRAN sub-routines can be obtained from the British Gear Association1).
Procedures for some factors are extracted or derived from Draft International
Standard ISO/DIS/6336/1, 2 and 3, Calculation of load capacity of spur and
helical gears.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.
Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 58, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.
1) British
Gear Association, c/o Institution of mechanical Engineers, Birdcage Walk, London

SW1 H9JJ.
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iii
iv
blank
BS 436-3:1986
Section 1. General
1 Scope and field of application
1.1 This Part of BS 436 is a general application standard for spur and helical external and internal gears
of accuracy grades 3 to 10 operating at any pitch line speed. The calculations given in this standard are not
applicable to the prediction of gear damage caused by scuffing, wear, welding or fracture of the gear rims,
web, or hub.
The standard covers methods for determining the actual and permissible contact stresses and bending
stresses in a pair of involute gears. Stress levels on the tooth flank and in the tooth root are calculated and
compared with basic permissible stress levels derived from simple test specimens. Modification factors are
given to take account of:
a) the effects of dimensional variations arising from manufacture and assembly;
b) vibrations arising from sources internal and external to the gears;
c) the effect of the lubricant film and gear flank roughness;
d) stress concentration effects in the tooth root;
e) the effect of different depths of case or surface hardened gears;
f) the effect of bending stress on the tooth flank stress cycle;
g) the effect of residual stress in the tooth root.
Procedures are included for calculating the peak load capacity and for taking account of variable duty.
1.2 The gear type and qualifications in respect of the gear design are as follows:
a) Types of gears: internal and external spur, helical and double helical gears.
b) Range of speed: no restriction but note that at pitch line speeds less than 1 m/s the load capacity is
often limited by wear.
c) Gear accuracy: grade 3 to 10 of BS 436-2. The calculation of load modifying factors are based on the
largest deviation allowed for the particular manufacturing grade.
d) Range of transverse contact ratio: 1.2 u & u 1.9.
e) Range of helix angle: u 45.
f) Basic racks: no restriction.
g) Pinion and pinion shaft: solid or hollow pinion with dil/dfl u 0.52).
h) Gear blank and rim: solid gear blanks and fabricated or cast wheels with rim thickness under the
root greater than 3.5m n 2).
j) Material:
1) through hardened steel;
2) surface hardened steel;
3) cast iron;
4) bronze.
Three grades of material and material production quality are specified (see Appendix F). The permissible
stresses are reduced by a factor ZM on contact stress and YM on bending stress for lower quality materials
(see clauses 10 and 23).
The effect of residual stress at the tooth root is included in this standard. Surface hardening processes,
e.g. carburizing, nitriding and induction hardening, induce beneficial compressive residual stress at the
surface balanced by tensile residual stress in the region of the case/core junction. Grinding the tooth surface
after hardening can reduce the compressive stress and may leave a tensile stress at the surface. A
compressive stress can be introduced (or re-introduced after grinding) by means of controlled shot peening.
Typical values of residual stresses resulting from good heat treatment practice are included in Appendix D.
Appendix H gives the equations and data from which the graphs in the appropriate figures are derived.
2) If
the gears have dimensions outside these limitations then additional calculations are necessary to check the stress levels at
the root of the teeth.
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BS 436-3:1986
Where no in-house data are available for the calculation of the endurance limit for contact stress, suitable
fatigue factors can be determined from the information contained in clause 9.
NOTE
The titles of the publications referred to in this standard are listed on the inside back cover.
2 Definitions and symbols

2.1 Definitions
For the purposes of this Part of BS 436 the definitions given in BS 2519-1 apply together with the following.
2.1.1
effective casedepth, ceff
the depth at which the hardness falls below 500 HV for carburized and nitrided cases or below 450 HV for
induction hardening
2.1.2
endurance limit for contact stress, H lim
the maximum contact stress that may be sustained for an infinite number of cycles without the occurrence
of progressive fatigue damage (pitting)
2.1.3
limiting casedepth, clim
that effective casedepth beyond which a further increase in casedepth does not produce a further increase
in failure load
2.1.4
nominal tangential force for bending stress, FFt
the force tangential to the reference cylinder and perpendicular to its straight generators
2.1.5
nominal tangential force for contact stress, FHt
the force tangential to the reference cylinder and perpendicular to its straight generators
2.1.6
peak torque capacity for bending stress, TF max
that torque which may be transmitted for up to 1 000 tooth cycles during the design life of the gears without
causing failure due to bending stress
2.1.7
peak torque capacity for contact stress, TH max
that torque which may be transmitted for up to 1 000 tooth cycles during the design life of the gears without
causing failure due to contact stress
2.1.8
tooth stiffness constant, c9 and c*
that force which will deform one or several meshing gear teeth having a facewidth of 1 mm by an amount
of 1 4m
2.2 Symbols
For the purposes of this British Standard the following symbols apply.
NOTE
This subclause is based on the symbols of BS 2519-2:1976.
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BS 436-3:1986
Symbol
Designation
Units
a
b
ceff
centre distancea
facewidth
effective casedepth
mm
mm
mm
c9
d
d1
maximum tooth stiffness of one tooth pair in

normal section
mean value of total tooth stiffness
(or mesh stiffness) per unit facewidth
reference diameter
reference diameter of pinion
d2
reference diameter of wheel
mm
da
tip diameter
mm
dan
virtual tip diameter
mm
db
base diameter
mm
dbn
virtual base diameter
mm
den
df
virtual diameter to highest point of

single tooth pair contact
root diameter
mm
mm
df2
root diameter of internal gear
mm
dfn2
virtual root diameter of internal gear
mm
di
internal diameter
mm
dm
mean diameter [= (da + df)/2]
mm
dn
virtual reference diameter
mm
dw1
pitch diameter of pinion
mm
dw2
pitch diameter of wheel
mm
f
ff
individual deviation
profile tolerance (maximum of pinion and wheel)
4m
4m
fma
mesh misalignment due to manufacturing tolerance
4m
fp
permissible single pitch deviation
4m
fpe
tolerance on pitch
4m
fsh
mesh misalignment due to shaft deflections
4m
g
g!
grinding allowance
length of path of contact
mm
mm
h
ha0
tooth depth
addendum of the basic rack of the tool
mm
mm
hf2
dedendum of internal gears
mm
hfp
dedendum of the basic rack of the gearing
mm
hpr
height of protuberance
mm
hF
bending moment arm
mm
l
lc
bearing span
length of end relief per flank
mm
mm
m
mn
module
normal module
mm
c*
N/(mm4m)
N/(mm4m)
mm
mm
a, u and z2 are negative for internal gears.
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BS 436-3:1986
Symbol
Designation
Units
n
p
pbn
rotational speed
pitch
normal base pitch
r/min
mm
mm
pbt
transverse base pitch
mm
pr
protuberance of tool
mm
q
qs
combined flexibility of a pair of teeth

notch parameter
mm4m/N
qy
reduction factor on misalignment due to running-in
sFn
thickness of virtual tooth at critical section
mm
spr
residual undercut left by the protuberance
mm
u
v
w
gear ratioa
pitch line velocity
specific loading Ft/b
m/s
N/mm
wm
mean load intensity
N/mm
x
y
y!
addendum modification coefficient

running-in allowance (only with subscript or )
running-in allowance for KH!
4m
4m
z
zv
number of teetha
virtual number of teeth
B
Ca
parameter for effect of load

height of tip or root relief
4m
Cb
height of end relief
4m
Cc
height of crowning
4m
D
E
tool diameter
Youngs modulus of elasticity
mm
Fm
mean tangential force
MN/m2
N
Ft
nominal tangential force at reference circle
FFt
nominal tangential force for bending stress
FHt
nominal tangential force for contact stress
Fx
mesh misalignment prior to running-in
4m
Fy
effective mesh misalignment
4m
(HV)
I
Vickers hardness value

polar moment of inertia
Kv
dynamic factor
kgm2
Kv350
dynamic factor for FtKA/b = 350
Kv
dynamic factor for spur gears
Kv
dynamic factor for helical gears

(&W 1)
KA
application factor
KF
transverse load factor for bending stress
KF
face load factor for bending stress
KH
transverse load factor for contact stress
a, u and z2 are negative for internal gears.
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BS 436-3:1986
Symbol
Designation
Units
KH
face load factor for contact stress (Hertzian pressure)
Mred
PF
mass per unit facewidth of the gear pair referred

to the line of action
actual power capacity based on bending stress
kg/mm
kW
PFP
permissible power capacity based on bending stress
kW
PH
actual power capacity based on contact stress
kW
PHP
permissible power capacity based on contact stress
kW
R
Ra
roughness
arithmetic average roughness (CLA value)
4m
4m
Rz
mean roughness
4m
S
SF
SH
safety factor
actual safety factor for bending
stress (against breakage)
minimum demanded safety factor for bending stress
(against breakage)
actual safety factor for contact stress
SH min
minimum demanded safety factor for contact stress
T
T1
torque
pinion torque
Nm
Nm
T2
wheel torque
Nm
TF
actual torque based on bending stress
Nm
TF max
peak torque capacity for bending stress
Nm
TFP
permissible torque based on bending stress
Nm
TH
actual torque based on contact stress
Nm
TH max
peak torque capacity for contact stress
Nm
THP
permissible torque based on contact stress
Nm
Y
YF
factor for bending stress

tooth form factor for bending stress
YM
material quality factor for bending stress
YN
life factor for bending stress
YR
surface condition factor for bending stress
YS
stress correction factor for bending stress
YX
size factor for bending stress
helix angle factor for bending stress
sensitivity factor for bending stress
Z
Zc
factor for contact stress

