Gears

Contents
SPUR GEAR, GEAR RACK ................................................................................................................................................... 2
GROUNDWORK CALCULATIONS............................................................................................................................................. 2
SCOPE OF THE PROGRAM .................................................................................................................................................... 4
GEOMETRY OF SPUR GEARS ................................................................................................................................................. 5
GROUNDWORK CALCULATIONS AND SCOPE............................................................................................................................ 15
SPUR GEARS CALCULATION - STRENGTH - DETERMINATION OF RESULTS ....................................................................................... 16
CALCULATION OF LOADS ................................................................................................................................................... 22
SPUR GEARS CALCULATION - STRENGTH - PITTING MAXIMUM LOADING ....................................................................................... 23
LOAD DUTY CYCLE ........................................................................................................................................................... 27
ROOT BEARING CAPACITY .................................................................................................................................................. 29
LOAD DUTY CYCLE ........................................................................................................................................................... 32
SCUFFING LOAD CAPACITY.................................................................................................................................................. 34

STANDARD GAUGE SPUR GEARS ......................................................................................................................................... 40

CALCULATING GROUNDWORK............................................................................................................................................. 40
STANDARD GAUGE SPUR GEARS - DETERMINATION OF RESULTS ................................................................................................. 40
BEVEL-, HYPOID GEAR .................................................................................................................................................... 45
GROUNDWORK CALCULATIONS........................................................................................................................................... 45
CALCULATION GEOMETRY .................................................................................................................................................. 46
CALCULATION OF GEOMETRY.............................................................................................................................................. 47
CYLINDRICAL WORM GEAR ............................................................................................................................................ 72
CALCULATION BASE ......................................................................................................................................................... 72
RANGE OF APPLICATION ................................................................................................................................................... 72
CYLINDRICAL WORM GEAR DETERMINATION OF RESULTS........................................................................................................ 73
STRENGTH PROOF ........................................................................................................................................................... 75

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Gears

Spur Gear, Gear Rack

With the following program based on the groundwork 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 bearing capacity, root bearing capacity,
scuffing 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 groundwork 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

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Gears

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 groundwork calculations for the module Strength Examination of Spur Gears is described by the
following DIN specifications:
- DIN 3990
- DIN 3990
- DIN 3990
- DIN 3990
- DIN 3990
- DIN 3990
- DIN 3990
- DIN 3961
- DIN 3962

Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part
11
Part 1

edition December 1987

edition December 1987
edition December 1987
edition December 1987
edition December 1987
edition December 1994
edition February 1989

(general influence factors)

(calculation of the pitting bearing capacity)
(calculation of the root bearing capacity)
(calculation of the corrosion bearing capacity)
(fatigue stress values and material qualities)
(operational stability)
(application standards for industrial gears)

edition August 1961

edition August 1978

(ground tolerances)
(tolerances for deviation of individual
determined dimensions)
(tolerances for flank line deviations)
(conversion table for Vickers - RockwellBrinell hardness and ultimate strength)
(Basic principles, influence factors)

- DIN 3962
- DIN 50 150,

Part 2

edition August 1978

edition December 1976

- ISO 6336

Part 1

- ISO 6336

Part 2

- ISO 6336

Part 3

- ISO 6336

Part 6

- ISO 1328

Part 1

edition September
2006
edition September
2006
edition September
2006
edition September
2006
edition August 2005

(Calculation of surface durability (pitting))

(Calculation of tooth bending strength)
(Calculation of service life under variable
load)
(Definitions and allowable values of
deviations)

Gauge Design for Spur Gears

The groundwork calculations for this program are described by DIN 3960, edition March 1987.
The following DIN specifications will also be utilized:
- DIN 3961
- DIN 3962
- DIN 3964

Part 1

edition August 1978

edition August 1978

- DIN 3967

edition November
1980
edition August 1978

- DIN 3977

edition February 1981

(tolerances for spur gearing)

(tolerances for deviation of individual
determined dimensions)
(axis position and Axis position tolerances of
housing for spur gears)
(flank play, tooth thickness dimension, tooth
thickness tolerances)
(dimension diameter for the radial or diametric
standard gauge of the tooth thickness of spur
gears (cylinder gears))

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Gears

Scope of the Program

Geometry of the Spur Gear Pair and the Gear
With the following module Spur Gear Geometry deviation profiles also from the basic profile DIN867 and
ISO 53 - 1974 can be calculated (profile angle, P, topland thickness factor, san*, topland height factor,
haP*, prominence profile).
The validity will be bounded by the following dimensions:
-

inner gearing, outer gearing

profile angle: 15 P 30

topland height factor: 0.7. haP1* 1.5

topland height factor: 0.7 haP2* 1.5

topland play factor: 0.1 cP* 0.4

standard module: 0.01mm mn 70mm

even-, helical- and double helical gearing

lead: 0 45

profile overlapping: 0.1

topland thickness fact: 0.1 san* 0.4

optional allowance of the topland shortening for gears and pinions.

Cases of a specified minimum topland thickness, sa, cannot be observed, the program automatically
calculates the necessary topland shortening.
Strength Examination of Spur Gears
With the following module, Strength Examination of Spur Gears the pitting bearing capacity, root
bearing capacity and corrosion bearing capacity of involute spur gears of outer and inner gearing can be
calculated.
For the calculation of simple and double helical gearing the lead must lie within 0 45.
The calculable velocity ranges are

MDESIGN

Gears
(basic speed N 0.85)

Lower critical range

chief resonance

Intermediate range

(1.15 < N < 1.5)

Upper critical range

(N 1.5)

(0.85 < N < 1.15)

Qualities are considered by this program from 1 (finest class) up to 12 (roughest class).
The consideration of the profile correction as spherical broadening, base relief profile ease off and
topland relief profile ease off are possible.
The broadening factors for root, flank, and seizing can be optionally specified.
Gauge Design for Spur Gears
The scope of the program for the calculation module is determined as follows:
- Gearing quality
- Tolerance rows
- Dimension rows
- Axis pos. tolerance

:
:
:
;

1 - 12
a-h
21 - 30
js5 - js11

The following standard gauge will be calculated:

-

Housed Axis Position, a

Backlash theoretical, jt

Standard Tooth Thickness, sn

Tooth Width, Wk

Number of Teeth Dimension, k (optional)

Spherical Dim.-Roll Diameter, DM (optional)

Radial Gauge Roll/Spherical, MrK and MrR (Mr)

Diametral Gauge Roll/Spherical, MdK und MdR

Tolerance Factor, AW*, AMr*, AMd*

Geometry of spur gears

Clearance for expansion at initial profile, c [mm]
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Gears
c h hw c p mn

Notice:
If the present clearance for expansion c deviates off the initial profile of the respective clearance for
expansion cP, you must make changes of head height (shorten heads) to retain clearance for expansion
(DIN 3960, equation 4.3.07).
Effective teeth number ratio, u [-]
z
u 2
z1

Effective gear ratio, ieff [-]

Pinion is driven
z
i e ff 1
z2

Wheel is driven
i e ff

z2
z1

Zero centre distance, ad [mm]

ad

mn z 1 z 2
2 c os

Sum of profile coefficients, xg [-]

xg

x 1 x 2 in v wt in v t
2 ta n

Transverse pressure angle, at []

ta n
p
at a ta n
c os

Pressure angle at pitch cylinder, awt []

a

aw t a c o s d c o s t
a

Base helix angle,b []

b a s i n s i n c os p

Length of path of contact-engagement, gf [mm]

g f 0, 5

z2
2
2
d Na
2 d b 2 d b 2 ta n wt
z2

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Gears

Notice:
The calculation of gf is only valid, if the pinion is the driving part. If the spur gear is the driving part, the
calculation for gf meets length of distance of action from gearing to disengagement ga.
Length of path of contact-disengagement, ga [mm]

2
2
g a 0, 5 d Na
1 d b 1 d b 1 ta n wt

Notice:
The calculation of gf is only valid, if the pinion is the driving part. If the spur gear is the driving part, the
calculation for gf meets length of distance of action from gearing to disengagement ga.
Length of path of contact, ga [mm]

z2
2
2
2
2

g 0,5 d Na
1 d b 1 z d Na 2 d b 2 a sin wt

With rack:

2
2

g 0,5 d Na
1 d b 1 d b 1 tan t

hNaP 2 x 1 mn
sint

Transverse contact ratio, a [-]

g
pet

Overlap ratio, [-]

b ta n b
pet

Total contact ratio, [-]

Tooth thickness on tip diameter, san [mm]

For the calculation of the teeth thickness sa on the tip diameter for pinion and gear the equation 3.5.25
from the DIN 3960 is used,
Note:

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Gears

The minimum teeth thickness on the tip samin is determined through the input of the tooth-tip thickness
factor san*. This also leads to the upper threshold of the profile shift. (see DIN 3960, Picture 12).
Tooth depth, h [mm]
d df
hf a
2

Addendum, ha [mm]
d d
ha a
2

Dedendum, hf [mm]
d df
hf a
2

Reference diameter, d [mm]

d

mn z
c o s

Base diameter, db [mm]

d b d c os t

V- circle diameter, dv [mm]

dv d 2 mn x

Pitch diameter, dw [mm]

Pinion

Wheel

2 z1
dw 1
z1 z 2

2 z2
dw 2
z1 z 2

With rack:
Pinion

Wheel

dw 1 d1

dw 2 d 2 x 1 mn

Root diameter, df [mm]

Pinion
d f 1 d1 2 x 1 mn 2 hfP

d f 1 d1 2 mn haP 2* c P 1* x 1

Wheel

d f 2 d 2 2 x 2 mn 2 hfP

d f 2 d 2 2 mn haP 1* c P 2* x 2

Tip diameter, da [mm]

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Gears
Pinion

Wheel

d a 1 d1 2 mn haP 1* x 1 k1

d a 2 d 2 2 mn haP 2* x 2 k 2

Theoretical tip diameter, da_th [mm]

Pinion

d a 1th d1 2 mn haP 1* x 1

Wheel

d a 2th d 2 2 mn haP 2* x 2

Tip shortening, k [mm]

k a ad mn x 1 x 2

k k1 k 2

Tip clearance, c [mm]

Pinion

Wheel

d d fE 2
c 1ta t a a 1
2

d d fE 1
c 2ta t a a 2
2

Root Form Circle Diameter ,dFf [mm]

The calculation of the root form circle diameter dFf is calculated depending on the finish-machining (Gear
rack, cutting wheel) according to DIN 3960, chapter 3.6.7.
Root Form Diameter dNf [mm]
Pinion

Wheel
2

z
2
2
2
d Nf 1 2 a sin wt 2 d Na
2 d b 2 d b 1

z
2

z
d Nf 2 2
z2

2
2
2
2 a s in wt d Na 1 d b 1 d b 2

Notice:
For internal toothing look into DIN 3993 part 1 - 4.
Spare teeth number zn [-]
Pinion
z n1

z1
2

c o s b c o s

Wheel
zn 2

z2
2

c o s b c o s

Maximum specific sliding at point A of a pinion [-]

A 1

A2

A1

Maximum specific sliding at point A of the wheel [-]

