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On the Distribution of the Profile Shift Coefficients Between Mating Gears in the Case of Cylindrical Gear
R.-F. Miric * University POLITEHNICA Bucharest, Romania
AbstractAspects of the distribution1 of the profile shift coefficients between mating wheels of the speed-reducing cylindrical gears of general use is analyzed in the paper. The problem of the distribution of the shift coefficient sum on each gear wheel was standardized [2], [1] or recommended in special guides [5], [7]. The paper [7] approaches this problem that will be treated in extended form in the present one. The analyzed aspects are the effects of the applying ISO/TR 4467 [5], DIN 3992 [2] and PD 6457 [7] on the report of the safety factors of tooth bending stress at each wheel, in the case of speed-reducing cylindrical gear pairs having case hardened toothing (the most employed at power transmissions of general use). The results obtained by these different methods are compared and discussed. The conclusions reveal the possibilities to use better some methods in function of the teeth number and sum profile shift coefficients, to ensure a favourable report of bending safety factors of gear wheels. Keywords: profile shift coefficients, cylindrical gears, speed-reducing gear pairs, case hardened toothing, bending safety factors.
I. Introduction The problem of the distribution of the sum of profile shift coefficients on each gear wheel in the case of cylindrical gears was treated and recommended especially in standards. These recommendations were basically employed in technical literature and industrial practice. The distribution of the sum of profile shift coefficients has to ensure multiple tasks [1], [5]: avoiding undercut; avoiding narrow top lands; equalizing specific sliding, with effect on the pitting fatigue life; equalizing flash temperature; equalizing bending fatigue life. All these tasks/criteria do not be simultaneously fulfilled. AGMA 913 [1] recommends the choice of the criterion considered of great importance for practice. It is the reason why the problem of the distribution of the shift coefficient sum on each gear wheel could be met in the case of the largest used thermal treatment for cylindrical gears of general use: case hardening. In this case, the
* E-mail: mirica@meca.omtr.pub.ro E-mail: geo@ meca.omtr.pub.ro
Line of interpolation
x1 , by all these standardized methods, the wheel profile shift coefficient is: x 2 = x x1 . (7) The presented methods differ between themselves. The figure 2 shows differences between results, by graphical representation of the pinion shift coefficient in function of the gear ratio, for some values of sum of profile shift coefficients.
0.5 x1 0.4 0.3 0.2 0.1 0 PD x=0.2 DINx=0.45 PD x=045 ISO x=0.2 ISOx=0.45
z1 z1
B. Method PD 6457 [7] PD 6457 uses computation formulae, that is, the calculus is easier in report with DIN method. Three cases are considered in this method: for general applications: 1 1 x x 1 = 1 + ; (1) 3 u 1+ u for approximate equality of bending strength factors for pinion and wheel: 1 1 x x1 = 1 + ; (2) 2 u 1+ u for approximate balance of ratios of specific sliding or slideroll ratio at extremes of contact path: 1 1 x x1 = . 1 + (3) z v1 u 1 + u Above the following sizes intervenient: the gear ratio: z u= 2 ; z1 the virtual number of teeth: z1 . z v1 = cos 3 C. Method ISO/TR 4467 [5] The ISO method defines the pinion profile shift coefficient in the form: u 1 x x1 = + , (6) u +1 1+ u where: is a factor adopted in the range 0.5 0.75 for speed reducing gears; if u > 5, the limited calculation value is u = 5. Being established the pinion profile shift coefficient,
DIN x=0.2
1.5
2.5
3.5
4.5
5.5
6.5
7.5
Fig. 2. Comparison between the values of pinion shift profile coefficient carried out by different standardized methods, for: x=0, 0.2, 0.45. The method PD 6457 [7] was applied in variant of expression (1). The expression (6) of ISO/TR 4467 [5] was used with = 0.5.