casedepth factor for contact stress
Zv
speed factor for contact stress
ZE
elasticity factor for contact stress
ZG
disc/gear correlation factor for contact stress
ZH
zone factor for Hertzian pressure at pitch point for

contact stress
lubricant factor for contact stress
SF min
ZL
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BS 436-3:1986
Symbol
Designation
Units
ZM
material quality factor for contact stress
ZN
life factor for contact stress
ZR
roughness factor for contact stress
ZW
work hardening factor for contact stress
ZX
size factor for contact stress
Z&
contact ratio factor for contact stress
en
!n
pressure angle at highest point of single tooth

pair contact
normal pressure angle at reference cylinder
radians
radians
transverse pressure angle at reference cylinder
radians
tw
transverse pressure angle at pitch cylinder
radians
Fen
angle for application of load at highest point of

single tooth pair contact
helix angle (without subscript: at reference cylinder)
base helix angle
radians
radians
radians
contact ratio
transverse contact ratio
virtual transverse contact ratio
overlap ratio
total contact ratio
v
2
Poissons ratio
root radius of internal gear
mm
a0
tip radius of the basic rack of the tool
mm
tooth root fillet radius
mm
fp
root fillet radius of the basic rack of the gearing
mm
rel
radius of relative curvature
mm
root fillet radius at critical section
mm
ultimate tensile strength
MN/m2
actual tooth root bending stress
MN/m2
F0
MN/m2
FP
basic endurance limit of a polished specimen

under a reversing bending load
permissible tooth root bending stress
FY
yield strength for bending stress
MN/m2
actual contact stress (Hertzian pressure)
MN/m2
H lim
endurance limit for contact stress for gears
MN/m2
HD
endurance limit for contact stress for discs
MN/m2
HP
MN/m2
HY
permissible contact stress (permissible Hertzian

pressure)
yield strength for contact stress
residual stress
MN/m2
MN/m2
MN/m2
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BS 436-3:1986
Subscripts
1
pinion
wheel
core
core material properties of surface hardened steels
eff
effective values, real stress
est
estimated value
lim
value of endurance limit
min
minimum
max
maximum
red
reduced
sh
shaft
stat
static load
3 Guide to using the calculation procedure

3.1 Calculation procedure
The calculation procedure is used to calculate gear load carrying capacity either:
a) in terms of stresses; or
b) in terms of power.
In the case of a) the permissible stress is calculated from the material endurance limits modified by the
stress modifying factors. This has to exceed the actual stress which is calculated from the nominal
tangential force, modified by the load modifying factors and the gear geometry.
In the case of b) the power capacity of the gear pair is calculated from the permissible stress, the load
modifying factors and the gear geometry. This has to exceed the power required of the gear pair.
In either case the calculation is performed separately for four cases:
1) pinion contact stress (see section 2);
2) wheel contact stress (see section 2);
3) pinion bending stress (see section 3);
4) wheel bending stress (see section 3).
Illustrative examples are given in Appendix G.
NOTE The values of some factors (Kv, KH, KH, KF, KF) depend on the value of the nominal tangential force, Ft. When calculating
the maximum rating of a pair of gears the value of Ft has to be estimated in order to calculate these factors. It is recommended that
if the final rated value of Ft differs from the estimated value by more than 10 % then the load dependant factors are re-calculated
using the rated value of Ft.
3.2 Lubrication
The procedure is valid for gears having adequate lubrication.
NOTE At slow speed, particular care is required to ensure an adequate supply of lubricant at the mesh. It should also be ensured
that the lubricant will not cause corrosion of the gears or any other parts of the gear unit. Corrosion is not covered by this procedure.
3.3 System dynamics

The values of application factor provided for design purposes do not apply if the driving or driven
machinery causes an excitation at a frequency at or close to one of the systems natural frequencies.
NOTE In such cases it is recommended that the designer of the system supplies a value of the application factor, based on calculation
or measurements on similar systems.
3.4 Safety factors

The use of this procedure requires a realistic appraisal of the influencing factors. When experience has been
gained by running other similar gears in similar environments such experience can be used in choosing
appropriate values of the safety factors.
BSI 06-1999
BS 436-3:1986
Section 2. Contact stress calculations

4 Basic equations for contact stress calculations
4.1 Permissible contact stress HP
The permissible contact stress, HP, is calculated separately for pinion and wheel from the equation:
(1)
4.2 Actual calculated contact stress H
The actual calculated contact stress, H, is calculated separately for pinion and wheel from the equation:
(2)
where the value of FHt is the nominal tangential force at the reference circles appropriate to pinion or wheel
calculations respectively from equation (6) or (7).
4.3 Permissible power capacity and torque based on contact stress PHP and THP
The permissible power capacity, PHP, based on contact stress is calculated separately for pinion and
wheel from the equation:
(3)
The permissible torque, THP, based on contact stress is calculated separately for pinion and wheel
from the equation:
(4)
4.4 Peak torque capacity for contact stress, TH max
The peak torque capacity for contact stress expressed as a multiple of THP is given by the equation:
(5)
where HY is obtained from Figure 1.
NOTE The lines for surface hardened steels in Figure 1 are to be extended downwards as far as the B line corresponding to
the condition of the core.
5 Nominal tangential force for contact stress, FHt

The nominal force for contact stress, FHt, is calculated from either equation (6) or (7):
(6)
(7)
For information:
(8)
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BS 436-3:1986
If either
a) the gear pair is subject to variable duty; or
b) the gear pair is subject to intermittent high loads (for instance at start-up) greater than the nominal
running torque
then the pinion torque, TH1, in equation (6) is calculated in accordance with the variable duty procedure in
Appendix A for TZH1.
6 Zone factor for contact stress, ZH

6.1 Purpose of ZH
The zone factor, ZH, accounts for the influence of tooth flank curvature at the pitch point on Hertzian stress
and converts the tangential force at the reference cylinder to a normal force at the pitch cylinder.
6.2 Calculation of ZH
The zone factor, ZH, is calculated from the equation:
(9)
For gears at standard centres this simplifies to:
(10)
7 Contact ratio factor for contact stress, Z&

7.1 Purpose of Z&
The contact ratio factor accounts for the load sharing influence of the transverse contact ratio and the
overlap ratio on the specific loading.
7.2 Calculation of Z&
7.2.1 For spur gears, the contact ratio factor, Z&, is calculated from the equation:
(11)
7.2.2 For helical gears with & < 1, the contact ratio factor, Z(, is calculated from the equation:
(12)
7.2.3 For helical gears with & W 1, the contact ratio factor, Z, is calculated from the equation:
(13)
For information, equations for and are given in B.8 and B.9, respectively.
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BS 436-3:1986
Figure 1 Yield strength for contact stress, HY
8 Elasticity factor for contact stress, ZE

8.1 Purpose of ZE
The elasticity factor accounts for the influence of the specific material properties E (modulus of elasticity)
and v (Poissons ratio) on the Hertzian stress.
8.2 Calculation of ZE
The elasticity factor ZE is calculated from the equation:
(14)
This is tabulated for some gear materials in Table 1. For properties of bronzes see BS 1400.
Table 1 Value of ZE for some
material combinations
Gear materials
Steel/steel
Steel/SG cast iron
SG cast iron/SG cast iron
Grey iron/grey iron
ZE
189
181
174
146
9 Basic endurance limit for contact stress, Hlim

The basic endurance limit for contact stress, H lim, is calculated separately for pinion and wheel from the
equation:
(15)
10
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where
HD is obtained from Figure 2;
Zc
for through hardened steels = 1.0;
Zc
for surface hardened steels is obtained from Figure 4 and the limiting casedepth from Table 2;
ZG2
is obtained from Figure 3;
ZG1
is the greater of:

(16)
(17)
Table 2 Limiting casedepth
Hardening process
Carburizing and hardening

Nitriding
Induction hardening
Limiting casedepth
clim
0.16 mn
0.16 mn
0.32 mn
NOTE Values of HD in this figure are derived from disc tests performed under the auspices of the Admiralty Vickers Gear
Research Association and the Navy and Vickers Gear Research Association
Figure 2 Values of HD
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BS 436-3:1986
NOTE For internal gears the value of relfor an equivalent external gear should be used, i.e. the value of rel obtained from B.11
should be multiplied by (|u| 1)/(|u| + 1).
Figure 3 Values of ZG2
Figure 4 Casedepth factor, Zc
10 Material quality for contact stress, ZM

10.1 Purpose of ZM
Better quality control exercised in the manufacture of a material results in less scatter on the mechanical
properties of the finished material. Hence, for a given confidence level, better quality materials have a
higher permissible stress and, conversely, lower quality materials a lower permissible stress. Material
qualities are defined in Appendix F.
10.2 Values of ZM
The value of ZM is obtained from Table 3.
12
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Table 3 Values of ZM
ZM
Material
Quality A
Quality B
Quality C
Surface hardened steels
1.0
0.9
0.8
Through hardened or
normalized steels
1.0
0.9
0.8
Through hardened or
normalized cast steels or
bronze.
0.9
0.8
0.7
Nodular cast iron
0.9
0.8
0.7
Other cast irons
0.7
0.5
0.5
11 Lubricant influence, roughness and speed factors for contact stress, ZL, ZR
and Zv
11.1 Purpose of ZL, ZR, Zv
The lubricant viscosity, surface roughness and pitch line speed affect the lubricant film thickness which in
turn affects the Hertzian component of the total stress at the pitch cylinder.
11.2 Calculation of ZL, ZR and Zv
The value of the product (ZLZv) is obtained from Figure 5.
The roughness factor ZR is obtained from Figure 6. If the pinion and wheel roughnesses are different, then:
Ra = (Ra1+Ra2)/2
(18)
If the roughness is measured in terms of Rz, then the value of Ra is calculated from the equation:
Ra = Rz/6
(19)
NOTE The values of Ra1 and Ra2 relate to the flank roughness in the finished condition after completing any running-in treatment
or other manufacturing process which may improve the roughness of the flanks. This includes running-in during commissioning,
when it is specified.
12 Work hardening factor for contact stress, ZW