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Gears

A 1

A1

A2

Maximum specific sliding at point E of a pinion [-]

E 1

E2

E1

Maximum specific sliding at point E of the wheel[-]

E 1

E1

E2

Base cylinder normal base pitch, pbn [mm]

pbn pet c os b

Base cylinder transverse base pitch, pbt [mm]

mn
pbt
c os t
c os

normal base pitch, pen [mm]

pen pet c os b

transverse base pitch, pet [mm]

mn
pet
c os t
c os

Rack tool values to produce a pinion:

Addendum of basic rack haP0.1* [-]
h
haP * 01 fP 1 haP * 2 c P * 2
mn

Dedendum of basic rack hfP0.1* [-]

haP * 01 haP *1

Dedendum circle diameter of a pinion, (manufacturing) dfE1 [mm]

The calculation of dedendum circle diameter dfE1 is realised dependent on final treatment (rack, gear
cutter) according to DIN 3960, section 3.6.4.
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Gears
Rack

Gear cutter

d fE 1 d1 2 x E 1 mn 2 haP 01

d fE 1 2 a 01 d a 01

Rack tool values to produce a pinion:

Addendum of basic rack, haP0.2* [-]
h
hfP * 02 fP 2 haP *1 c P *1
mn

Dedendum of basic rack, hfP0.2* [-]

hfP * 02 haP * 2

Dedendum circle diameter of a wheel, (manufacturing) dfE2 [mm]

The calculation of dedendum circle diameter dfE2 is realised dependent on final treatment (rack, gear
cutter) according to DIN 3960, section 3.6.4.
Rack
d fE 1 d 2 2 x E 2 mn 2 haP 02

Gear cutter
d fE 2 2 a 02 d a 02

Graphical Evaluation of Results:

Real part geometry

In the module "Geometry Spur Gears" are following result graphs at your disposal:
Tooth form (evolvent) of a pinion/gear
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Gears

Tooth space (envelope and evolvent) of a pinion/gear

Side view of a pinion/gear
Front view of a pinion/gear
Gear ring (evolvent) of a pinion/gear
Every result graph can be stored in DXF format on a hard disk or implemented in CAD systems!

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Gears

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Gears

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Gears

Spur Gears Calculation - Strength

With the following program the strength examination (pitting bearing capacity, root bearing capacity,
corrosion bearing capacity) of spur gears will be calculated. Therefore the calculation base DIN 3990 and
also the international ISO 6336 can chose by the user.

Groundwork Calculations and scope

Groundwork
The groundwork calculations for the module Strength Examination of Spur Gears is 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 bearing capacity)

DIN 3990

Part 3,

edition December 1987 (calculation of the root bearing capacity)

DIN 3990

Part 4,

edition December 1987 (calculation of the corrosion bearing 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 50150
- ISO 6336

edition December 1976 1976 (conversion table for Vickers - RockwellBrinell hardness and ultimate strength)
Part 1

edition September 2006 (Basic principles, influence factors)

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Gears

- 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 1328

Part 1

edition August 2005 (Definitions and allowable values of deviations)

Scope
With the following module, Strength Examination of Spur Gears the pitting bearing capacity, root
bearing capacity and corrosion bearing capacity of involute spur gears of outer and inner gearing can be
calculated.
For the calculation of simple and double helical gearing the lead must lie within 0 45.
The calculable velocity ranges are
-

Lower critical range

(basic speed N 0.85)

chief resonance

Intermediate range

(1.15 < N < 1.5)

Upper critical range

(N 1.5)

(0.85 < N < 1.15)

Qualities are considered by this program from 1 (finest class) up to 12 (roughest class).
The consideration of the profile correction as spherical broadening, base relief profile ease off and
topland relief profile ease off are possible.
The broadening factors for root, flank, and seizing can be optionally specified.

Spur Gears Calculation - Strength - Determination of Results

Spur Gears Calculation - Strength- Common Factors
Primary effective flank line deflection, Fx [m]
The primary effective flank line deflection Fx, presenting the absolute value of amount of manufactured
deflection and deformation of pinion and pinion shaft (measured in the locking level), is to be calculated
according to DIN 3990, part 1 as follows,
Without modification of flank
F x 1 . 33 f ma

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Gears

With crowning, Base Relief:

F x 1 . 33 f sh f H 5

Helix Slope Deviation, fH [m]

The Helix Slope Deviation fH is defined dependent on tooth width and gear ring quality according to DIN
3962, part 2.
Manufacturers flank line deflection fma [m]
Flank line angle deflection fma is defined dependent on tooth width and gear ring quality according to
DIN 3962, part 2.
Without modification and presetting:
f ma 1 . 0 f H

For gear pairs with rationally chosen crowning:

f ma 0 . 5 f H

For gear pairs with rationally chosen base relief:

f ma 0 . 7 f H

Component of equivalent misalignment due to shaft and pinion deformation [m]

This value will be calculated from deformation of shaft and pinion for the following cases:
Without crowning and base relief:
F
f s h m 0 . 023
b

For spur gears with crowning:

F
f s h m 0 . 012
b

For spur gears with base relief:

F
f s h m 0 . 016
b

Profile form deflection ff1 [m] for pinion or ff2 [m] for gear

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Gears

Profile form deflection ff for a pinion and a gear is defined dependent on normal modulus mn and gear
ring quality according to DIN 3962, part 1.
Transverse Pitch deviation fpe1 [m] pinion and fpe2 [m] wheel
The Transverse Pitch Deviation fpe for a pinion and a gear is defined dependent on normal modulus mn,
pitch diameter d and gear ring quality according to DIN 3962, part 1.
Effective profile form deviation, ffeff [m]
Effective profile form deviation ffeff, used to define the dynamic factor KV, is to be calculated as follows:
f feff f f y 1

Notice:
For ff the higher value of ff1 and ffis used.
Effective transverse Pitch deviation fpeeff [m]
Effective transverse Pitch deviation fpeeff, used to define the dynamic factor KV, is to be calculated as
follows:
f peeff f pe y p

Notice:
Look DIN 3990, part 1, section 5.3.3 for detailed information.
Rotation speed of wheel, n2 [1/min]
n 2

n1
u

Number of loading cycles NL1 [-] of pinion and NL2 [-] of wheel
The Numbers of loading cycles is to be calculated as follows:
N L1 Lh n1
n
N L 2 Lh 1
u

With rack:

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Gears

N L 2

N L1
d1
Lz

Resonance speed, nE1 [1/min]

To define the relative number of revolutions N per minute you have to calculate the resonant revolutions
per minute ne1:
c
1

2 z1 mred

n E 1

Relative number of revolutions, NR [-]

To differ the ranges of revolution numbers, necessary to define the dynamic factor KV, you have to
calculate the relative number of revolutions per minute N:
N R

n1
nE 1

Reduced mass, mred [kg/mm]

The reduced mass per mm tooth width mred is to be calculated as follows:
2

m red

d m1

8 d b 1

1 q14 M 1

2
dm
1

1 q 24 M 2 u 2

with:
d m 1

d a 1 d f 1
2

q 1

d i1
d m1

d m 2

d a 2 d f 2
2

q 2

d i2
dm 2

Peripheral velocity at reference diameter, v [m/s]

The Peripheral velocity at reference diameter is to be calculated as follows:
v d1 n 1

Peripheral velocity at pitch diameter, vw [m/s]

The Peripheral velocity at pitch diameter is to be calculated as follows:
v dw 1 n 1

Single tooth stiffness, c' [N/mmm]

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Gears

The single tooth stiffness c', necessary to define the dynamic factor KV, is to be calculated as follows:
C M C R C BS c os
c c th

Notice:
About defining the theoretical single tooth stiffness c look DIN 3990, part 1, section 9.3.1.
Single tooth stiffness ,c [N/mmm]
The single tooth stiffness c is to be calculated as follows:
c c 0 . 75 0 . 25

Dynamic factor, Kv [-]

The dynamic factor KV considers the effect of internal dynamic forces, caused by oscillations of pinion and
gear against one another, on the flank pressure and the dedendum loading.
It is calculated according to DIN 3990, part 1, method B as follows:
Dynamic factor KV [-] under the critical range (N 0.85):
Kv N R C v 1B P Cv 2 B f Cv 3 B k 1

Dynamic factor KV [-] in the main resonance range (0.85 < N 1.15):
Kv C v 1B P Cv 2 B f Cv 4 B k 1 Kv 1 . 15

Dynamic factor KV [-] over the critical range (N 1.5):

Kv C v 5 B P Cv 6 B f Cv 7 Kv 1 . 5

Dynamic factor KV [-] in the intermediate range (1.15 < N < 1.5):
Kv Kv 1 . 5

Kv 1 . 15 Kv 1 . 5
0 . 35

1 . 5 N R

Face load factor KF [-] (root stress)

The face load factor KF, considering the influence of the force distribution over the tooth width on the
stress at dedendum, is to be calculated as follows:
NF

KF KH

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Gears
b
h

NF
1

b b

h h

Notice:
for h/b is required the smaller value of h1/b1 and h2/b2, for b/h < 3 substitute b/h = 3.
Face load factor KH [-] (contact stress)
The face load factor KH, considering the influence of the force distribution over the tooth width on the
flank pressure, is calculated according to DIN 3990, part 1, method B as follows:
case 1:
F y c b
2 Ft K A Kv

KH

2 F y c b
Ft K A Kv

case 2:
F y c b
1
2 Ft K A Kv

KH 1

F y c b
2 Ft K A Kv

Transverse load factor KF [-] (root stress) and KH [-] (contact stress)
The transverse load factor consider the effect of force, unevenly distributed on many tooth pairs
engaged, on the flank pressure (KH) and dedendum loading (KF). It is calculated according to DIN 3990,
part 1, method B as follows:
case 1: total contact ratio 2

c f peeff
KF KH
0.9 0.4
FtH
2

case 2: total contact ratio > 2

K F K H 0.9 0.4

c f peeff

2 1

FtH
b

Notice:
For limitations of KH and KF, look DIN 3990, part 1, section 7.3.3 or 7.3.4.