As a result, a necessary comparative analysis is done using a specific criterion defined below, that describing better the effects of the results by different methods on the gear loading capacity. III. Analysis criterion to compare the methods As shown previously, the case of the speed reducing gears of general use and having hardened tooting is considered. Their principal damage modes are: the tooth breakage; the micro-pitting. The micro-pitting influence of the distribution of the sum of profile shit coefficients is not analyzed in the restraint space of the paper. The increasing of tooth bending loading capacity by this distribution could be carried out equalizing the safety factors of wheels in this stress mode: SF1 = SF 2 , (8) that are given by [9]: F lim 1( 2) S F1( 2) = . (9) F1( 2) The limit tooth bending stress intervening above is [4]: F lim 1( 2) = FE YN 1( 2) Y rel T1( 2) YR rel T YX , (10) where: FE is the endurance strength of the even sample; YN - stress cycle factor for bending strength, spur and helical gears; Y rel T - the relative notch sensitivity factor;
(4)
(5)
YR relT
dimension factor. An observation: YN1 = YN 2 = YN , because the numbers of cycles (rotations number) of both wheels exceed generally the limited number of 3106 cycles, specific to case hardened toothing. The tooth-root stress is [4], [9]: Ft K A K v K F K F YFa1,2 YSa1( 2) Y Y F1,2 = .(11) b1( 2) m n where: Ft is the nominal peripheral force on the reference cylinder; K A - the application factor; K v - the one dynamic; K F - the face load factor; K F - transverse load factor; YFa 1( 2) - the form factor; YSa 1( 2) - the stress correction factor; Y - the contact ratio factor; Y - the helix angle factor; b1( 2) - the face width, m n - the normal module. The expressions (9)(11) leads to the criterion report: S F2 YFa1 YSa1 Y rel T 2 b 2 = . (12) S F1 YFa 2 YSa 2 Y rel T1 b1 The values of the face widths are not generally equal, but their difference is insignificant. By simplification of the face width, the expression (12) becomes: S F2 YFa1 YSa1 Y rel T 2 . (13) S F1 YFa 2 YSa 2 Y rel T1 It is desired that:
was {0.5; 0.65; 0.7; 0.75} . This range is used only in the statistical diagram from the figure 20; in the restraint space of the paper, the diagrams of criterion report are given only for the values {0.5; 0.65; 0.75} , including the inferior and exterior limits and a value around the one mean (figures 7...9 and 1417). Another observation: the relative notch sensitivity factor, Y rel T , is taken as value in calculus for case hardened steels [4]. B. Comparison between the results of methods as regards the effect on bending strength The values of the criterion report, S F 2 / S F1 , are represented in illustrative figures below. The first range of figures 39 represent the results carried out by all methods for the number of teeth large used in industrial practice: z1 = 15 .
S F2 S F1 1.06
1.04 1.02 1.00 0.98 1 2 3 4 5 6 u 7 Fig. 3. Criterion report in the case of DIN 3992 [2], for the number of pinion teeth of 15, in function of gear ratio and sum of shift profile coefficients in the range indicated at the point IV, A
S F2 <1, (14) S F1 because the pinion is more stressed as number of cycles, so this safety factor has to be greater as the one of the wheel. This is the main analysis criterion pursued in the comparison of the results carried out by different methods. Finally, a statistical analysis of these results is developed, to include all results.
IV. Analysis of the results carried out by different methods A. Calculus data The following data ranges are considered: numbers of pinion teeth: z1 {12; 13; 14; 15; 16; 17; 18; 19} ; gear ratios: u {1.12; 1.25; 1.4; 1.6; 1.8; 2; 2.24; 2.5;
S F2 1.06 S F1 1.05
1.04 1.03 1.02 1.01 1.00 1 2 3 4 5 6 u 7 Fig. 4. Criterion in the case of PD 6457 [7] in variant given by (1), for the number of pinion teeth of 15, in function of gear ratio and the sum of shift profile coefficients in the range indicated at the point IV, A
2.8; 3.15; 3.55; 4; 4.5; 5; 5.6; 6.3; 7.1} sums of profile shift coefficients: x {0; 0.05; 0.1; 0.15; 0.2; 0.25; 0.3; 0.35; 0.4; 0.45; 0.5; 0.55; 0.6; 0.65; 0.7; 0.75; 0.8; 0.85; 0.9; 0.95; 1; 1.05; 1.1; 1.15; 1.2}. The range of values for the factor intervening in ISO
Analyzing these representations, the following conclusions could be noted. The method PD 6457 [7] in the form given by (3) is the most disadvantageous because of high values of criterion report (this means a great difference between the two bending safety factors and a low bending safety factor of
pinion). As a result, this method and variant cannot be recommended for case hardened gears.
S F 2 1.02 S F1 1.01
1.00 0.99 0.98
dimensioning of the pinion). A general observation noted for all results: increasing the sum of the profile shift coefficients, x , the criterion report has smaller values, more favorable for pinion tooth bending stress as in the case of smaller values of x .