12.1 Purpose of ZW
The work hardening factor accounts for the increase of surface durability due to meshing a through
hardened steel wheel with surface hardened pinion. In all other cases, ZW = 1.0.
12.2 Calculation of ZW
For pinions, ZW = 1.0.
For wheels of hardness less than 400 HV, the value of ZW is obtained from Figure 7.
If the roughness is measured in terms of Rz then calculate Ra from equation (19).
For wheels of hardness greater or equal to 400 HV, ZW = 1.0.
13 Size factor for contact stress, Zx

The size factor is included to take into account possible influences of size on material quality and its
response to heat treatment and other manufacturing processes. The value is taken as Zx = 1.0.
14 Life factor for contact stress, ZN

14.1 Purpose of ZN
The life factor for contact stress takes account of the increase in permissible stress if the number of stress
cycles is less than the endurance life.
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Figure 5 Combined speed and lubricant factors, ZLZv
Figure 6 Roughness factor, ZR
14
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BS 436-3:1986
14.2 Calculation of ZN
If the gear pair is subject to variable duty (and the design torque has therefore been calculated using the
variable duty procedure in Appendix A), then ZN = 1.0. Otherwise, the value of ZN is derived from the
SN curve of the material if it is available, failing which it is taken from Figure 8. The number of cycles of
tooth loading, N, are those appropriate to pinion and wheel, respectively, taking into account the gear ratio
and the number of pinions and wheels in mesh.
Material type 1 applies to through hardened steels, surface hardened steels with casedepth greater than
or equal to the limiting casedepth3) and cast irons other than grey cast iron when some pitting is
permissible (see curve 1 in Figure 8).
Material type 2 applies to through hardened steels and cast irons other than grey cast iron when pitting is
not permissible (see curve 2 in Figure 8).
Material type 3 applies to surface hardened steels with casedepth greater than or equal to the limiting
casedepth3) when pitting is not permissible (see curve 3 in Figure 8).
Material type 4 applies to surface hardened steels with casedepth less than the limiting casedepth3),
bronze and grey cast iron (see curve 4 in Figure 8).
Material type 5 applies to bath nitrided steels (see curve 5 in Figure 8).
Figure 7 Values of ZW
3)
See Table 2 for values of limiting casedepth.
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Figure 8 Life factor for contact stress, ZN
15 Application factor, KA
15.1 Purpose of KA
The application factor accounts for load fluctuations from the mean load or loads in the load histogram
caused by sources external to the gearing. The fluctuations depend on the characteristics of the prime
mover, the driven machinery and the system vibration response to the working conditions.
A typical total gear load is shown broken down into individual components including the application factor
in Figure 9.
15.2 Determination of KA
The application factor is assessed from measurements on similar existing systems or, if such information
is not available, from the empirical information given in Table 4,Table 5 and Table 6.
Table 4 Values of application factor, KA
Load characteristic
of prime mover
Uniform
Light shock
Moderate shock
Heavy shock
Load on driven machine

Uniform
1.0
1.10
1.25
1.50
Moderate shock
1.25
1.35
1.50
1.75
Medium shock
1.50
1.60
1.75
2.0
Heavy shock
1.75
1.85
2.0
2.25
Table 5 Examples of prime mover with different working characteristics

Character of operation
Prime mover
Uniform
Electric motor
Light shock
Steam turbine, gas turbine
Moderate shock
Multi-cylinder combustion engine
Heavy shock
Single cylinder combustion engine
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Table 6 Examples of driven machines with different working characteristics

Character
Uniform
Driven machine
Generator, uniformly loaded belt or platform conveyors, worm conveyors, light

elevators, packaging machines, feed gears for machine tools, ventilators, light
centrifuges, centrifugal pumps, mixer for light fluids or constant density material,
shearing, pressing, punching, turning gears, moving gears
Moderate shock Non-uniformly (e.g. mixed cargo) loaded belt or platform conveyors, main drives of
machine tools, heavy elevators, turning gears of cranes, industrial and mine
ventilators, heavy centrifuges, centrifugal pumps, mixer for high viscosity or variable
density material, multi-cylinder piston pumps, feed pumps, extruders (general),
calenders, rotary furnaces, rolling mills (continuous zinc strip, aluminium strip as well
as wire and bar rolling mills)
Medium shock
Extruders for rubber, mixers with interrupted operation for rubber and plastics, ball
mills (light), wood working (mills, saws, lathes), billet rolling mills, lifting gear, single
cylinder piston pump
Heavy shock
Excavators (bucket wheel gears, multi-bucket gears, sieve gears, power shovels), ball
mills (heavy), rubber dough mills, breaker (stone, ore) metallurgical machines, heavy
feed pumps, rotary drilling apparatus, brick moulding press, braking drums, peeling
machines, cold strip rolling mills, briquette press, pug mills
Figure 9 Constituent parts of typical gear load
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16 Dynamic factor, Kv
16.1 Purpose of Kv
The dynamic factor accounts for load fluctuations arising from contact conditions at the gear mesh. The
main influences are:
a) gear tooth accuracy;
b) the tooth contact frequency divided by the natural frequency of torsional oscillations due to pinion and
wheel inertias acting against the mesh stiffness.
The portion of a typical gear load accounted for by the dynamic factor is illustrated in Figure 9.
The values included in this standard are appropriate.
NOTE At low-load the value of Kv may be higher than given by the standard, but the stress will not exceed the stress at the
maximum rating of the gear on which the values of Kv are based. If a gear pair is operating at or near resonance speed or at multiples
or sub-multiples of resonance speed (particularly the second and third harmonics and sub-harmonics, respectively) then a thorough
dynamic analysis is recommended. This is beyond the scope of this standard.
16.2 Calculation of Kv
The value of Kv is calculated from the equation:
(20)
For helical gears of overlap ratios greater than or equal to unity,
Kv350 = Kv350
where Kv350 is obtained from Figure 10.
For spur gears,
Kv350 = Kv350
where Kv350 is obtained from Figure 11.
For helical gears of overlap ratio less than unity:
(21)
where
Kv350 is obtained from Figure 10;
Kv350 is obtained from Figure 11.
The value of B is calculated from the equation:
(22)
where X is obtained from Table 7.
If the value of FtKA/b is less than 100, then use FtKA/b = 100.
If the procedure is being used to calculate a maximum rating, then estimate the value of FtKA/b from the
equation:
(23)
where HP is the lesser of HP1 and HP2.
It is advisable to check the accuracy of this estimate when the rating has been calculated and, if necessary,
re-calculate Kv using the new value of Ft.
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Table 7 Values of X
Grade
3
4
5
6
7
8
9
10
FtKA/b # 350
0.4736
0.6110
0.7153
0.8017
0.8635
0.9005
0.9334
0.9530
FtKA/b > 350
0.2931
0.4211
0.5402
0.6361
0.7303
0.7954
0.8687
0.8954
16.3 Values of auxiliary parameter Qv

16.3.1 Qv takes account of the shift in the resonance frequency of the gear pair when both or either of the
pinion and wheel are not solid gears. The general equation for Qv is:
(24)
where Mred 0 is the value of Mred for the particular example of a solid pinion mating with a solid wheel and:
(25)
where
M1 is the moment of inertia of the pinion and
(26)
M2 is the moment of inertia of the wheel, and
(27)
16.3.2 Qv and Mred for some common gear arrangements when the pinion and wheel material are of the
same density are given in a) to d) below. If the density of the pinion and wheel materials are different, Qv
is calculated from equations (24) to (27).
a) For a solid pinion meshing with a solid wheel:
Qv = 1.0
(28)
b) For a solid pinion meshing with a wheel with a fabricated rim:

(29)
where
dm2 = (da2 + df2)/2
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(30)
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BS 436-3:1986
c) Planetary gears
1) for sun pinion with planet gear wheel:
(31)
where
np la is the number of planets meshing with the sun;
Mpla is the moment of inertia of the planet gear and is calculated from equation (27);
Msun is the moment of inertia of the sun pinion and is calculated from equation (26).
2) planet gear with annulus rigidly connected to the gear case.
In this and other cases where the mass of the stationary annulus is sufficiently large to be assumed
infinite:
(32)
3) planet gear with rotating annulus:
(33)
where
do2 is the outside diameter of the annulus.
(d) Idler gears
(34)
where
Ml, Midl and M2 are the reduced masses of the small gear (pinion), idler gear and large gear
(wheel) respectively.
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Figure 10 Kv350 for helical gears, & W 1
Figure 11 Kv350 for spur gears
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17 Load distribution factors, KH and KH

17.1 Purpose of the face load factor for contact stress KH
KH is the maximum specific load divided by the mean specific load.
It accounts for the increase in local load due to mal-distribution of load across the face of the gear caused
by deflections, alignment tolerances and helix modifications.
These include:
pinionshaft bending deflections
pinionshaft torsional deflections
misalignment because of manufacturing tolerances
end relief4)
helix correction4)
crowning4)
17.2 Calculation of KH
17.2.1 The calculation of the face load factor involves the following.
a) determination of the mean load intensity wm;
b) determination of the mesh misalignment due to deflections and manufacturing tolerance modified by
the effect of running-in and helix modifications Fy;
c) determination of mesh stiffness, c*
d) calculation of the face load factor, KH
17.2.2 Calculate the value of beff from the equation:
beff = b lc/2
(35)
17.2.3 Calculate the value of wm

If the tangential load on the gears is known and the procedure is being used to calculate a safety factor,
then wm is calculated from the equation:
wm = FtKAKv/beff
(36)
If the calculated value of wm is less than 100 N/mm then use wm = 100 N/mm.
If the procedure is being used to determine the maximum rating of the gear pair, then an estimated value
of Fm is calculated from the equation:
(37)
where HP is the minimum of HP1 and HP2 then:
wm est = Fm est/beff
(38)
wm est is then used in place of wm in the following analysis.