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Calculation of loads
Transverse tangential load Ft [N] at reference diameter
The transverse tangential load Ft at reference diameter is to be calculated as follows:
Ft

P
d1 n 1

Nominal torque T1 [Nm] pinion, and T2 [Nm] wheel

The Nominal torque for pinion and wheel is to be calculated as follows:
F d
T1 t 1
2

F d2
T2 t
2

Tangential load in pitch plane, Ftw [N]

Tangential load in pitch plane Ftw is to be calculated as follows:
Ftw

P
dw 1 n 1

Radial load in pitch plane, Frw [N]

The Radial load in pitch plane Frw is to be calculated as follows:
Frw Ftw ta n w t

Axial load in pitch plane, Faw [N]

The Axial load in pitch plane is to be calculated as follows:
Faw Ftw ta n

Tooth load in pitch plane, Fw [N]

The Tooth load in pitch plane Fw is to be calculated as follows:
2
2
Fw Frw
Ftw
Fa2w

Line load [N/mm]

K
Linie load Ft A
b

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Spur Gears Calculation - Strength - Pitting Maximum Loading

Zone factor, ZH [-]
The zone factor ZH, considering the influence of the tooth flank bend at a pitch point on the flank
pressure and recalculating the peripheral force at a spur section on the normal force at the pitch spur, is
calculated as follows:
ZH

2 c os b c os w t
c os t

s i n w t

Elasticity factor, ZE [N/mm2]

Using the coefficient of elasticity ZE you consider the influence of specific material values E (modulus of
elasticity) and n (Poisson's ratio) on the flank pressure. It is to be calculated as follows:
ZE

1
1 2 1 2
1
2

E1
E2

Contact ratio factor (contact stress) Z [-]

Contact ratio factor Z, considering the influence of profile and jump overlapping on the pitting
maximum loading, is calculated dependent on the gearing type as follows, straight gearing:
Z

4
3

Helical toothing and < 1:

Z

4
1
3

Helical toothing and 1:

Z

Helix angle factor (contact stress) Z [-]

The helix angle factor Z considers the influence of tooth line inclinations on the pitting maximum
loading and is to be calculated as follows:
DIN 3990
Z c os

ISO 6336
Z

cos

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Work hardening factor ZW [-]

The work hardening factor ZW considers the increase of the pitting maximum loading of a steel spur gear
owing to the combination with a hardened or a substantially harder pinion with smooth teeth flanks. It is
defined by means of the method B as follows:
ZW 1

Lubricant factor ZLd [-] and. ZLs [-]

With the lubricant factor ZLd (= fatigue strength) or ZLs (= static strength) you consider the influence of the
nominal viscosity on the effect of lubricant film and define it according to the method B as follows:
4 1 . 0 C ZL

Z Ld C ZL

134
1 . 2

40

Z Ls 1

Notice:
To define CZL look in DIN 3990, part 2 , section 9.2.1.1
Velocity factor ZVd [-] and ZVs [-]
Dependent on the peripheral velocity and the fatigue strength value for flank pressure Hlim of a softer
material, the velocity factor ZVd (= fatigue strength) or ZVs (= static strength) is defined using the method B
as follows:
ZVd C Zv

2 1 . 0 C Zv

32
0.8
v

with
Z Zv C ZL 0 . 02
ZVs 1

Notice:
To define CZL look in DIN 3990, part 2 , section 9.2.1.1
Roughness factor ZRd [-] and ZRs [-]

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Gears

The roughness factor can be defined as follows dependent on the surface nature of teeth flanks, on the
construction dimensions and on the fatigue strength value for flank pressure Hlim of a softer material of a
gear pairs:
According to DIN 3990:
C ZR

3
Z Rd

R z 100
Z Rs 1

According to ISO 6336:

C ZR

3
Z Rd

R z 10
Z Rs 1

Notice:
To define CZR look in DIN 3990, part 2 , section 9.2.1.3 and ISO 6336-2, 12.3.1.3.3
Life factor for contact stress ZNTd [-] and ZNTs [-] for pinion and wheel
The service life factor ZNTd (= fatigue strength) or ZNTs (= static strength) for a pinion and a gear is defined
according to DIN 3990, part 2, method B, table 8.1.
-

or according to ISO 6336-2, 11.2 table 2

Notice:
The service life factor for root stress gets the value 1 while obtaining the fatigue limit. According to DIN
3990 the factor is also over the fatigue limit constant. In the ISO 6336 this factor will be reduced to 0.85 if
1010 load changes exceeded.
Size factor (pitting) ZXd [-] and. ZXs [-] for pinion and wheel
-

According to DIN 3990:

The size factor (flank) ZXd (= fatigue strength) or ZXs (= static strength) for a pinion and a gear is to be
defined dependent on the material and on the normal modulus according to DIN 3990, part 2, method B,
table 11.1.
-

According to ISO 6336:

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Gears
Z Xd 1

Z Xs 1

Single pair tooth factor ZB [-] (pinion) and ZD [-] (wheel)

The single gearing factors ZB (pinion) or ZD (gear) consider the influence of the tooth flank bend on the
flank pressure. They are defined as follows:
Spur gearing:
M 1 1
ZB =1
M 2 1
ZD =1

M 1> 1
ZB = M1
M 2> 1
External
toothing
ZD = M2

Internal toothing
ZD =1

Helical gearing:
1

< 1
M1 - (M1 - 1) < 1
ZD =1
ZB = 1
External toothing
1
< 1
M2 - (M2 - 1) < 1
ZD =1
ZD = 1
M1

M2

M1 - (M1 - 1) 1
ZB =M1

M2 - (M2 - 1) 1
ZD =M2
tanwt

Internal
toothing
ZD =1

d a21
2 d a22
2
1

1 1

z1 d 2
z2
d b21

b 2
tanwt

d a22
2 d a21
2
1

1 1

z2 d 2
z1
d b22

b 1

Pitting stress limitHG [N/mm] for pinion and wheel

The pitting stress limit HG for pinion and wheel is to be calculated as follows:
HG H l i m Z NT Z L Zv Z R ZW Z X

Permissible contact stress HP [N/mm] for pinion and wheel

The permissible contact stress HP for pinion and wheel is to be calculated as follows:
HP

HG
H mi n

Nominal contact stress H0 [N/mm]

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Gears

The nominal contact stress H0 is to be calculated as follows:

Ft
u 1
H 0 Z H Z E Z Z

d1 b
u

Contact stress H [N/mm] for pinion und wheel

The contact stress H for pinion and wheel is to be calculated as follows:
Pinion

Wheel

H Z B H 0 K A KV K H K H

H Z D H 0 K A KV K H K H

Safety factor for pitting SH [-] for pinion und wheel

S H HG
H

Service-life, Lh [h] for pinion und wheel

H
Lh N D
HG da uer

exp 1

for 105< NL< 107 for structural steel and chilled steel, perlite or bainite pig with spheroidal graphite,
perlite malleable cast iron, cemented steel or case-hardened steel, if some number of pits is allowable
105< NL 107

HP statisc h
e x p 0, 3705 l og
HP dauer

N D 3 108

107< NL 109

HP statisch
e x p 0, 2791 l og
HP dauer

N D 109

for 105< NL< 5107 for structural steel and chilled steel, perlite or bainite pig with spheroidal graphite,
perlite malleable cast iron, cemented steel or case-hardened steel
105< NL 5 107

HP statisch
e x p 0, 3705 l og
HP dauer

N D 5 107

for 105< NL< 2106 chilled steel and nitrided steel, gas-nitrided or nitrid-carburized, ferrite pig with
spheroidal graphite, grey iron
105< NL 2 106

HP statisc h
e x p 0, 7686 l og
HP dauer

N D 2 106

Load duty cycle

According to DIN 3990 part 6

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Gears

The inputted load duty cycle will be sorted according the maximum values. Then for every load level an
allowable load function (according to DIN 3990 part2) and so the maximal allowable stress cycles Ni will
be calculated.
The sum of damage U according to Palmgren-Miner will be calculate as follow:
U

Nii
i

Notice:
In the DIN 3990 the calculation is according to original-Miner (only stress higher the fatigue stress will be
taken into consideration)
The ISO 6336 calculation is according to modified -Miner (also stress smaller the fatigue stress will be
taken into consideration)
As graphical evaluation you receive a pitting maximum loading diagram for a pinion and a
gear:

28

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Gears

Root bearing capacity

contact ratio factor Y [-] (root stress)
The contact ratio factor Y (root stress) is to be calculated as follows:
for< 1

Y 0, 2

for 1

0, 8

Helix angle factor Y [-]

The Helix angle factor Y, considering the difference in dedendum loading between the oblique gearing
and the substitute straight gearing as primarily laid into the calculation groundwork in the normal
section, is to be calculated as follows:
Y 1

120

Notice:
If the overlap ratio is > 1, it is set on = 1. If the tooth line inclination is > 30, it is set on = 30.
Stress correction factor YST [-]
The stress correction factor YST for the dimensions of standard reference test gears is set on YST = 2.0.
Tooth form factor Yf [-] for pinion and wheel

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Gears

The tooth form factor Yf considers the influence of the tooth form on the nominal bending stress and is
calculated according to the method B respectively for a pinion and a gear as follows:
h
6 Fe c os Fen
m
YF n
2
s
Fn c os n
m
n

Notice:
The values hFe, sFn, aFen necessary for the calculation are exactly defined by means of an iterative method
(look DIN 3990, part 3, section 3.2).
Stress correction factor Ys [-] for pinion and wheel
With the stress correction factor Ys (= notch form number) you recalculate the nominal bending stress on
the local dedendum stress and involve in this way the stress raising effect of a notch (= dedendum
rounding). The stress adjustment factor Ys is calculated according to the method B respectively for a
pinion and a gear as follows:
1
1 . 21

YS 1 . 2 0 . 13 L q s

2.3
L

with:
s
L Fn
hFe

qs

s Fn
2 F

Notice:
The values hFe and sFn and qs necessary for the calculation are exactly defined by means of an iterative
method (look DIN 3990, part 3, section 3.2).
Life factor YNTd [-] and YNTs [-] for pinion and wheel
The service life factors YNTd (= fatigue strength) and YNTs (= static strength) for a pinion and a gear are
defined dependent on the material and on the heat treatment according:
-

DIN 3990 part 3, table 8.1

ISO 6336-3, 12.2.2 table 1.

Notice:

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Gears

The service life factor for root stress gets the value 1 while obtaining the fatigue limit. According to DIN
3990 the factor is also over the fatigue limit constant. In the ISO 6336 this factor will be reduced to 0.85 if
1010 load changes exceeded.
Relative notch sensitivity factor, YrelTd [-] and YrelTs [-] for pinion and wheel
The relative notch sensitivity factor YrelTd (= fatigue strength) and YrelTs (= static strength) for a pinion and
a gear are defined dependent on the material, on the heat treatment and on the notch parameters
according to DIN 3990, part 3, method B, section 9.3.
Notice
The relative reference value for the fatigue strength range can be defined by means of linear
interpolation between the values for the fatigue strength and the static strength.
Relative surface factor, YRrelTd [-] and YRrelTs [-] for pinion and wheel
The relative surface factors YRrelTd (= fatigue strength) and YRrelTs (= static strength) for a pinion and a gear
are defined dependent on the surface nature and on the material according to DIN 3990, part 3, method
B, section 10.3.2.
Notice:
The relative surface factor for the fatigue strength range is to be defined by means of linear interpolation
between the values for the fatigue strength and static strength.
Size factor YXd [-] and YXs [-] for pinion and wheel
The size factor YXd (= fatigue strength) and YXs (= static strength) for a pinion and a gear are defined
dependent on modulus, material and heat treatment according to DIN 3990, part 3, method B, table 11.1.
Notice:
The size factor for the fatigue strength range is to be defined by means of linear interpolation between
the values for the fatigue strength and static strength.
Tooth root stress limit FG [N/mm] for pinion and wheel
The tooth root stress limit FG for pinion and wheel is to be calculated as follows:
FG F l i m YST YNT Y rel T YRrel T Y X

Permissible tooth root stress FP [N/mm] for pinion and wheel

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Gears

The permissible tooth root stress FP for pinion and wheel is to be calculated as follows:
FP