If higher accuracy is required, then the procedure can be used iteratively by calculating a value of KH
using wm est, then re-calculating using wm est/KH. Three such iterations will normally converge to give a
constant value of KH.
17.2.4 Calculate the value of Fy . If:
a) the gears are helix corrected, or
b) the gear layout does not conform to Figure 12, or
c) substantial forces other than pure shaft torque are to be applied (e.g. pulley loads), or
d) wheel shaft deflections are significant,
then Fy is calculated by a thorough analysis of all contritutions to the mesh misalignment (bearing
clearances, case and shaft deflections, manufacturing tolerances, etc.).
4) Recommendations
22
on the design of end relief, helix correction and crowning are given in Appendix C.
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Otherwise Fy is calculated as follows.

1) Calculate the value of fsh.
Values of K, l and s are defined in Figure 12 and A is taken from Table 8. If the value of s is greater
than 0.3l then use
s = 0.3 l
(39)
Then for spur and single helical gears:
(40)
or for double helical gears
(41)
The value of s for double helical gears is the distance to the centre of the helix which is nearer to the
torqued end of the gear.
Table 8 Auxiliary value, A
Gear pairs
without crowning
or end relief
Gears with
suitably chosen
crowning
Gear pairs with

suitably chosen
end relief
mm4m/N
mm4m/N
mm4m/N
0.023
0.012
0.016
2) Calculate fma. The value of fma depends on the manufacturing tolerance of the gears, the case and
bearings and the bearing clearances.
For gears without helix modifications and without any adjustment on assembly, use:
fma = fH
(42)
where fH is the larger of the tooth alignment tolerances of the pinion and wheel given in Table 5 of
BS 436-2:1970.
For gears with crowning or gears where the contact is adjusted on assembly
fma = 0.5 fH
(43)
provided that this assumption is verified by inspection of the contact marking under light load.
For gears with suitable end relief
fma = 0.7 fH
(44)
3) Calculate Fx from the equation:

Fx = |1.33 fsh fma|
(45)
The negative sign is to be used only if the gears are adjusted on assembly and if the contact pattern is
inspected to justify the assumption.
The value of Fx is to be the maximum of
i) the value from equation (45);
ii) 0.005 wm;
iii) half the actual manufacturing tolerance (higher value of pinion and wheel)
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BS 436-3:1986
4) The value of qy is obtained from Figure 13. If the pinion and wheel material are different then:
qy = (qy1 + qy2)/2
(46)
5) Calculate the value of Fy from the equation:

Fy = qyFx
(47)
Factor K
Shrink fit
Key fit
a)
0.0
(s = 0)
0.0
(s = 0)
b)
0.0
(s = 0)
0.0
(s = 0)
c)
0.48
0.8
d)
0.48
0.8
e)
1.33
f)
0.36
0.6
g)
0.6
1.0
1.33
Figure 12 Constant K for calculation of fsh

17.2.5 For gears conforming to the basic rack profile specified in BS 436-1 or BS 436-2 and
with 1.2 u (! u 1.9 average values of c* are:
c* = 20 N/(mm4m) for a steel/steel gear pair;
c* = 18.2 N/(mm4m) for a steel/SG cast iron gear pair;
c* = 16.8 N/(mm4m) for an SG cast iron/SG cast iron gear pair;
c* = 14.8 N/(mm4m) for a steel/grey cast iron gear pair;
c* = 11 N/(mm4m) for a grey cast iron/grey cast iron gear pair.
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BS 436-3:1986
If greater accuracy is required use the procedure in Appendix E.

17.2.6 Calculate the value of KH from either:
(48)
(49)
Figure 13 Values of qy
17.3 Purpose of the transverse load factor for contact stress KH
The transverse load factor for contact stress accounts for the mal-distribution of load down the tooth flank
due to profile and pitch deviations and tooth modifications.
17.4 Calculation of KH!
For gears with * < 2
(50)
where fpe is the single pitch tolerance given in Table 3 of BS 436-2:1970.
For gears with * W 2
(51)
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BS 436-3:1986
Table 9 Minimum and maximum values

of KH!
Gear type
Minimum value of
KH!
Maximum value
KH!
Spur gears
1.0
1/Z2
Helical gears
1.15
!/cos2 b
17.5 Running-in allowance y!

For through hardened steels and cast steels:
(52)
when
v u 5:
no limit
5 < v u 10: y! u 12 800/BH lim
v > 10:
y! u 6 400/BH lim
For cast iron and bronze
y! = 0.275fpe
(53)
when
v u 5:
no limit
5 < v u 10: y! u 22
v >10:
y! u 11
For surface hardened steels
y! = 0.075fpe
(54)
subject to y! u 3 at any speed.

If the pinion and wheel are of different materials then
y! = (y!1 + y!2)/2
(55)
18 Minimum demanded and actual safety factors on contact stress, SHmin and SH
18.1 Minimum demanded safety factor SHmin
The choice of the minimum demanded safety factor is to be agreed between the gear manufacturer and the
purchaser.
NOTE The value should reflect the confidence in the actual operating conditions and material properties being truly reflected in this
standard. When the load histogram is not surely known or where high tooth loads are likely to occur due to circumstances outside the
scope of this standard an appropriately high value of the minimum demanded safety factor should be used. The recommended ranges
of SHmin are
a) for normal industrial applications SHmin = 1.0 to 1.2;
b) for high reliability and critical applications (high consequential damage, loss of life etc.) SHmin = 1.3 to 1.6.
18.2 Calculation of the actual safety factor SH

The value of SH is calculated from the equation:
SH = SH min HP/H
26
(56)
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Section 3. Bending stress calculations

19 Basic equations for tooth root bending stress
19.1 Permissible bending stress FP
The permissible bending stress is calculated separately for pinion and wheel from the equation:
(57)
NOTE The residual stress, R, is viewed algebraically, i.e. R is negative if compressive or positive if tensile. Typical values of R
resulting from good heat treatment practice are given in Appendix D. When requested by the user, the designer should make known,
with justification, the residual stresses assumed for calculation purposes.
19.2 Actual calculated bending stress, F

The actual calculated bending stress is calculated separately for pinion and wheel from the equation:
(58)
19.3 Permissible power capacity and torque based on bending stress PFP and TFP
The permissible power capacity based on bending stress is calculated separately for pinion and wheel from
the equation:
(59)
The permissible torque based on bending stress is calculated separately for pinion and wheel from the
equation:
(60)
19.4 Sub-surface bending in surface hardened gears
Because of the possibility of a sub-surface bending failure, especially when the hardened case is thin, a
check is made at the case/core junction. In this calculation the permissible stresses are calculated from
equation (61) in which the values of material properties relate to the core material.
(61)
To allow for the reduced bending stress below the surface the actual bending stress is calculated from
equation (62), in which F is obtained from equation (58).
(62)
where either
(63)
or 1, whichever is the greater.
The power capacity based on core bending stress is calculated from the equation:
(64)
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BS 436-3:1986
19.5 Idler duty

For frequently reversing duties or any drive where the direction of loading on the teeth is reversed each
cycle (for example, idler gears or planets in epicyclic gearing) the permissible tooth root stress is calculated
from the equation:
(65)
and FP W F
For surface hardened gears the permissible core root stress is calculated from the equation:
(66)
19.6 Peak torque capacity for bending stress TF max
The peak torque capacity for bending stress expressed as a multiple of TFP is given by the equation:
(67)
For surface hardened gears, a further requirement is a calculation of the peak torque capacity of the core
material. In this calculation, the value of FY in equation (67) is replaced by FY core where
(68)
20 Nominal tangential force for bending stress, FFt

The nominal tangential force for bending stress, FFt, is calculated from either equation (69) or (70):
(69)
(70)
(71)
NOTE If either:
a) the gear pair is subject to variable duty, or
b) the gear pair is subject to intermittent high loads for instance at start-up) greater than the nominal running torque,
then the pinion torque TF1 in equation (69) is calculated in accordance with the variable duty procedure in Appendix A.
21 Geometry factors for bending stress, YF, Ys and Y"

21.1 Purpose of geometry factors
21.1.1 Form factor, YF
The form factor takes into account the influence of the tooth form on the nominal bending stress for
application of load at the highest point of single tooth pair contact.
21.1.2 Stress correction factor, YS
The stress correction factor takes into account the stress increasing effect of the fillet and the proximity of
the bending moment arm on the nominal bending stress for application of load at the highest point of single
tooth pair contact.
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21.1.3 Helix angle factor for bending stress, Y

The helix angle factor for bending stress accounts for the fact that the conditions for tooth root stress in
helical gears are more favourable as a result of the inclined line of contact than for the virtual spur gears
on which the calculations are based.
21.2 Calculation of geometry factors
21.2.1 Geometrical equations
The parameters used for calculating the auxiliary parameters in 21.2.2 and 21.2.3 are calculated from
equations (72) to (79).
(72)
(73)
(74)
ad
dana = dn + da d
(75)
(76)
(77)
(78)
dana = mnzv + (da d)
(79)
fn
is calculated by substituting dan and da by dfn and df, respectively.
21.2.2 Auxiliary parameters , G, H and qs for YF, YS and Y of external gears. Auxiliary parameters used
for calculating YF, YS and Yfor external gears are calculated from equations (80) to (90).
NOTE
For the purposes of calculation it may be assumed that hfp = ha0 and fp = ao
Figure 14 Dimensions of the basic rack of the gearing
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BS 436-3:1986
For the calculation of these parameters the dimensions of the basic rack of the gearing, hfp and fp are
introduced, these are defined in Figure 14. The nominal tooth form is taken as a basis, i.e. for this purpose
the influence of backlash and grinding allowance is ignored.
(80)
= ;/6 radians can be used as a starting point for the solution of equation (80).
Where
(81)
(82)
(83)
For tools without protuberance use Spr = 0
(84)
(85)
(86)
(87)
(88)
(89)
(90)
* Inv is the involute form of which is tan.
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21.2.3 Auxiliary parameters for YF, YS and Y of internal gears (approximated by a rack). Auxiliary
parameters used for calculating YF,YS and Y for internal gears are calculated from equations (91) to (94).
(91)
(92)
@ F2
@ fp1
As a first approximation for calculation purposes --------- = ---------mn
2
(92a)
(93)
(94)
with den2 according to equation (86)

and dfn2 analogous to dan according to equation (78) or (79).
21.2.4 Tooth form factor YF
The value of YF is calculated from the equation:
(95)
with parameters according to 21.2.2 for external gears and 21.2.3 for internal gears.
21.2.5 Stress correction factor YS
The value of YS is calculated from the equation:
(96)
where
(97)
qs is the notch parameter and
(98)
with parameters according to 21.2.2 for external gears and 21.2.3 for internal gears.
21.2.6 Helix angle factor Y
The value of Yis calculated from the equation:
(99)
When & > 1, use & = 1, when > 30, use = 30.
22 Basic endurance limit for bending stress, Fo

The basic endurance limit for bending stress used in this standard is based on the fully reversed bending
endurance limit of a 0.3 in (7.62 mm) diameter polished specimen, at a 99 % confidence level.
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BS 436-3:1986
This stress has to be modified for the effects of loading condition, size, surface finish, quality and life before
it can be used as a permissible stress for gear tooth root bending calculations. These factors are included
in equation (57).
The basic endurance limit is taken from the graph in Figure 15.
If the value of (HV) is known, this shall be used in preference to B when using Figure 15. For values of
(HV) not covered by Figure 15, use the equations in H.12.9
Figure 15 Values of F0
23 Material quality factor for bending stress, YM

23.1 Purpose of YM
Better quality control exercised in the manufacture of a material results in less scatter on the mechanical
properties of the finished material. Hence for a given confidence level, better quality materials have a
higher permissible stress and, conversely, lower quality materials a lower permissible stress. Material
qualities are defined in Appendix F.
23.2 Values of YM
The value of YM is taken from Table 10.
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Table 10 Values of YM
YM
Material
Quality A
Quality B
Quality C
Surface hardened steels
1.0
0.9
0.6
Through hardened or
normalized steels
1.0
0.9
0.6
Through hardened or
normalized cast steels or
bronze
0.9
0.8
0.5
Nodular cast iron
0.7
0.6
0.5
Other cast irons
0.3
0.2
0.2
24 Sensitivity factor for bending stress, Y

24.1 Purpose of Y
The sensitivity factor accounts for the sensitivity of the gear material to the presence of notches (i.e. the
root fillet).
24.2 Calculation of Y
24.2.1 Y at the endurance limit
The value of Y at the endurance limit is calculated from the equation:
(100)
where is obtained from Table 11 and qs is obtained from equation (98).
Linear interpolation can be used between the values given in Table 11.
24.2.2 Y at static strength (peak torque capacity)
The value of Y is calculated as follows:
a) for grey cast iron:
Y stat = 1.0
(101)
Table 11 Values of 9
Material
Grey cast iron

Nitrided steel
Soft steel
and bronze
9 (in mm)
FY = 300 MN/m2
FY = 400 MN/m2
0.310
0.100
0.083
0.045
Through hardened
0.2a = 500 MN/m2
0.028
steel cast steel
0.2 =
600 MN/m2
0.019
and S.G. cast iron
0.2 =
800 MN/m2
0.006
B0.2 = 1 000 MN/m2

Carburized, induction and flame hardened steels
0.001
0.2
0.003
is the 0.2 % proof stress.
b) for nitrided steels, from the equation:

Y$ stat = 0.27 Ys + 0.72
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(102)
33
BS 436-3:1986
c) for soft steels and bronze, from the equation:

(103)
d) for through hardened steel, from the equation:
(104)
where 0.2 is the 0.2 % proof stress
e) for carburized, induction and flame hardened steels, from the equation:
Y$ stat = 0.77 Ys + 0.22
Equation 106 deleted.
(105)
(106)
25 Surface condition factor for bending stress, YR

25.1 Purpose of YR
The surface condition factor accounts for the reduction of endurance limit due to flaws in the material and
the surface roughness of the tooth root fillets.
25.2 Calculation of YR
The surface condition factor is taken from Figure 16.
Material type 1 applies to through hardened steels, bronze and cast iron other than grey cast iron
(see curve 1 in Figure 16).
Material type 2 applies to surface hardened steels with casedepth greater than or equal to the limiting
casedepth (see Table 2 for values of limiting casedepth) (see curve 2 in Figure 16).
Material type 3 applies to surface hardened steels with casedepth less than the limiting casedepth
(see Table 2 for values of limiting casedepth) and grey cast iron (see curve 3 in Figure 16).
26 Size factor for bending stress, Yx

The size factor is included to take into account possible influences of size on material quality and its
response to heat treatment and other manufacturing processes. Its value is taken from Figure 17.
Material type 1 applies to through hardened steels and cast iron other than grey cast iron (see curve 1 in
Figure 17).
Material type 2 applies to surface hardened steels (see curve 2 in Figure 17).
Material type 3 applies to grey cast iron and bronze (see curve 3 in Figure 17).
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NOTE
Ra is the roughness (CLA value) of the root.
Figure 16 Values of YR
Figure 17 Values of Yx
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BS 436-3:1986
27 Life factor for bending stress, YN

27.1 Purpose of YN
The life factor for bending stress accounts for the increase in permissible stress if the number of stress
cycles is less than the endurance life.
27.2 Calculation of YN
If the gear is subject to variable duty (and the design torque has therefore been calculated using the
variable duty procedure in Appendix A), then the value of YN is 1.0. If the S/N curve of the material is
known then this is used as the basis for the life factor. Otherwise, YN is obtained from Figure 18,
Figure 19 or Figure 20, as appropriate.
Figure 18 applies to through hardened steels.
Figure 19 applies to surface hardened steels with casedepth greater than or equal to the limiting casedepth
(see Table 2 for values of limiting casedepth) and cast iron.
Figure 20 applies to surface hardened steels with casedepth less than the limiting casedepth
(see Table 2 for values of limiting casedepth), grey cast iron and bronze.
For bath nitrided steel YN = 1.0 for all values of N, the number of tooth cycles.
28 Load factors for bending stress, KF and KF

28.1 Purpose of Kf and KF
The load factors for bending stress account for uneven distribution of bending moment across the facewidth
caused by uneven loading across the face.
28.2 Calculation of KF! and KF
KF! = KH!
(107)
where KH! is obtained from 17.4.

(108)
where KH is obtained from 17.2 and h/b is the maximum of h1/b1 and h2/b2.
29 Minimum demanded and actual safety factors on tooth root stress, SFmin
and SF
29.1 Minimum demanded safety factor SF min
The choice of the minimum demanded safety factor is to be agreed between the gear manufacturer and the
purchaser.
NOTE The value should reflect the confidence in the actual operating conditions and material properties being truly reflected in this
standard. When the load histogram is not surely known or where high tooth loads are likely to occur due to circumstances outside the
scope of this standard an appropriately high value of the minimum demanded safety factor should be used. The recommended ranges
of SF min are
a) for normal industrial applications SF min = 1.4 to 1.5;
b) for high reliability and critical applications (high consequential damage, loss of life, etc.) SF min = 1.6 to 3.0.
29.2 Calculation of the actual safety factor SF

The value of SF is calculated from the equation:
SF = SFmin FP/F
36
(109)
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Figure 18 YN for through hardened steel
Figure 19 YN for thick case surface hardened steel and cast iron
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BS 436-3:1986
Figure 20 YN for thin case surface hardened steel, grey cast iron and bronze
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BS 436-3:1986
Appendix A Variable duty calculations

A.1 Symbols, terms and units
Symbol
Designation
Units
Ni
number of tooth cycles endured at torque Ti
Nmax
number of cycles at upper knee of S/N curve (see Figure 21)a
NZ
number of cycles at lower knee of S/N curve (see Figure 21)a
exponent (see equation (110) or (111)
Ti
applied pinion torques
Nm
TZ
design torque for W N cycles equivalent to the specified dutya
Nm
lim
stress at lower knee of S/N curve (see Figure 21)a
MN/m2
max
stress at upper knee of S/N curve (see Figure 21)a
MN/m2
torque number (i = 1 for largest torque)
Subscripts
i
a
With additional subscript H for contact stress or subscript F for bending stress calculations.
A.2 Preliminary calculations (applicable to both contact and bending stress)

A.2.1 Arrange the applied pinion torques, Ti, in descending order of magnitude.
A.2.2 For each level of torque calculate the number of cycles of tooth engagement experienced by pinion
and wheel respectively. The number of pinions and wheels in engagement and the gear ratio have to be
taken into account.
A.3 Contact stress calculations
The value of QH is calculated from the equation:
(110)
or if the S/N curve of the material is not available, use the value in Table 12.
Figure 21 Typical S/N curve
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BS 436-3:1986
Table 12 Default values for contact stress S/N curve parameters