FG

S F min

Nominal tooth root stress F0 [N/mm]

The Nominal tooth root stress F0 is to be calculated as follows:
Ft
F 0
b mn

YF YS Y

Tooth root stress F [N/mm] for pinion and wheel

The tooth root stress F for pinion and wheel is to be calculated as follows:
F F 0 K A Kv K F K F

Safety factor for tooth breakage SF [-] for pinion and wheel
The safety factor for tooth breakage SF for pinion and wheel is to be calculated as follows:

S F FG
F

Service-life Lh [h] for pinion and wheel

1
6 F e x p 1
Lh 3 10

n
FG

for structural steel and chilled steel, perlite or bainite pig with spheroidal graphite, perlite malleable cast
iron (104<NL<3106):
FP statisch
e x p 0 . 4037 l og
FP dauer

for cemented steel and case-hardened steel, chilled steel and nitrided steel, gas-nitrided or nitridcarburized, ferrite pig with spheroidal graphite, grey iron
FP statisch
e x p 0 . 2876 l og
FP dauer

Load duty cycle

According to DIN 3990 part 6

32

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Gears

The inputted load duty cycle will be sorted according the maximum values. Then for every load level an
allowable load function (according to DIN 3990 part2) and so the maximal allowable stress cycles Ni will
be calculated.
The sum of damage U according to Palmgren-Miner will be calculate as follow:
U

Nii
i

Notice:
In the DIN 3990 the calculation is according to original-Miner (only stress higher the fatigue stress will be
taken into consideration)
The ISO 6336 calculation is according to modified -Miner (also stress smaller the fatigue stress will be
taken into consideration)
As graphical evaluation you receive a pitting maximum loading diagram for a pinion and a
gear:

33

MDESIGN

Gears

scuffing load capacity

Flash factor according to the integral and flash temperature method XMI [-] or XMB [-]
The flash factor describes the influence of material properties of a pinion and of a gear on the flash
temperature.
Integral temperature method:

2
X MI
2
1 1 1 22

E
E2
1

1 E 1 E

B M 1 1 E B M 2 1 E

Flash temperature method:

2
X MB
2
1 1 1 22

E
E2
1

1
4

1
1

BM 1 BM 2

y
u
y
1

u
1 y

Geometry factor for pinion addendum XBE [-]

The factor XBE considers the Hertz pressure at pinion addendum.

34

MDESIGN

Gears

X BE 0.51

z2
z2

u 1

E 1

E 2
u
1

E 1 E 2 4

with:
E 1 0 . 5 d a21 d b21
E 2 a s i n w t E 1

Angle factor X [-]

Using the angle factor X you calculate the influence of the gearing angle at, operational gearing angle
wt and tooth line inclination on the integral temperature.
1

X 1 . 22

s i n w t 4 c os n 4 c os 4
1

c os w t 2 c os t 2

Pitch factor XQ [-]

The pitch factor XQ considers the effect of the engagement start at the head of the driven gear in the
range of high slippage. It is presented from the coefficient of the engagement overlap f and of the
disengagement overlap a.
f
1.5
a

XQ = 1.0
XQ 1.4

4 f

15 a

1.5 f 3
a
f
3
a

XQ = 0.6

with

2
z1 d a1

1 tanwt
2 d b 1

2
z 2 da 2

1 tanwt
2 d b 2

Notice:
Here are f = 2 and a = 1, if the gear is driving; or f = 1 and a = 2, if the pinion is driving.
Tip relief factor XCa [-]
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Gears

The tooth head pull back factor considers the positive influence of the profile adjustments on the
overload at tooth head in the ranges of high slippage, caused on account of elastic deformation of
engaged teeth.
for12:

X Ca 1 1, 55 10 2 14 C a

for1<2:

X Ca 1 1, 55 10 2 24 C a

for gear ring quality> 7:

X Ca 1

Notice:
The considerable head pull back Ca is to be calculated as follows: At driving pinion and 1> 1.52, or at
driving gear and 1.512,
Ca = Ca1 for Ca1Ceff
Ca = Ceff for Ca1>Ceff
At driving pinion and 1 1.52 or at driving gear and 1.51<2
Ca = Ca2 for Ca2Ceff
Ca = Cefffor Ca2>Ceff
with:
for spur gearing: C e ff K A

Ft
b c

for helical gearing: C eff K A

Ft
b c

Contact ratio factor X [-]

The Contact ratio factor X recalculates the flash temperature at pinion tooth head without load sorting
to a mean flash temperature along the tooth flank. For the following calculation formula is supposed a
linear processing of the flash temperature along the distance of action.

for < 1, 1< 1, 2< 1:

1
2 22
2 1 1

for 1 < 2, 1< 1, 2< 1:

1
0 . 7 12 22 0 . 22 0 . 52 0 . 60 1 2

2 1

for 1 < 2, 1 1, 2< 1:

for 1 < 2, 1< 1, 2 1:

for 2 < 3, 12:

1
X
0 . 7 12 0 . 18 22 0 . 52 1 0 . 82 2 0 . 30 1 2
2 1
1
X
0 . 44 12 0 . 59 22 0 . 30 1 0 . 30 2 0 . 15 1 2
2 1
1
0 . 18 12 0 . 7 22 0 . 82 1 0 . 52 2 0 . 30 1 2
2 1

36

MDESIGN

Gears
X

for 2 < 3, 1<2:

1
0 . 59 12 0 . 44 22 0 . 30 1 0 . 30 2 0 . 15 1 2
2 1

Lubricant factor, XS [-]

The Lubricant factor XS on sides a better heat transfer at oil bath lubrication than at injection lubricating.
The lubricating factor for the oil bath lubrication is XS = 1.0;
With injection lubricating the lubricating factor is XS = 1.2.
Mean local coefficient of friction mC [-]
The mean value of the coefficient of friction over the distance of action is approximated as follows:
w Bt
mC 0 . 12
v
oil C

0 . 25

Ra

redC

0 . 25

with:
v C 2 s i n w t

redC

1 u

s i n w t

c os b

Notice:
The arithmetic mean rough values Ra1 and Ra2 of a pinion and of a gear are measured towards the tooth
height (manufactured roughness, Ra = 0.5(Ra1 + Ra2)).
Mean local coefficient of friction my [-] (method B)
The value of the coefficient of friction, necessary at the flash temperature method, is calculated according
to the method B for many points on the distance of action with the help of the parameter y. It means,
that it is an instant value. The displayed value my is pertinent to the maximum contact temperature. The
calculation occurs with integration of five most important values in two dimensionless groups:
w Bt
my 0 . 12

v
M

0 . 25

R
a
red

0 . 25

with:
y

v 2 y
v s i n w t

red

1 y u y a s i n w t
1 u 2

c o s b

Notice:

37

MDESIGN

Gears

The arithmetic mean rough values Ra1 and Ra2 of a pinion and of a gear are measured towards the tooth
height (manufactured roughness, Ra = 0.5(Ra1 + Ra2)).
Mass Temperature MC [C] (Integral temperature procedure)
The mass temperature MC is the temperature of the teeth flank areas imminently before the
engagement. For the integral temperature procedure after method C , the following equation is used:
MC X S oil C 1 flaE X

Notice:
C1 describes an empirically determined factor. C1 = 0.7
Mass temperature MB [C] (Flash temperature procedure)
The mass temperature is the temperature of teeth flank surfaces directly before gearing. It is calculated
for the integral temperature method according to the method C with the help of the following formula:
MB X S oil 0 . 47 fla ma x

with:
3

fl a my X M X B X X

w Bt 4 v 2
1

a 4

Integral temperature, int [C]

The integral temperature int is calculated with the help of mean value formation and flash temperature
estimation using the following formula:
i nt M C 2 fl a E X

with:
3
1
4
w
v 2
1
fl a E mC X MI X BE X Bt

1
X Q X Ca
a 4

Maximum contact temperature, Bmax [C]

The contact temperature B is calculated at every point of gearing line as follows:
B M fl a

38

MDESIGN

Gears
B ma x M fl a ma x

Determinative tangential force at every tooth width, wBt [N/mm]

The tangential force at every tooth width is used to calculate the coefficient of friction and the flash
temperature at a pinion tooth. The calculation is realized using the overload factors and the tangential
force Ft.
F
w Bt K A Kv K B K B K B t
b

Force ratio, SSL [-]

Edge fin safety means "temperature ratio", expressing indirectly the factor, used to increase the gear
moment to receive just a safety of 1. In order to define a "force ratio" you must know the relation
between the present loading and the flank temperature.
S SL

w t ma x
w teff

Scuffing Load Safety Factor, SintS [-] (integral temperature method)

S i ntS i ntS
i nt

Scuffing Load Safety Factor, SB [-] (flash temperature method)

SB

S oi l
B ma x oi l

Working temperature T [C]

To determine the influence of working temperature and part dimensions on strength characteristics such
as ultimate strength, Rm, Rp and yield strength, you should use the FKM guideline "Rechnerischer
Festigkeitsnachweis fr Maschinenbauteile" (Calculation strength proof for machine parts), 5th,
extended edition of 2003. This method is realised in the module Material Data. The material parameters
are transferred from the input page to the module Material Data. Being calculated, the corrected
parameters are returned from the module Material Data to the actual calculation taking to account the
influence of temperature and part dimension.
The FKM guide line considers the influence of normal and elevated temperature and part dimensions on
the material strength characteristics by determining such parameters as effective diameter deff,
technological dimension factor Kdm (Kdp), anisotropy factor KA and other temperature factors. In detail, the
method of determining strength characteristics according to the FKM guideline is expounded in the help
for the module Material data.
39

MDESIGN

Gears

Standard Gauge Spur Gears

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 Centre
Distance and Deviations of Teeth Thickness are optional.