Material type (see 14.2)
1
NHZ
109
5 107
5 107
2 106
2 106
N B H max
104
5 104
105
105
105
H max/H lim
2.0
2.0
1.6
1.3
1.1
QH
8.305
4.983
6.611
5.709
15.72
NOTE In order to facilitate the calculations for surface stress when pitting is allowed, the three
sections of the life curve (see Figure 8) have been approximated to one straight line. This will
result in a slightly over-estimated value of THZ for low numbers of cycles.
A.4 Bending stress calculations

The value of QF is calculated from the equation:
(111)
where Nmin is the minimum of the values Ni, or N F max calculated for pinion or wheel, and YN(Nmin) is the
value of YN for Nmin cycles.
If the S/N curve of the material is not available, values of NFZ and NF max can be taken from the
appropriate life curve in clause 27.
A.5 Variable duty calculations
A.5.1 The following calculation has to be performed for each of the following conditions:
a) contact stress values of QH and NZ using
1) pinion tooth cycles;
2) wheel tooth cycles;
b) bending stress values of QF and NZ using
1) pinion tooth cycles;
2) wheel tooth cycles.
A.5.2 Starting with i = 1 (i.e. including the largest torque only) and continuing with further values of Ti in
descending order, calculate TZi for successive values of Ti using the equation:
(112)
Then:
a) If any value of TZi is greater than the next level of torque T(i+1) then that value of TZi is used as TZ
in the calculation of actual stress or power.
b) If TZi is less than T(i+1) (i.e. if condition a) does not apply), but TZ(i + 1)is greater than T(i + 1), then
T(i + 1) is used as TZ in the calculation of actual stress or power.
c) If when all torques have been included the final value of TZi is less than the final Ti, then TZi is used
as TZ in the calculation of actual stress or power. If the final value of TiZ is greater than the final value
of Ti then the final value of Ti is used. This is equivalent to using a) and b) above with an additional
imaginary infinitesimal torque Ti.
40
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Appendix B Gearing equations

B.1 Reference diameter of pinion, d1
The value of d1 is calculated from the equation:
B.2 Length of path of contact g

The value of g is calculated from the following equations.
NOTE
Centre distance a is a negative quantity for internal gears.
B.3 Transverse base pitch, pbt

The value of pbt is calculated from the equation:
B.4 Pitch line velocity, v

The value of v is calculated from the equation:
B.5 Transverse pressure angle at reference cylinder, !t

The value of t is calculated from the equation:
B.6 Transverse pressure angle at pitch cylinder, !tw

The value of tw is calculated from the equation:
B.7 Base helix angle, b

The value of b is calculated from the equation:
b = sin1(cos n sin )
B.8 Transverse contact ratio, &!
The value of &! is calculated from the equation:
B.9 Overlap ratio, &"

The value of &" is calculated from the equation:
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BS 436-3:1986
B.10 Total contact ratio, &*

The value of &* is calculated from the equation:
&* = &" + &!
B.11 Radius of relative curvature, rel
The value of rel is calculated from either of the equations:
B.12 Virtual number of teeth, Zv

The value of zv is calculated from the equation:
Appendix C Design guidance on tooth modifications

C.1 General
This design guide is included as an aid to gear designers in choosing suitable amounts of tooth reliefs and
corrections.
C.2 End relief
End relief is used:
a) on a helical gear to allow for tooth deflections such that a tooth entering the meshing zone receives
minimum shock which is important in gearing with a low noise requirement, and/or
b) to prevent high loading at the ends of the teeth due to mesh misalignment.
The height of end relief is related to tooth deflection and misalignment.
The recommended range of length of end relief is:
lc = 0.05 b
(113)
to
lc = 0.1 b
(114)
The recommended range of height of end relief is:
Cb = FY
(115)
to
Cb = FY + 20
(116)
where Fy is calculated in accordance with 17.2.4.
Figure 22 Height and length of end relief
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Figure 23 Height of crowning

C.3 Helix correction
Helix correction is determined by calculating the deflected shape of the pinion at a particular load
assuming a uniform distribution of load across the facewidth (but excluding the end-relieved portion of the
facewidth). The complement of this deflected shape (usually approximated to a straight line) is then applied
to the tooth in terms of metal removed.
Since helix correction is fully effective only when the gear is operating at the load for which the correction
was calculated, the choice of design load is important. The following points should be considered when
choosing the load.
a) When running at loads less than the design load, KH will increase and may become greater than its
value without helix correction. The specific loading will however be less than at the design load.
b) When running at loads greater than the design load, KH will increase but will always be less than
the value without helix correction at the particular load.
Unless the correction is designed after a no-load meshing test, manufacturing and location errors cannot
be compensated for by helix correction. It is recommended therefore that helix correction is used only for
gears of sufficient manufacturing and location accuracy that any such errors are negligible, unless
corrections are designed to accommodate errors as measured on a no-load meshing test. Crowning (see C.4)
is recommended in preference to helix correction if significant alignment errors are anticipated.
C.4 Crowning
Crowning is a crude form of helix modification used to compensate for manufacturing errors and
deformations of the gear under load. It is recommended that crowning be used only if the value of KH
without crowning (clause 17) is greater than 2.
The recommended range of crowning height is
Cc = F
(117)
Cc = F + 20
(118)
to
where fsh is calculated in accordance with 17.2.4.
C.5 Tip and root relief
On helical gears, tip and root relief is used to prevent high loading at the tip/root contact where the sliding
velocity is a maximum and scuffing is likely to occur. On spur gears, tip and root relief is used to allow for
tooth deflection, prevent tip loading and to reduce noise levels at tooth-contact frequency.
The lengths and heights of relief depend largely on the capabilities of the gear cutting machine used to
finish the gears. The following recommendations can therefore only be regarded as typical values.
The length and height of tip relief should not exceed the maximum permissible amounts specified in
BS 436-2.
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BS 436-3:1986
The recommended ranges of height of relief are:

a) for helical and double helical gears:
Ca = (0.06 Ft/b) + 5
to
Ca = (0.06 Ft/b) + 25
b) for spur gears:
Ca = fp + (0.06 Ft/b) + 5
to
Ca = fp + (0.06 Ft/b) + 25
(119)
(120)
(121)
(122)
The value selected from these ranges should be the minimum of the tolerance band.
This amount of relief may be disposed as tip and/or root relief on pinion and/or wheel in one of the following
ways:
1) the relief calculated in equations (119) to (122) applied as tip relief only on both pinion and wheel;
2) the relief calculated in equations (119) to (122) applied as both tip and root relief on one gear only
(usually the pinion);
3) one-half the relief calculated in equations (119) to (122) applied as both tip and root on both pinion
and wheel;
4) other dispositions between pinion and wheel tip and root with the relief calculated in equations (119)
to (122) disposed between pinion tip and wheel root, and between pinion root and wheel tip.
Appendix D Typical residual stresses

D.1 General
The residual stresses in Table 13 are typical of the values pertaining after the gear material has undergone
the listed hardening processes. If the actual residual stress of the gear or a test piece is measured, then
that value should be used in preference to the values in Table 13 and Table 14 and should be made known,
with justification, to the user.
D.2 Carburizing and hardening
Incorrect heat treatment may result in compressive residual stress levels lower than those indicated. In
particular, decarburization will reduce the residual stress level. The degree of decarburization can be
detected by surface hardness measurement or by filing and re-checking.
D.3 Gear grinding
Grinding of the surface may affect the residual stress at the immediate surface and, for guidance, the
values in Table 14 may be added algebraically to those in Table 13.
Table 13 Typical values of residual stress, R
Hardening process
Quality A or B
Quality C
Rcore
Rcore
MN/m2
MN/m2
MN/m2
MN/m2
Carburized and hardened
400
240
240
Nitride hardened
400
140
140
Induction hardened
140
450
450
D.4 Shot peening

Shot peening can be used to increase the surface residual compressive stress. Correct selection of shot and
of intensity is extremely important and should be controlled by Almen strips. For guidance, a typical value
of the change in residual stress after shot peening with correct technique is given in Table 14.
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BS 436-3:1986
Table 14 Change in residual stress due to

post-hardening operations
Operation
Algebraic change to R
Very light grinding

carefully controlled
MN/m2
0
Light full-form grinding
+ 300 (tensile)
Heavy abrasive grinding
+ 600 (tensile)
Controlled shot peening
500 (compressive)
Appendix E Tooth and mesh stiffness c9 and c*

E.1 General
The main factors influencing tooth stiffness are:
a) tooth thickness;
b) tooth form;
c) tooth height;
d) helix angle;
e) radii of profile curvature;
f) rim section design;
g) gear manufacturing deviations and alignment errors;
h) Youngs modulus.
E.2 Calculation of c99 and c*
E.2.1 Single stiffness c9
The maximum stiffness of one pair of teeth (single stiffness) in the normal plane can be evaluated using
equations (123) and (124).
(123)
(124)
Where the coefficients C1 ... C9 are:
C1 =
0.04723; C2 =
0.15551; C3 =
0.25791;
C4 = 0.00635; C5 = 0.11654; C6 = 0.00193;

C7 = 0.24188; C8 =
0.00529; C9 =
0.00182.
E.2.2 Mesh stiffness c*

The mean value of the total tooth stiffness constant in the transverse plane can be calculated from
equation (125). This equation is valid for spur gears and for helical gears up to = 45.
c* = c9 (0.75 &! + 0.25)
(125)
with c9 from equation (123).

E.2.3 Materials other than steel
Equations (123) to (125) apply to steel/steel gear pairs.
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BS 436-3:1986
For other materials:

(126)
(127)
where is the ratio of E for the material to E for steel, i.e.
(128)
and
(129)
Appendix F Definition of material quality

F.1 General
The following three levels of material quality are recommended.
a) Quality C defines the minimum requirements for materials and their heat treatments for lightly
loaded gears in non-critical applications.
b) Quality B defines the requirements for materials and their heat treatments for the majority of
industrial gears at reasonable cost.
c) Quality A defines the maximum requirements for materials and their heat treatments for special
applications, e.g. high power or high reliability requirements.
F.2 Quality specifications
F.2.1 General
In order to rate a pair of gears to a particular material quality level, a specification needs to be drawn up
to define the level of inspection expected at different stages of the manufacture. Such a specification may
be the subject of agreement between the gear manufacturer and the gear purchaser.
Guidance and comments are given in F.2.2 to F.2.4 under headings which would normally be included at
each grade level. This is not intended to form the basis of a specification, but rather to be an aid to
determining the quality level of a material manufactured to an existing specification. In practice, a full
specification will probably cover additional items.
F.2.2 Quality C
The inspection requirements for quality C are as follows.
a) Mechanical properties (in final condition): HB or HV only (see BS 240-1 and BS 427-1).
b) Casedepth: Etch check on a test piece carburized with the gear. For induction or flame hardened gears,
etch check on the tooth end face of a sample gear.
c) Weld repairs: For cast steels, permitted with an approved procedure. For other materials, not
permitted in toothed areas.
F.2.3 Quality B
For cast iron other than nodular cast iron, the permissible stresses for quality B are the same as for
quality C on the grounds of safety. The inspection requirements are therefore as for quality C. For other
materials the inspection requirements are as follows.
a) Chemical analysis: Supplier certification.
b) Mechanical properties (in final condition): HB, HV or HRC (see BS 240-1, BS 427-1 and BS 891-1). B
and Charpy or Izod (random samples) (see BS 131-1 and BS 131-2).
c) Crack detection: Magnetic particle inspection (100 % inspection on surface hardened, otherwise
random samples) (see BS 6072).
d) Weld repairs: For cast steels, permitted with an approved procedure. For other materials, not
permitted in toothed areas.
e) Ultrasonic inspection: 100 % checks on cast materials (see BS 4080).
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BS 436-3:1986
f) Casedepth: Etch check on a test piece carburized with the gear. For induction or flame hardened gears,
etch check on tooth end face and full tooth profile on a sample or every gear (dependent on batch size).
g) Core structure (nodular irons): Sample check from batch for pearlite and ferrite content and graphite
spheroidization.
h) Heat treatment (carburized steel): Furnace fitted with atmosphere control instrumentation.
F.2.4 Quality A
All tests applicable to quality B apply also to quality A, but random sampling (when applicable to
quality B) is replaced by 100 % testing. Additional inspection requirements are as follows:
a) Ultrasonic inspection: 100 % check (see BS 4080, BS 4124-1 and BS 5996).
b) Casedepth: Hardness traverse check on a test piece (same material cast and heat treatment condition)
carburized with the gear. For induction or flame hardened gears, hardness traverse check at nominated
positions across the facewidth on a sacrificial test gear or segment hardened under the same conditions
as the gear.
c) Surface structure (carburized steel): Check on test piece: essentially fine martensite and specified
retained austenite and carbide.
d) Heat treatment: Furnace temperature chart records.
Appendix G Examples of calculations

G.1 Example 1
G.1.1 The following pair of single helical gears are to be rated against the standard to find the maximum
power rating.
Gear details
Pinion
Wheel
Centre distance, a
325 mm
325 mm
Normal module, mn
8 mm
8 mm
Normal pressure angle at reference

cylinder, !n
20
20
Helix angle,
18 379
18 379
Number of teeth, z1, z2
19
58
Facewidth, b
125 mm
125 mm
Reference diameters, d1, d2
160.392 mm 489.619 mm
Tip diameters, da1, da2
180.708 mm 501.292 mm
Tooth depth, h1, h2
19.2 mm
Mounting arrangement
Both central between bearings
Shaft diameters
130 mm
Number of revolutions, n1
1 450 r/min
Manufacturing accuracy
BS 436-2, grade 5
Construction
solid
solid
Helix modification
none
none
Mean roughness, Ra (flank)
0.8 4m
0.8 4m
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19.2 mm
47
BS 436-3:1986
Mean roughness, Ra (root)
3.2 4m
3.2 4m
Hob details
Thickness at reference diameter
12.72 mm
Hob addendum, ha0
11.2 mm
Hob tip radius, a0
2.40 mm
Offset of tip radius from centreline, D
0.80 mm
Material and operating conditions (pinion and wheel)

Material type
steel quality B
Hardening process
carburized and hardened
Surface hardness
825 HV
Effective casedepth, ceff
1.3 mm
Ultimate tensile strength, B
2 130 MN/m2
Core tensile strength, B core
1 000 MN/m2
Residual stress (surface), R
400 MN/m2
Residual stress (core), R core
240 MN/m2
Lubricant viscosity at 40 C
303 cSt
Application factor, KA
1.0
Required life
25 000 h
Minimum demanded safety factor for

contact stress, SH min
1.0
Minimum demanded safety factor for

bending stress, SF min
1.4
G.1.2 From the given gear details the following geometry is calculated.
dw1
= 2 a/(u + 1)
= 160.390 mm
dw2
= dw1 u
= 489.610 mm
= tan1 (tann/cos)
= 21 09 360
db1
= d1 cos!t
= 149.729 mm
db2
= d2 cos!t
= 457.068 mm
&
= b sin/(mn;)
= 1.588
g!
from B.2
= 37.015 mm
g!
used in subsequent
= 34.462 mm
calculations, allowing for
undercut on the pinion
(calculated separately from
this procedure)
bt
from B.3
= 24.757 mm
&!
= g/bt
= 1.392
= sin1 (cos nsin)
= 17 279 240
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BS 436-3:1986
rel
from B.11
= 22.703 mm
zv1
= z1/cos3
= 22.32
zv2
= z2/cos3
= 68.15
= d1n1/19098
= 12.178 m/s
G.1.3 Contact stress factors are now calculated as follows.

Zone factor, ZH, from equation (9)
= 2.3877
Contact ratio factor, Z&, from equation (12)
= 0.8477
Elasticity factor, ZE, from Table 1
= 189
Endurance limit for contact stress, H lim

BHD from Figure 2
= 2 130 MN/m2
ZG2 from Figure 3
= 0.925
ZG1 from equation (16)
= 0.887
Limiting casedepth from Table 2
= 1.28 mm
Zc from Figure 4
= 1.0
then H lim 1 from equation (15)
= 1 888 MN/m2
and H lim 2 from equation (15)
= 1 969 MN/m2
Material quality factor, ZM, from Table 3
= 0.9
Lubricant influence, roughness and speed factors, ZL, ZR, Zv

ZLZv from Figure 5
= 1.076
ZR from Figure 6
= 0.943
Work hardening factor, Zw, from clause12
= 1.0
Size factor for constant stress, Zx, from clause 13= 1.0
Life factor for contact stress, ZN
Number of tooth cycles
N1 = 25 000 60 1450
= 2.18 109
Number of tooth cycles

N2 = N1/u
= 7.13 108
then ZN1 and ZN2 from curve 3 of Figure 8
= 1.0
Minimum demanded safety factor for contact

stress, SH min (value specified)
= 1.0
Permissible contact stress, HP1

from equation (1)
= 1 724 MN/m2
and HP2 from equation (1)
= 1 798 MN/m2
Application factor, KA (uniformly loaded)
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49
BS 436-3:1986
Dynamic factor, Kv
Qv from 16.3
= 1.0
Kv350 from Figure 10
= 1.05
(FtKA/b)est from equation (23)
= 2 337 N/mm
B from equation (22)
= 0.3586
then Kv
= 1.018
Load distribution factors KH!, KH

beff
from equation (35)
= 125 mm
Fm est
from equation (37)
= 306 700 N
wm est
from equation (38)
= 2 454 N/mm
from Figure 12
=0
from Table 8
= 0.023
fsh
from equation (40)
= 34.3 4m
fma
from equation (42)
= 12.9 4m
FX
from equation (45)
= 58.5 4m
qY
from Figure 13 and equation (46)
= 0.83
FY
from equation (47)
= 48.6 4m
c*
from 17.2.5
= 20 N/(mm4m)
KH
from equation (49)
= 1.20
fpe
from Table 3 of BS 436-2:1970
= 12.2 4m
y!
from equation (54)
= 0.9 4m
KH!
from 17.4
= 1.15
Power capacity PHP1 from equation (3)
= 2 659 kW
PHP2 from equation (3)
= 2 892 kW
G.1.4 Bending stress factors are now calculated as follows:

(sFn/mn) from equation (84):
pinion = 2.075
wheel = 2.159
(F/mn) from equation (85):
pinion = 0.475
wheel = 0.548
Fen from equation (89):
pinion = 0.387 rad

wheel = 0.340 rad
(hF/mn) from equation (90):
pinion = 1.188
wheel = 1.384
Then form factor YF from equation (95):
pinion = 1.630
wheel = 1.788
L from equation (97):
pinion = 1.748
wheel = 1.559
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qs from equation (98):
pinion = 2.187
wheel = 1.968
Then stress correction factor Ys from

equation (96):
pinion = 1.945
wheel = 1.805
Helix angle factor Y from equation (99):
= 0.845
Basic endurance limit for bending stress, F0

from Figure 15 (pinion and wheel)
= 560 MN/m2
Surface residual stress, R (value supplied)
= 400 MN/m2
Material quality factor YM from Table 10
= 0.9
Sensitivity factor Y from equation (100):

pinion = 1.032
wheel = 1.030
Surface condition factor, YR from Figure 16
= 0.904
Size factor for bending, Yx from clause 26
= 0.97
Life factors for bending, YN1 and YN2 from

clause 27
= 1.0
Load factors for bending

KF! from equation (107)
= 1.15
KF from equation (108)
= 1.168
Minimum demanded safety factor, SF min