Calculating groundwork
The calculating groundwork for this program is given in the DIN 3960, Edition of March 1987.
Besides this, the following DIN-standards are also used:
- DIN 3961

Tolerances for spur gearing, edition August 1978

- DIN 3962

Tolerances for deviation of individual determined dimensions, part 1, edition

August 1978

- DIN 3964

Axis position and Axis position tolerances of housing for spur gears, edition
November 1980

- DIN 3967

Flank play, tooth thickness dimension, tooth thickness tolerances, edition August
1978

- DIN 3977

dimension diameter for the radial or diametric standard gauge of the tooth
thickness of spur gears (cylinder gears), edition February 1981

Operating zone
The scope of this calculation module is specified as follows:
- gear ring quality

1 - 12

- limit deflection row

a-h

- tolerance row

21 - 30

- tolerance of spacing on centers

js5 - js11

Standard Gauge Spur Gears - Determination of Results

Gear guard distance a [mm]
Distance dimensions are defined according to DIN 3964, table 1.
Flank clearance (theoretical) jt [mm]
A
As ne 2
2 Aa i ta n w t
j t mi n s ne 1

c os

A
As ni 2
2 Aa e ta n w t
j t ma x s ni 1

c o s

40

MDESIGN

Gears
j
j t mi n
j t t ma x
2

Quality / Tolerance field [-]

This value contains the gear ring quality as well as limits of tooth thickness deflection. For example,
displaying 8cd26 means:
8 = gear ring quality according to DIN 3961 up to 63
cd = limit deflections row according to DIN 3967
26 = tolerance row according to DIN 3967
Upper limit of tooth thickness deflection Asne [m]
If the upper tooth thickness dimension Asne is not specified by the user as a free limit of deflection, it is
defined according to DIN 3967, table 1.
Lower limit of tooth thickness deflection Asni [m]
If the lower tooth thickness dimension Asni is not specified by the user as a free limit of deflection, it is
defined according to DIN 3967, tables 1 and 2.
A s ni A s ne T s n

Tooth thickness tolerance Tsn [m]

Tooth thickness tolerance Tsn is defined according to DIN 3967, table 2 or at free specification from the
difference between Asne and Asni.
Tooth thickness deviation Rs [m]
Tooth thickness deviation Rs is defined according to DIN 3962, part 1.
Theoretical normal tooth thickness snth [mm]

s nth m n 2 x ta n n
2

Notice:
Limits of tooth thickness deflection result from the tables of DIN 3967.
Normal tooth thickness sn [mm]
s
s n mi n
s n n ma x
2

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MDESIGN

Gears

Notice:
Limits of tooth thickness deflection result from the tables of DIN 3967
Tooth width Wkth [mm]

z
Wkth mn c os n k

z i n v t

2 x m n s i n n

Notice:
Limit deflections of tooth width Wk result from tooth thickness limit deflections and limit deflection
factor AW* according to DIN 3960 (look Limit Deflection Factors).
Control teeth number k [-]
z
z
k int n
z

z
x
ta n vn 2
ta n n i n v n
1
zn

Notice:
The function (int) means, to round to next integer value near zero.
Notice:
Many control teeth numbers can be regarded. The validity of k is verified using Dial diameter dM (look DIN
3960, equation 3.8.15). For external gears is:
(dv - mn) dM (dv + 1,44mn)
Testing ball and roller diameter DM [mm]
Testing part diameter is to be defined using the theoretical value (look DIN 3960, equation 3.8.24) and
the value stored in the file.
Notice:
Many control means diameter can be regarded. The validity is verified using dial diameter dM (look DIN
3960, equation 3.8.31). In general it is allowable that at external gears the distance between the dial and
V-cylinder lies in the range (0.5 mn) towards head cylinder and (-0.1 mn) towards foot cylinder.
Radial control dimension roller / ball MrK [mm]
M rK

d K

DM
2

42

MDESIGN

Gears

Notice:
The limits of deflection of radial control dimension Mr result from the tooth thickness limit deflections
and the factor of limit of deflection AMr* according to DIN 3960 (look Factors of limit deflections).
Diametrical control dimensions for rollers or balls MdR [mm]
Spur gear with even teeth number:
M dR M dK d K DM

Spur gearing with odd teeth number:

M dR M dK d K c o s
DM
2 z2

Helical gearing with even teeth number:

M dR M dK d K DM

Helical gearing with odd teeth number:

M dR d K DM

M dK d K c o s
DM
2 z2

Notice:
The limit deflections of diametrical control dimensions result from the tooth thickness limit deflections
and the limit deflections factor AMd* according to DIN 3960 (look Factors of limit deflections).
Factors of limit deflections [-]
Factor of limit deflections for tooth width Wk is to be calculated as follows:
AW * c os n

The factor of limit deflections AMd* of the diametrical dimension Md amounts at even teeth number as
well as at external helical gear ring with odd teeth number, if it is tested with rollers:
A Md *

c os t

s i n Kt 1 c os

with odd teeth number (for oblique gear rings but only if measured with balls):

43

MDESIGN

Gears

A Md *

c o s t

c o s

s i n K t 1 c o s
2 z1

44

MDESIGN

Gears

Bevel-, Hypoid Gear

With the following program, based on the groundwork calculations according to DIN 3991 the theoretical
strength calculation (pitting bearing capacity, root bearing capacity) of bevel gears will be calculated.
Additional the geometrical calculation according to ISO23509 can be taken. Therefore both data types
(EN and AGMA) and for different input methods according to the different producers can be chosen.
The bevel gears will be approached through equivalent spur gears (Tredgold Approximation). The bearing
capacity calculation according to DIN 3991 relates consequently to compensate spur gears with involute
gearing, whereby in general the ratio in mean tooth width of the bevel gear will be based upon.

Groundwork Calculations
The groundwork calculations for this module are described by the following DIN specifications:
- DIN 3991
- DIN 3991
- DIN 3991
- DIN 3990

Part 1 ,
Part 2 ,
Part 3 ,
Part 5 ,

Edition September 1988

Edition September 1988
Edition September 1988
Edition December 1988

- DIN 3971,
- DIN 3965
- DIN 3965

Part 1 ,
Part 2 ,

Edition July 1980

Edition August 1986
Edition August 1986

- DIN 50 150

Edition December 1976

- ISO 23509

Edition September 2006

(influence factors in general)

(calculation of pitting bearing capacity)
(calculation of the root bearing capacity)
(fatigue strength values and material
qualities)
(concept and determinants)
(tolerances for bevel gearing groundwork)
(tolerances for bevel gearing tolerances for
deviations of individual determinants)
(conversions table for Rockwell- Brinell
hardness and endurance strength)
(Calculation of geometry of bevel- and
hypoid gears)

Scope of the program

With the following module Theoretical Strength Calculations of Bevel Gears the pitting bearing capacity
and root bearing capacity of bevel gears without treatment can be calculated. Geometrical calculations
according to ISO 23509 can be taken for bevel and hypoid gears.
Straight- , helical- and curved gearing will be able to be considered. For the calculation of straight- and
curved gearing, the angle (and for curved the spiral angle) must amount
0 m 45 .

Any axial angles desired can be calculated.

The calculation speed ranges are
- Under critical range

(basic speed N 0 . 85 )

45

MDESIGN

Gears
- Chief resonance

0 . 85 N

1 . 15

- Intermediate range

1 . 15 N

1.5

- Over critical range

1.5

Qualities are from 1 (finest class) to 12 (roughest class) according to DIN 3965 are considered by this
program.

Calculation geometry
Input method for geometrical calculation
The input of basic data depends on the different input methods (0-3).
These methods based on the different producers.

Method 0
The input of basic data depends on the different input methods (0-3). These methods based on
the different producers.

Method1
This method is used by Gleason.

Method2
This method is used by Oerlikon.

Method3
This method is used by Klingelnberg.

Data type
Some inputs depend on the data type.
-

EN (European standard)

AGMA (American standard)

The following inputs are different:

EN
Profile shift coefficient
Basic crown gear addendum factor
Basic crown gear dedendum factor
Thickness modification coefficient (theoretical)

AGMA
Mean addendum factor of wheel
Depth factor
Clearance factor
Circular thickness factor
Wheel mean slot width

This input data can be converting into the other one.

46

MDESIGN

Gears

Manufacturing considerations
Some of the geometrical calculations depend on the used manufacturing considerations.
The following manufacturing considerations can chose.

Face milling

Face hobbing

Calculation of geometry
Determination of basic data:
Gear ratio
u

z
2
z1

Pinion mean pitch diameter

d m 1 2 Rm 1 s i n 1

Wheel mean pitch diameter

d m 2 2 Rm 2 s i n 2

Shaft angle departure from 90

90
hmw 2 mmn k ha p

Offset angle in the pinion axial plane

2 a

m s i n 1
c os 2
d m 2 d m1

c os 1

Offset angle in the pitch plane

s in m s in
mp s in 1

c os 1

Offset in the pitch plane

47

MDESIGN

Gears

a p Rm 2 s in mp

Mean normal module

mmn

2 Rm 2 s in 2 c os m 2
z2

Limit pressure angle

tan1 tan2

coc

mp

1
lim tan

sin

sin

m
1
m
1
m
2
m
2

Rm 1 tan1 Rm 2 tan2

Outer pitch diameter, wheel

d e 2 2 Re 2 s in 2

Determination of tooth depth at calculation point:

Mean working deep
hmw 2 mmn k hap

Mean addendum

ham 2 mmn k hap hm 1

Mean addendum
hfm 2 mmn k hfp hm 1

Mean addendum
ham 1 mmn k hap hm 1

Mean addendum
hfm 1 mmn k hfp hm 1

Clearance
C

mmn k hFp k hap

48

MDESIGN

Gears

Mean whole depth

hm mmn k hap k hfp

Determination of root angles and face angles:

Face angle, wheel
a 2 2 a 2

Root angle, wheel

f 2 2 f 2

Face angle pinion

s i n s i n

f2

a 1 s i n 1
c os c os
c os R
f2

Root angle pinion

s i n s i n
a2

f 1 s i n 1
c os c os a 2 c os O

Addendum angle, pinion

a 1 a 1 1

Dedendum angle, pinion

f 1 1 f 1

Determination of pinion face width:

Pinion face width in pitch plane
b p 1 Re22 a p2 Ri22 a p2

Pinion face width from calculation point to front crown

2
2
2
2
b1A Rm
2 a p Ri 2 a p

Pinion face width from calculation point to outside

49

MDESIGN

Gears
Method 0, 2, 3
be 1 c be 1 b1

Method 1

g xe ham 1 s i n 1
be 1
c os a 1
c os a 1

Pinion face width from calculation point to inside

bi 1 b1 be 1

Determination of inner and outer spiral angles:

Cone distance of outer pinion boundary point

2
2
Re 21 Rm
2 be 1 2 Rm 2 be 1 cos mp

Wheel cone distance of inner pinion boundary point

2
2
Ri 21 Rm
2 bi 1 2 Rm 2 bi 1 cos mp

Pinion offset angle in pitch plane at outer boundary point

ap
ep 21 s i n 1

R
e 21

Pinion offset angle in pitch plane at inner boundary point

ap
ip 21 s in 1

R
i 21

Outer pinion spiral angle

e 1 e 21 ep 21

Inner pinion spiral angle

i 1 i 21 ip 21

Determination of tooth depth:

Outer addendum
hae 1 ham 1 be 1 ta n a 1
hae 2 ham 2 be 2 ta n a 2

Outer addendum

50

MDESIGN

Gears
hfe 1 hfm 1 be 1 ta n f 1
hfe 2 hfm 2 be 2 ta n f 2

Outer whole depth

he 1 hae 1 hfe 1
he 2 hae 2 hfe 2

Inner addendum
hai 1 ham 1 bi 1 ta n a 1
hai 2 ham 2 bi 2 ta n a 2

Inner addendum
hfi 1 hfm 1 bi 1 ta n f 1
hfi 2 hfm 2 bi 2 ta n f 2

Inner whole depth

hi 1 hai 1 hfi 1
hi 2 hai 2 hfi 2

Determination of tooth thickness:

Mean normal pressure angle
d fE 1 2 a 01 d a 02

Mean normal circular tooth thickness

s mn 1 0 . 5 mmn 2 mmn x s m 1 x hm 1 ta n n

s mn 2 0 . 5 mmn 2 mmn x s m 2 x hm 1 ta n n

Mean transverse circular thickness

s mt 1

s mn 1
c os m 1

s mt 2

s mn 2
c os m 2

51

MDESIGN

Gears

Mean normal diameter

d mn 1

d mn 2

d m1

1 s i n
m1 2 c os n 2 c os m1 c os 1

dm 2
2
1 s i n
m 2 c os n 2 c os m 2 c os 2

Mean normal chordal tooth thickness

s

s mnc 1 d mn 1 s i n mn 1
d mn 1
s

s mnc 2 d mn 2 s i n mn 2
d
mn 2

Mean chordal addendum

hamc 1 ham 1 0 . 5 d mn 1 c os 1 1 c os mn 1

d mn 1

hamc 2 ham 2 0 . 5 d mn 2 c os 2 1 c os mn 2

d mn 2

Determination of remaining dimensions:

Outer pitch cone distance, pinion
Re 1 Rm 1 be 1

Inner pitch cone distance, pinion

Ri 1 Rm 1 bi 1

Outer pitch diameter, pinion

d e 1 2 Re 1 s in 1

Inner pitch diameter, pinion

d i 1 2 Ri 1 s in 1

Outside diameter, pinion

d ae 1 d e 1 2 hae 1 c os 1

52

MDESIGN

Gears
d ae 2 d e 2 2 hae 2 c os 2

diameter

d fe 1 d e 1 2 hfe 1 c os 1
d fe 2 d e 2 2 hfe 2 c os 2

diameter

d ai 1 d i 1 2 hai 1 c os 1

d ai 2 d i 2 2 hai 2 c os 2

diameter

d fi 1 d i 1 2 hfi 1 c os 1

d fi 2 d i 2 2 hfi 2 c os 2

Undercut check:
Pinion:
Working tool addendum at checkpoint
k hapx k hap

R x 2 Rm 2 ta n a 2
mmn

Minimum profile shift coefficient at check point

z
m s i n eminx
x hx 1 1 . 1 k hapx nx 1 xn
2 mmn

Minimum profile shift coefficient at calculation point

x hmminx 1 x hx 1

d Ex 1 d x 1 c os 1
2 mmn

x hm 1 x hmminx 1

then undercut check failed

Wheel:
Working tool addendum at checkpoint
k hapx k hap

R x 2 Rm 2 ta n f 2
mmn

Maximum profile shift coefficient at calculation point

53

MDESIGN

Gears
2

z
m xn s i n eminx
x hmmaxx 2 1 . 1 k hapx nx 2

2 mmn

x hm 1 x hmmaxx 2

then undercut check failed

Strength calculation DIN 3991:
Tangential force, moment:
Moment
T1

P 159 . 2
n1

Tangential force
Fmt

2000 T1
d m1

Equivalent moment
Teq T1 K A

Equivalent tangential force

Fmt _ eq Fmt K A

Tangential speed
v mt

d m 1 n1
318 . 3

Calculation of factors of influence:

Resonance velocity
nE 1

cy
30 103

z1
mred

Basic velocity
N B 4 . 3810 10 8 n1 z1 d m 1

u2

1 u 2
54

MDESIGN

Gears

Dynamic factor Kv
if NB 0.85:

Kv N B K x 1

if 0.85 < NB 1.15

peff

c
Kv
cv 12 cv 4 1
Fmt

K A

b
eH

if 1.15 < NB 1.5

f
f

peff

c
peff

cv 12 cv 4 1
cv 56 cv 7

F
F

mt K
mt K

b
A
A

b
f peff c
eH
Kv
cv 56 cv 7 eH
1.5 N B


0.35
Fmt K

A
beH

if NB> 1.5

peff c
Kv
cv 56 cv 7
Fmt

K A

beH

Width factors
K H _ C 1, 5
K H _ be 1,1
K H _ d 1, 5 K H _ be
KH KH _d
KF KH
KB KH

Calculation surrogate spur gear:

Number of teeth
55

MDESIGN

Gears

If 90
z1
zv 1

c os
1

z2
zv 2

c os
2

If = 90

u 2 1
zv 1 z1

zv 2 z 2 u 2 1

Gear ratio
If 90
z
uv v 2
zv 1

If = 90

uv u 2

Pitch diameter
If 90
d m1
dv 1

c os
1

dm 2
dv 2

c os
2

If = 90

u 2 1
dv 1 d m 1

dv 2 dv 1 uv

Tip- and root diameter

56

MDESIGN

Gears
dva 1 dv 1 2 ham 1
dva 2 dv 2 2 ham 1

dvb 1 dv 1 c os vt

dvb 2 dv 2 c os vt

Overlap ratio
b s in m 1 beH
v 1

mmn
b1

Base helix angle

vb sin 1 sin m 1 c os n

Centre distance
av

dv 1 dv 2
2

Length of path of contact

gv

2
2
2
2
dvb
dva
d
2 dvb 2 av s i n vt
1
2 va 1

Transverse contact ratio

v

gv c os m 1

mmn c os vt

Calculation surrogate spur gear in pitch plane:

Number of teeth
zvn 1

zvn 2

zv 1
2

c os vb c os m 1
zv 2
2

c os vb c os m 1

Pitch diameter
dvn 1

dv 1
c os vb

dvn 2 dvn 1 uv

57

MDESIGN

Gears

Tip diameter
dvan 1 mmn zvn 1 dva 1 dv 1
dvan 2 mmn zvn 2 dva 2 dv 2

Root diameter
dvbn 1 dvn 1 c os n
dvbn 2 dvn 2 c os n

Spur factor according to method B:

Circumference at the pitch circle
FmtH Fmt K A KV K H

Overlapping factor Z
If m1 =0
Z

4 v

If (m1>0) (v<1)
Z

v
4 v
1 v
3
v

If v 1
Z

Spur Factor (flank) KH

If v 2

cy fp ya
v
KH
0.9 0.4

FmtH
2

beH

If v> 2

58

MDESIGN

Gears

K H 0.9 0.4

2 v 1 c y f p y a

FmtH
v
beH

Spur Factor (flank) KH

KH KH

If KH< 1
KH 1

If Kh> (v) /vZ2

v

KH
Z 2
v

Overlapping factor (root stress)

Y 0 . 25

0 . 75
v n

KF KH

If KH>v
v
KF

Y
v

Helical factor KM
If v 2
KM 1

If 2 <v< 3.5
K M 1 0.2

v 2 5 v

If v 3.5
K M 1.3

Pitting bearing capacity - DIN 3991 part 2:

Factors for flange stress

59

MDESIGN

Gears
c os vb

ZH 2

s i n 2 vt

Zone factor
ZE

1
1 2 1 2
1
2

E1
E2

Elasticity factor ZB
Individual meshing factor (pinion)
If m1 = 0
tanvt

ZB

2
dva 1
2 1 z
d

v1
vb 1

2
dva 2

2 1 v 1 z
d

v2
vb 2

If (m1> 1) (v 1)
ZB 1

If (m1> 0) (v< 1)
tanvt

ZB

2
dva 1
2 1 z
d

v1
vb 1

2
dva 2

2 1 v 1 z
d

v2
vb 2

Individual meshing factor (wheel) ZD

If m1 = 0
tanvt

ZD

2
dva 2
2 1 z
d

v2
vb 2

2
dva 1

2 1 v 1 z
d

v1
vb 1

If (m1> 0) (v 1)
ZD 1

60

MDESIGN

Gears

If (m1> 0) (v< 1)
tanvt

ZD

2
dva 2
2 1 z
d

v2
vb 2

2
dva 1

2 1 v 1 z
d

v1
vb 1

Bevel gear factor

With modification of flank
Z K 0 . 85

Without modification of flank

ZK 1

Helical factor
Z c os m 1

Lubricant factor
Hlim _ min min Hlim 1, Hlim 2

If 850 N/mm2 Hlim_min 120 N/mm2

C ZL Hlim _ min 0 . 6357

N
4375
mm 2

If Hlim_min < 850 N/mm2

C ZL 0 . 83

If Hlim_min >120 N/mm2

C ZL 0 . 91
Z L C ZL

4 1 C ZL

134
1 . 2
s

40

mm 2

If 850 N/mm2 Hlim_min 120 N/mm2

61

MDESIGN

Gears
C ZR 0 . 32 0 . 0002 Hlim _ min

1
N
mm 2

If Hlim_min < 850 N/mm2

C ZR 0 . 15

If Hlim_min >120 N/mm2

C ZR 0 . 08

Roughness factor
R z 100

R zfl 1 R zfl 2
100

3 av
2
mm

3
ZR
R z 100
6
10 m

C ZR

Velocity factor
C Zv C ZL 0 . 002
Zv C Zv

2 1 C Zv
0.8

32
v mt
m
s

Nominal flank pressure H0

H 0 Z H Z E Z Z Z K

Fmt
u 1
v
dv 1 beH
uv

H 0 Z H Z E Z Z Z K

Fmt
u 2 1

d m 1 beH
u2

If = 90

Existing flank pressure (pinion)] H1

H 1 Z B H 0 K A KV K H K H

If (m1> 0) (v< 1)
62

MDESIGN

Gears
H 1 Z B H 0 K A KV K H K H

Existing flank pressure (wheel) H2

H 2 Z D H 0 K A KV K H K H

If (m1> 0) (v< 1)
H 2 Z D H 0 K A KV K H K H

Boundary flank pressure

HG 1 Hlim 1 Z L Zv Z R Z X 1 ]
HG 2 Hlim 2 Z L Zv Z R Z X 2

Flank safety factor

S H 1 HG 1
H 1

S H 2 HG 2
H 2

Root bearing capacity - DIN 3991 part 3

Form factor

YFa 1

h
6 Fa 1 c os Fan 1
mmn

fp 1
G help 1

zvn 1 s in 1 3
3
c
os

1
mn

c os n

Stress correction factor

s
La 1 Fn 1
hFa 1

qs 1

s Fn 1
2 F 1

s
La 2 Fn 2
hFa 2

qs 2

s Fn 2
2 F 2

Scope 1 qs1.2 < 8

2.3

1
.
21

La 1
YSa 1 1 . 2 0 . 13 La 1 q s 1

63

MDESIGN

Gears

2.3

1 . 21 L
a2
YSa 2 1 . 2 0 . 13 La 2 q s 2

Helical factor (root stress) Y

Y 1 v m 1
120

If v> 1

Y 1 m 1
120

If m1> 30
Y 1 v

30
120

If (m1> 30) (v> 1)

Y 0 . 75

Bevel gear factor

YK 1

Size factor YX1

If WGruppel = 1 2 6 7
Y X 1 1 . 03 0 . 006

mmn
mm

If WGruppel = 3 4 8
Y X 1 1 . 05 0 . 01

mmn
mm

If WGruppel = 5

Y X 1 1 . 075 0 . 015

WGruppel=

mmn
mm

Structural steel
Heat treatable steel
Casehardening steel
64

MDESIGN

Gears
Nitride steel
Cast iron
Spheroidal graphite pearlitic
Spheroidal graphite ferritic
Austenitic steels-stainless steel

Relative surface factor

If (RZZ1< 1 10-6 m) (WGruppel = 2 3 6)
YR _ rel _ T _ 1 1 . 12

If (RZZ1< 1 10-6 m) (WGruppel = 1)