(value specified)
Permissible bending stress, BFP from
equation (57):
= 1.4
pinion = 629 MN/m2

wheel = 628 MN/m2
Permissible power capacity, PFP from

equation (59):
pinion = 2 090 kW
wheel = 2 051 kW
Sub-surface bending calculations:

Permissible core bending stress,
FP core from equation (61):
Actual bending stress, Fcore from
equation (62):
= 319 MN/m2
pinion = 218 MN/m2
wheel = 235 MN/m2
Core power capacity from equation (64):pinion = 3 056 kW

wheel = 2 787 kW
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BS 436-3:1986
G.2 Example 2: variable duty calculation using Appendix A

The design torque of the pair of gears in example 1 is to be calculated from Table 15.
From Table 12, QH = 6.611
and NHZ = 5 107
For the calculation of QF,
pinion
wheel
YX
= 0.97
0.97
YR
= 0.904
0.904
= 2 130
2 130
F0
= 560
560
Nmin
= 3 105
9.8 104
NFZ
= 3 106
3 106
YN(N min)
= 1.352
1.565
Then QF
= 9.685
9.852
Then THZ1
= 9 486 Nm [see A.5.1 a)]
THZ2
= 8 017 Nm [see A.5.1 a)]
TFZ1
= 14 336 Nm [see A.5.1 b)]
TFZ2
= 12 838 Nm [see A.5.1 b)]

Table 15 Variable duty calculation example
Required duty
Ti
n1
Pinion calculation
Duration of
applied
torque
Nm
Ni1
Wheel calculation
THZi1
TFZi1
Nm
Ni2
THZi2
TFZi2
Nm
Nm
Nm
17 500
500
10
3.0 105 8 072
13 797
9.8 104 6 815
12 366
15 000
500
20
6.0 105 8 763
14 336
2.0 105 7 408
12 838
12 500
1 450
25
2.1 106 9 259
6.9 105 7 827
10 000
1 450
60
5.2 106 9 486
1.7 106 8 017
8 000
1 450
Continuous
> 5 107
> 5 107
Appendix H Equations of graphs

H.1 Equations for graph of yield strength for contact stress, HY, in Figure 1
For through hardened steels and cast irons:
HY = 0.96362 B + 838.755
For surface hardened steels:
HY = 9.81 [(31.0 log10 (6ceff) 275.5) log10 (rel) + 130.0 log10 (6ceff) + 526]
H.2 Equations for graph of values of HD in Figure 2
If B < 2 130, then HD = B.
If B W 2 130, then HD = 2 130.
52
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BS 436-3:1986
H.3 Equations for graph of values of ZG in Figure 3
if B W 2 130 or the material is surface hardened and rel/mn W 12.0 then ZG = 0.5667.
Use linear interpolation for values of B between the curves.
H.4 Equations for graph of casedepth factor, Zc, in Figure 4
If ceff/clim < 1.0 then Zc = [5.0 + 3(ceff/clim)]/8.
If ceff/clim > 1.0, then Zc = 1.0.
H.5 Equation for graph of combined speed and lubricant factor, ZLZv, in Figure 5
H.6 Equation for graph of roughness factor, ZR, in Figure 6
H.7 Equation for graph values of ZW in Figure 7
BSI 06-1999
53
BS 436-3:1986
H.8 Equations for graph of life factor for contact stress, ZN, in Figure 8
H.8.1 Curve 1
H.8.2 Curve 2
H.8.3 Curve 3
H.8.4 Curve 4
H.8.5 Curve 5
54
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BS 436-3:1986
H.9 Data for graph of Kv350 for helical gears, &" W 1, in Figure 10
Table 16 gives values of Kv350 at discontinuities
Grade
Qvvz1
0
1 400
1 440
2 000
2 540
Values of Kv350
1.0
1.18
1.47
1.47
1.18
1.0
1.23
1.54
1.54
1.23
1.0
1.31
1.65
1.65
1.31
1.0
1.45
1.80
1.80
1.45
1.0
1.65
1.0
1.96
1.0
2.44
10
1.0
3.38
Use linear interpolation between the above points.

The lines for grades 7 to 10 are terminated at the points given in Table 17.
Grade
Kv350
1.50
1.50
1.50
10
1.42
H.10 Data for graph of Kv350 for spur gears in Figure 11

Table 18 gives values of Kv350 at discontinuities
Table 18 Values of Kv350! at discontinuities
Grade
Qvvz1
0
1 000
1 040
1 400
1 800
Values of Kv350
1.0
1.21
1.77
1.77
1.21
1.0
1.30
1.89
1.89
1.30
1.0
1.42
2.06
2.06
1.42
1.0
1.61
2.26
2.26
1.65
1.0
1.92
2.60
2.60
1.98
1.0
2.29
1.0
2.78
10
1.0
3.50
Use linear interpolation between the above points.

The lines for grades 7 to 10 are terminated at the points given in Table 19.
BSI 06-1999
55
BS 436-3:1986

Grade
Kv350!
2.40
1.96
1.96
10
1.82
H.11 Equation for graph of values of q in Figure 13
H.12 Equations for graph of values Fo in Figure 15
H.13 Equations for graph of values of YR in Figure 16

H.13.1 Curve 1
YR = 1.49 0.471(6Ra + 1)0.1
H.13.2 Curve 2
YR = 4.924 3.9(6Ra + 1)0.01
H.13.3 Curve 3
YR = 4.161 3.155(6Ra + 1)0.005
H.14 Equations for graph of values of YX in Figure 17
H.14.1 All curves
If mn u 5, then
Yx = 1.0
H.14.2 Curve 1
If 5 < mn < 30, then
Yx = 1.03 0.006 mn
If mn W 30, then
Yx = 0.85
H.14.3 Curve 2
Yx = 1.05 0.01 mn
If mn W 30, then
Yx = 0.75
H.14.4 Curve 3
Yx = 1.075 0.015 mn
If mn W 25, then
Yx = 0.70
56
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H.15 Equation for graph of YN for through hardened steel in Figure 18
H.16 Equation for graph of YN for thick case surface hardened steel and cast iron
in Figure 19
H.17 Equation for graph of YN for thin case surface hardened steel, grey cast iron and
bronze in Figure 20
BSI 06-1999
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58
blank
BS 436-3:1986
Publications referred to
BS 131, Methods for notched bar tests.
BS 131-1, The Izod impact test on metals.
BS 131-2, The Charpy V-notch impact test on metals.
BS 240, Method for Brinell hardness test.
BS 240-1, Testing of metals.
BS 427, Method for Vickers hardness test.
BS 436, Spur and helical gears.
BS 436-1, Basic rack form, pitches and accuracy (diametral pitch series).
BS 436-2, Basic rack form, modules and accuracy (1 to 50 metric module).
BS 891, Method for Rockwell hardness test.
BS 1400, Specification for copper alloy ingots and copper alloy and high conductivity copper castings.
BS 2519, Glossary for gears.
BS 2519-1, Geometrical definitions.
BS 2519-2, Notation.
BS 4080, Methods for non-destructive testing of steel castings.
BS 4124, Non-destructive testing of steel forgings.
BS 4124-1, Ultrasonic flaw detection.
BS 5996, Methods for ultrasonic testing and specifying quality grades of ferritic steel plate.
BS 6072, Method for magnetic particle flaw detection.
BS 6443, Method for penetrant flaw detection.
BSI 06-1999
BS 436-3:1986
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Licensed Copy: University of Manchester Library, The University of Manchester Library, 04/02/2013 16:37, Uncontrolled Copy, (c) The

British Standards Institution 2012

Spur and helical

Committees responsible for this

This British Standard, having

Amendments issued since publication

Indicated by a sideline in the margin

Figure 4 Casedepth factor, Zc

Gear Association, c/o Institution of mechanical Engineers, Birdcage Walk, London

2 Definitions and symbols

This subclause is based on the symbols of BS 2519-2:1976.

maximum tooth stiffness of one tooth pair in

reference diameter of wheel

virtual tip diameter

virtual base diameter

virtual diameter to highest point of

root diameter of internal gear

virtual root diameter of internal gear

mean diameter [= (da + df)/2]

virtual reference diameter

pitch diameter of pinion

pitch diameter of wheel

mesh misalignment due to manufacturing tolerance

permissible single pitch deviation

mesh misalignment due to shaft deflections

dedendum of internal gears

dedendum of the basic rack of the gearing

bending moment arm

a, u and z2 are negative for internal gears.

transverse base pitch

combined flexibility of a pair of teeth

reduction factor on misalignment due to running-in

thickness of virtual tooth at critical section

residual undercut left by the protuberance

mean load intensity

addendum modification coefficient

parameter for effect of load

height of end relief

mean tangential force

nominal tangential force at reference circle

nominal tangential force for bending stress

nominal tangential force for contact stress

mesh misalignment prior to running-in

effective mesh misalignment

Vickers hardness value

dynamic factor for FtKA/b = 350

dynamic factor for spur gears

dynamic factor for helical gears

transverse load factor for bending stress

face load factor for bending stress

transverse load factor for contact stress

a, u and z2 are negative for internal gears.

face load factor for contact stress (Hertzian pressure)

mass per unit facewidth of the gear pair referred

permissible power capacity based on bending stress

actual power capacity based on contact stress

permissible power capacity based on contact stress

minimum demanded safety factor for contact stress

actual torque based on bending stress

peak torque capacity for bending stress

permissible torque based on bending stress

actual torque based on contact stress

peak torque capacity for contact stress