YR _ rel _ T _ 1 1 . 07

If (RZZ1< 1 10-6 m) (WGruppel = 4 5 7 8)

YR _ rel _ T _ 1 1 . 025

If (1 10-6 m RZZ1 40 10-6 m) (WGruppel = 2 3 6)

R

YR _ rel _ T _ 1 1 . 64 0 . 529 zz 1
6
10 m

0.1

If (1 10-6 m RZZ1 40 10-6 m) (WGruppel = 1)

R

YR _ rel _ T _ 1 5 . 306 4 . 203 zz 1

6
10 m

0 . 01

If (1 10-6 m RZZ1 40 10-6 m) (WGruppel = 4 5 7 8)

R

YR _ rel _ T _ 1 4 . 299 3 . 259 zz 1

6
10 m

0 . 005

If RZZ1> 40 10-6 m
YR _ rel _ T _ 1 0 . 9

Relative support coefficient

If gs1 1.5
Y _ rel _ T _ 1 1

If gs1< 1.5

65

MDESIGN

Gears
Y _ rel _ T _ 1 0 . 95

If gs2 1.5
Y _ re l _ T _ 2 1

If gs2< 1.5
Y _ re l _ T _ 2 0 . 95

Local root stress

beF beH
F 01

Fmt
Y
Y
Y Y Y
beF mmn Fa 1 Sa 1 K

F 02

Fmt
Y
Y
Y Y Y
beF mmn Fa 2 Sa 2 K

Root stress
F 1 F 01 K A KV K F K F
F 2 F 02 K A KV K F K F

Root base capacity

YST 2
FE 1 Flim 1 YST
FE 2 Flim 2 YST

Root - boundary stress

FG 1 FE 1 Y _ re l _ T _ 1 YR _ re l _ T _ 1 Y X 1
FG 2 FE 2 Y _ re l _ T _ 2 R _ re l _ T _ 2 Y X 2

Root safety factor

S F 1 FG 1
F 1

S F 2 FG 2
F 2

66

MDESIGN

Gears

Scuffing load capacity- DIN 3991 Part 4

Mean friction coefficient VC
V C 2 v mt s i n vt

If vmt< 1 m/s
VC 2

m
s in vt
s

If vmt> 50 m/s
v C 100

Cn 0 . 5

m
s in vt
s

ta n vt

vb 1

c os vb

Fmt
K A KV K B K B

b
B 0 . 045 eH

c os vt v C Cn

uv
uv 1

0.2

l 0, 05 X R

If (Fmt / beH) < 150

150 K K K
A V
B KB
B 0 . 045
c os vt v C Cn

0.2

l 0 . 05

Flash
1

X M 50

K s 2m m
3

N 4m 2

Factor for pinion head geometry

E 1 0 . 5 dva 12 dvb 12

E 2 av sin vt E 1
E 1
X BE 0 . 5 1 uv

E 2
uv
1

E 1 E 2 4

Angle factor

67

MDESIGN

Gears
1

X 1 . 22

s i n n 4
3

c os vt 4

Meshing factor

2
zv 1 dva 1
1 tanvt

v 1
2 dvb 1

2
zv 2 dva 2
1 tanvt

v 2
2 dvb 2

If (f / a) 1.5
XQ 1

If 1.5 < (f / a) < 3

XQ 1.4

4 f

15 a

If (f / a) 3
XQ 0.6

Tip relief factor

Fbmt

Fmt
c os vt

v max ma x v 1, v 2

If m1 = 0
KA
C a Fbmt
beH c '

If m1> 0
KA
C a Fbmt
beH c y

If Korrektur = 2 3

68

MDESIGN

Gears
X Ca 1 1 . 55 10 2 vma x 4

Ca

10 6 m

If Korrektur = 1
X Ca 1

Overlapping factor X
If va< 1
X

1
2 2
2 va v 1 v 1 v 2

If (1 va< 2) (v1< 1) (v2< 1)

X

0 . 7 v21 v2 2 0 . 22 va 0 . 52 0 . 6 v 1 v 2

2 va v 1

If (1 va< 2) (v1 1) (v2< 1)

X

1
0 . 18 v21 0 . 7 v2 2 0 . 82 v21 0 . 52 v 2 0 . 3 v 1 v 2
2 va v 1

If (1 va< 2) (v1< 1) (v2 1)

X

1
0 . 18 v2 2 0 . 7 v21 0 . 82 v2 2 0 . 52 v 1 0 . 3 v 1 v 2
2 va v 1

1
0 . 44 v21 0 . 59 v2 2 0 . 3 v 1 0 . 3 v 2 0 . 15 v 1 v 2
2 va v 1

If (2 va ) (v1v2)

If (2 va ) (v1<v2)
X

1
0 . 44 v2 2 0 . 59 v21 0 . 3 v 2 0 . 3 v 1 0 . 15 v 1 v 2
2 va v 1

Flash temperature at meshing point

Fmt

K A KV K B K B
beH

fl _ E B X M X BE X
1

av 4

3
1

4
v mt 2
1

X X
Ca
Q

Averaged flash temperature

69

MDESIGN

Gears
fl a _ i nt fl a _ E X

Mass temperature
C 1 0, 7
C 2 1, 5

Type of oil distribution

=

splash lubrication
injection lubrication

If Type of oil distribution = splash lubrication

XS 1

If Type of oil distribution = injection lubrication

X S 1.2

M oil C 1 fla _ int X s

Integral temperature
i nt M C 2 fl a _ i nt

Relative structure factor

If WGruppel = 8
XW 1 0 . 45

If (WGruppel = 3) (WEinsatzl = 1)
XW 1 0 . 85

If (WGruppel = 3) (WEinsatzl = 2)
XW 1 1

If (WGruppel = 3) (WEinsatzl = 3)
XW 1 1 . 15

If WGruppel = 4
XW 1 1 . 5

70

MDESIGN

Gears

If WGruppel = 1 2 5 6 7
XW 1 i
XW mi n( XW 1, XW 2 )
X
XW _ rel _ T W
XWT

Scuffing load integral temperature

100
fla _ int _ T 0 . 2 T1T

40

0 . 02

i n t _ S MT C 2 XW _ re l _ T fl a _ i n t _ T

Safety factor for scuffing load

S int _ S int _ S
int

71

MDESIGN

Gears

Cylindrical Worm Gear

With this program basing on groundwork calculations of DIN 3996, method C, you can perform the
strength proof (pitting maximum loading, dedendum maximum loading), safety against deflection,
temperature safety and wear bearing strength of cylindrical worm gear.

Calculation Base
The calculation groundwork for the module cylindrical worm gear is provided by the following DIN
standards:
- DIN 3974 Part 1,

edition November 1995

- DIN 3974 Part 2,

edition November 1995

- DIN 3975

edition October 1976

- DIN 3976
- DIN 3996 Draft

edition November 1980

edition September 1996

- DIN 3998 Part 4,

edition September 1976

(Tolerances for cylindrical worm gear pairs,

foundations)
(Tolerances for cylindrical worm gear pairs,
foundations)
(Terms and parameters for cylindrical worm gear
pairs with axes angle 90)
(Cylindrical worms)
(Bearing strength calculation of cylindrical worm
gear pairs)
(Marking of tooth gears and tooth gear pairs,
worms)

Range of Application
Using the given module cylindrical worm gear pairs you can you can prove with this program strength
(pitting maximum loading, dedendum maximum loading), deflection safety, temperature safety as well as
the wearing maximum loading of worm gearing.
The operating area should be defined as follows:
-

cylindrical worm gears with axes angle 90

Flank forms: A, N, K, I, C, H according to DIN 3975

profile angle 15 << 25

Addendum thickness factor:

1 < x < 1- coefficient of clearance for expansion cP1* = cP2* = 0.2

oil bath lubrication, injection lubricating

72

MDESIGN

Gears

Cylindrical Worm Gear Determination of Results

Geometry:
Form factor q
q

d m1
m

Teeth number ratio u

z
u 2
z1

Gear ratio i
i u
1
i
u

worm is driving
worm gear is driving

Pitch diameter d2
d2 m z2

Axial pitch px
px m

Middle helix angle m

m z1
m a rc ta n

d m1

Middle tooth line inclination m

m 90 m

Basic helix angle b

b a rc c o s c o s m c o s

Middle circle diameter dm2

dm 2 2 a dm 1

Addendum circle diameter da1

da 1 dm 1 2 m

73

MDESIGN

Gears

Dedendum circle diameter df1

d f 1 d m 1 2 m 1 c P*

Dedendum circle diameter df2

d f 2 d a 2 2m 2 c P*

Basic circle diameter db1

ta n m
d b 1 d m1
ta n b

Outer diameter de2

de 2 da 2 m

Gearing angle x
ta n n
x a rc ta n
c os m

Addendum height ha1

ha 1 m

Addendum height ha2

ha 2 m 1 x

Dedendum height hf1

hf 1 m 1 c P*

Dedendum height hf2

hf2 m 1 x c P*

Normal tooth thickness smn

s mn

m
c os m
2

Basic spur pitch pb

pb m c os m

74

MDESIGN

Gears

Normal modulus mn
mn m c os m

Helix height pz1

pz 1 m z 1

Reduced helix height pz1 red

p z1 red

m z1
2

Normal gearing pitch of thread pn

pn m n

Minimal required worm width b1min

b 1 min d a 22 d 22

Minimal required worm width b2min

b2 mi n 2 m 0 . 5 q 1

Strength Proof
Number of revolutions of a worm-wheel n2
n2

n 1 z1
z2

Loading cycle of a warm NL1

NL 1 Lh n 1 60

Loading cycle of a worm-wheel NL2

NL 2

Lh n 1 60
u

Mean peripheral velocity vm1

v m1

dm1 n1
60 1000

75

MDESIGN

Gears

Mean sliding velocity vgm

v gm

v m1
c os m

Nominal torsion moment of a worm-wheel T2

P 9549
T2 2
n2

Limit coefficient of friction oT

oT 0, 028 0, 026

gm 0,17

oT 0, 018 0, 026

oT 0, 022 0, 013

mineral oil

0, 76

gm 0, 2

polyglycol E0:EP = 0:1

0, 78

polyglycol E0:EP = 1:1

1,16

gm 0, 2

Index for the mean Hertz pressure pm*

b 2H
x
*
pm
1 . 03 0 . 4 0 . 01 z 2 0 . 083

u
mx

u 1
9 50
2q 1
u

6.9
15 . 9 37 . 5 q

Notice:
only for flank forms ZI, ZA, ZN, ZK, ZH

b 2H
x
*
pm
1.03 0.31 0.78 0.08 z 2 0.065

u
mx

u 1
9 50
2q 1
u

8.9
20.3 47.9 q

Notice:
only for flank form ZC
Index for the mean sliding range S*
S * 0 . 78 0 . 21 u

5.6
ta n m

Notice:
only for flank forms ZI, ZA, ZN, ZK, ZH

76

MDESIGN

Gears
S * 0 . 78 0 . 21 u

5.6
ta n m

Notice:
only for flank form ZC
Index for die mean lubricating slot thickness h*
h * 0 . 018

b 2H
2q 1
q
1
x
u

7 . 86 q z 2 z 2 110 36300 370 . 4 m x

213 . 9

Notice:
only for flank forms ZI, ZA, ZN, ZK, ZH
h * 0 . 025

2q 1
q
1
x
u

5 . 83 q z 2 z 2 81 . 6 274 . 7 m x
158 . 6

Notice:
only for flank form ZC
Structure dimension factor YS
100
YS

0.5

Notice:
for a < 65mm is substituted a = 65mm!
for a > 250mm is substituted a = 250mm!
Geometry factor YG
0 . 07
YG

h*

0.5

Roughness factor YR
Rz 1
YR 4
6 0.5

Mean tooth coefficient of friction zm

zm o T Y s YG YW YR

77

MDESIGN

Gears

Gear ring efficiency Z

z

100 ta n m
ta n m a rc ta n zm

Notice:
Worm is driving!
'z

ta n m a rc ta n zm 100
ta n m

gear is driving!
Gear ring loss power Pvz
Pvz

0 . 1 T 2 n 1 100

1
u
z

'
Pvz

0 . 1 T 2 n 1 100

1
'

u
z

Notice:
Worm is driving!

gear is driving!
Idling power Pvo
Pvo 0 . 89 10 4 a n 14 / 3

Lager loss power Pvlp

Pvlp

0 . 03 P 2 a 0 . 44 u 1000
dm 2

Notice:
settled bearing!
Pvlp

0 . 013 P 2 a 0 . 44 u 1000
dm 2

fixed-free bearing!

78

MDESIGN

Gears

Power loss at a sealing Pvd

2
Pvd r 11 . 78 10 6 d m1
n1

Total power loss Pv

Pv Pvz Pvo Pvlp Pvd

Total efficiency ges

ges

P2
P 2 Pv

ges

P1
P1 Pv

Notice:
Worm is driving!

gear is driving!
Power P1
P1

P2
ges

Notice:
Worm is driving!
P 1 P 2 ges

gear is driving!
Nominal peripheral forces Ftm1, Ftm2
Ftm 1

2000 T1
dm 1

Ftm 2

2000 T 2
dm 2

Nominal axial forces Fxm1, Fxm2

F x m 1 Ftm 2

79

MDESIGN

Gears
F xm 2 Ftm 1

Nominal radial forces Frm1, Frm2

Ftm 1 ta n
Frm 1 Frm 2
s i n m z
Ftm 2 ta n
Frm 2 Frm 1
c o s m z

Nominal normal force Fnm1, Fnm2

Fnm 1 Fnm 2

Ftm 1
c os sin m zm c os m

Notice:
Worm is driving!
Fnm 1 Fnm 2

Ftm 1
c os sin m zm c os m

gear is driving!
Limit value of deflection lim
lim 0.01 m

Resultant deflection m
ta n2 m a rc ta n zm

2
2
m 3 . 2 10 5 l 11
l1 l11 Ftm 2

ta n2
c os 2 m

d m4 1 l1

Safety against deflection S

S F G
F

Substitute elasticity modulus Ered

E red

1 1 21
2

E1

E2

Mean surface pressure Hm

80

MDESIGN

Gears
*
4 p T 1000 K 1 E red
Hm m 2

a3

0.5

Service life factor ZH

1

25000 6
Z H

LH

Lubricant factor Zoil

Zoil = 1.0 (for polyglycols)
Zoil = 0.89 (petroleum oils)
Structure dimension factor Zs
Zs

3000
2900 a

Zv

5
4 v gm

Velocity factor Zv

Limit value of the flank pressure HG

HG H l i m Z H Zv Z s Z oi l

Safety against flank pressure SH

S H HG
Hm

Oil sump temperature s at oil bath lubrication

T K
s 0 a1 2 A a 0
3
a
63

With ao and a1 for housing without ventilator:

5 . 23 n 1
a0

0 . 28

100 60

0 . 68

40 2 . 203
100

0 . 0237

a 22 . 36

0 . 915

81

MDESIGN

Gears

3 . 4 n1
a1

0 . 22

100 60

0 . 43

10 . 8 40
100

0 . 0636

a 20 . 4

0 . 26

With ao and a1 for housing with ventilator:

a0

a1

8 . 1 n1

0 . 23

100 60

3 . 90 n 1

100 60

0 . 34

0.7

40
100

40
100

0 . 41

0 . 170

a 32

0 . 63

u 0 . 22 a 48

0 . 34

Limit value of oil sump temperature slim

slim = 90C
slim = 100C

(for petroleum oils)

(for polyglycols)

Safety related to the temperature at oil bath lubrication ST

ST s lim
s

Cooling power PK for injection lubricating

Pk c oil poil Qoil oil

Safety related to the temperature ST at injection lubricating

P
ST k
Pv

Gear mass temperature at oil bath lubrication

m s
m s

Pvz

for n1 150 min-1

for n1 < 150 min-1

K 1940 15 n 1 b2 R d m 2 10 6
Pvz

K 4190 b2 R d m 2 10 6

Gear mass temperature at injection lubricating

P
m t oil 16 K n K s Kv vz
1000

with:
Structure dimension factor Ks

82

MDESIGN

Gears
160
Ks

0.6

Viscosity factor Kv

Kv
55

0 . 35

Number of revolutions factor Kn

u 72 . 5

Kn
n1

0 . 35

Oil density at gear mass temperature

poilm

1 . 02
1 K m 1 . 5

with:
K 7 10 4
K 7 . 7 10 4

(mineral oil)
(polyglycol)

Mean lubricating slot thickness hmin m

100 poil m 0 . 7 1 . 39
0 . 03
21 h * C 0 . 6
E red
n 1 a

1000

h min m
K A T 2 0 . 13

with:
C 1 . 7 10 8

(mineral oil)

C 1 . 3 10 8

(polyglycol)

Wearing range sw

a NL 2
sw s * Hm
E red 1000

Allowable removal of metal wlimn

4 limitations are to be considered:
a) sharpness limit

w l i m n 1 m c o s m 2 ta n
2

83

MDESIGN

Gears
b) Tooth thickness
w lim n 2 m c os m *s

c)

Mass removal
w lim n 3

m lim c os m c os
b
2H
p 2 z 2 2m d m 1 a rc s i n
d a1

d) Tooth flank removal

w lim n4 0 . 3 m cos m

Notice:
The minimum value for the wearing removal is most substantial!
Wearing intensity Jw

Jw 2 . 4 10 11 h min m
Jw 127 10

12

3.1

h minm

100 poiLM

1000

WML

for mineral oil

WML

for polyglycol

Wearing removal wn
w n Jw sw

Safety against wearing SW

SW

w lim n
w n

Overlap factor Y
Y 0 . 5

Helix factor Y
Y

1
c os m

Dedendum thickness chord in front section Sft2

84

MDESIGN

Gears
S ft 2

m
ta n
*s m d m 2 d f 2
2
c os m

Form factor YF
YF

2.9 m
S ft 2

Gear ring thickness factor YK

YK=1.0

if

YK=1.25

if

d
SK f 2 1 . 5 m
2
df 2
SK
1.5 m
2

Nominal shear stress at dedendum F

F

Ftm 2 Y YF YK Y K A
b 2H m

Service life factor YNL

Notice:
The calculation of YNL is dependent on the number of loading cycles of the gear NL2 and on the material of
the gear as well as on the gear ring quality of the gear. Look DIN 3996, page 45.
Gear - Standards and Literature
G. Niemann:
Maschinenelemente, Bd. 1, 2. Auflage, 1981 Springer Verlag Berlin, Heidelberg
DIN Deutsches Institut fr Normung (Hrsg.):
Modulreihe fr Stirnrder
DIN 780
Bezugsprofil
DIN 867 Edition 2/86
Evolventenverzahnung
DIN 3960 Edition 3/87
DIN 3960 Appendix 1, Edition 7/80
Einflufaktoren
DIN 3990 Part 1, Edition 12/87
Grbchentragfhigkeit
DIN 3990 Part 2, Edition 12/87
Zahnfutragfhigkeit
DIN 3990 Part 3, Edition 12/87
Fretragfhigkeit
DIN 3990 Part 4, Edition 12/87
Dauerfestigkeitswerte und Werkstoffqualitten
DIN 3990 Part 5, Edition 12/87
Profilverschiebung bei Stirnrdern mit Auenverzahnung
DIN 3992, Edition 3/64
Geometrische Auslegung von zylindrischen
DIN 3993 Part 1 - 4, Edition 8/81
Innenradpaaren
Grundlagen
DIN 3961 Edition 8/61
Toleranzen fr Abweichungen
DIN 3962 Part 1, Edition 8/78
Flankenlinienabweichungen
DIN 3962 Part 2, Edition 8/78
Umwertungstabelle Vickers-Rockwell-Brinellhrte und
DIN 50150, Edition 12/76
Zugfestigkeit
Allgemeine Einflufaktoren
DIN 3991, Part 1, Edition 9/88
Grbchentragfhigkeit
DIN 3991, Part 2, Edition 9/88
Zahnfutragfhigkeit
DIN 3991, Part 3, Edition 9/88
Dauerfestigkeitswerte und Werkstoffqualitten
DIN 3990, Part 5, Edition 12/88
85

MDESIGN
Begriffe und Bestimmungsgren
Toleranzen fr Kegelradverzahnungen
Toleranzen fr Kegelradverzahnungen
Toleranzen fr Stirnradverzahnungen]
Toleranzen fr Abweichungen
Achsabstandsmae und Achslagetoleranzen von
Gehusen fr Stirnradgetriebe
Flankenspiel, Zahndickenabmessungen,
Zahndickentoleranzen
Mestckdurchmesser fr das radiale oder diametrale
Prfma der Zahndicke an Stirnrdern (Zylinderrder)
Beuth Verlag GmbH, Berlin, Kln
Tragfhigkeitsberechnung von ZylinderSchneckengetrieben

Gears
DIN 3971, 7/80
DIN 3965, Part 1, Edition 8/86 Grundlagen
DIN 3965, Part 2, Edition 8/86 Toleranzen
fr Abweichungen
DIN 3961, Edition 8/78
DIN 3962, Part 1, Edition 8/78
DIN 3964, Edition 11/80
DIN3967, Edition 8/78
DIN 3977, Edition 2/81
DIN3996, Edition 9/96

Temperature T [C]
To determine the influence of working temperature and part dimensions on strength characteristics such
as ultimate strength, Rm, Rp and yield strength, you should use the FKM guideline "Rechnerischer
Festigkeitsnachweis fr Maschinenbauteile" (Calculational strength proof for machine parts), 5th,
extended edition of 2003. This method is realised in the module Material Data. The material parameters
are transferred from the input page to the module Material Data. Being calculated, the corrected
parameters are returned from the module Material Data to the actual calculation taking to account the
influence of temperature and part dimension.
The FKM guideline considers the influence of normal and elevated temperature and part dimensions on
the material strength characteristics by determining such parameters as effective diameter deff,
technological dimension factor Kdm (Kdp), anisotropy factor KA and other temperature factors. In detail, the
method of determining strength characteristics according to the FKM guideline is expounded in the help
for the module Material data.

86