S F2 S F1 1.01
1.00 0.99 0.98 0.97 0.96 1 3 4 5 6 u 7 Fig. 8. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 15, in function of gear ratio, = 0.65, and the sum of shift profile coefficients in the range indicated at the point IV, A
0.97
1 2 3 4 5 6 u 7 Fig. 5. Criterion in the case of PD 6457 [7] in variant given by (2), for the number of pinion teeth of 15, in function of gear ratio and the sum of shift profile coefficients in the range indicated at the point IV, A
S F2 S F1 1.12
1.10 1.08 1.06 1.04 1.02
S F 2 1.00 S F1 0.99
0.98 0.97 0.96
1 2 3 4 5 6 u 7 Fig. 6. Criterion in the case of PD 6457 [7] in variant given by (3), for the number of pinion teeth of 15, in function of gear ratio and the sum of shift profile coefficients in the range indicated at the point IV, A
0.95 1 2 3 4 5 6 u 7 Fig. 9. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 15, in function of gear ratio, = 0.75, and the sum of shift profile coefficients in the range indicated at the point IV, A
S F 2 1.05 S F1 1.04
1.03 1.02 1.01 1.00 0.99
S F 2 1.10 S F1 1.08
1.06 1.04 1.02
1 2 3 4 5 6 u 7 Fig. 7. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 15, in function of gear ratio, = 0.5, and the sum of shift profile coefficients in the range indicated at the point IV, A
1.00 1 2 3 4 5 6 u 7 Fig. 10. Criterion report in the case of DIN 3992 [2], for the number of pinion teeth of 12, in function of gear ratio and sum of shift profile coefficients in the range indicated at the point IV, A
The method PD 6457 [7] in variant given by (1), the method DIN 3992 [2] and the method ISO/TR 4467 [5] with the parameter = 0.5 determine unfavorable results in lower measure as in the previous analysis case. The methods ISO/TR 4467 [5] with the parameter = 0.650.75 and PD 6457 [7] in the form (2) give favorable results: pinion tooth bending stress is equalized or greater as the one of the wheel (the last results leading to an over-
The representation from the figures 10 and 11 give the results for the method DIN 3992 [2] for other number of teeth than the one used in the figure 3. It is noted that the criterion report is favorable regarding the pinion tooth bending stress if the sum of the profile shift coefficients is approximately 1; it is confirmed in this way the same
recommendation done by Niemann and Winter [6]. Although, the small values of x determine unfavorable values of the criterion report from the point of view of the pinion tooth bending stress even in comparison with the other methods (see the figures 5, 8 and 9).
S F2 S F1 1.04
1.03 1.02 1.01 1.00 0.99 0.98 2 3 4 5 6 u 7 1 Fig. 11. Criterion report in the case of DIN 3992 [2], for the number of pinion teeth of 19, in function of gear ratio and sum of shift profile coefficients in the range indicated at the point IV, A
It is very interesting to see the influence of the factor specific for the method ISO/TR 4467 [5], for other number of teeth as 15. The figures 1417 permit to formulate the following conclusions: the values = 0.65...0.75 determine acceptable criterion report values regarding the pinion tooth bending stress; a favorable over-dimensioning of the pinion is visible for = 0.75 , as in the case of 15 teeth (figure 9): greater pinion bending safety factor in comparison to the one of the wheel.
S F 2 1.03 S F1 1.02
1.01 1.00 0.99 0.98 0.97 1 2 3 4 5 6 u 7 Fig. 14. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 12, in function of gear ratio, = 0.65, and the sum of shift profile coefficients in the range indicated at the point IV, A
Analyzing the figures 4, 12 and 13 of results carried out by the method PD 6457 [7] in variant (2), it can observe that this method is useful for all values of the sum x , the criterion report having small values for high values of sum x , and values around 1 for small values of x .
S F 2 1.03 S F1 1.02
1.01 1.00 0.99 0.98
S F 2 1.01 S F1 1.00
0.99 0.98
0.97 0.96 1 2 3 4 5 6 u 7 Fig. 12. Criterion in the case of PD 6457 [7] in variant given by (2), for the number of pinion teeth of 12, in function of gear ratio and the sum of shift profile coefficients in the range indicated at the point IV, A 0.97 0.96 1 2 3 4 5 6 u 7 Fig. 15. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 19, in function of gear ratio, = 0.65, and the sum of shift profile coefficients in the range indicated at the point IV, A
S F 2 1.01 S F1
1.00
S F 2 1.00 S F1 0.99
0.98
0.99 0.97 0.96 0.97 1 2 3 4 5 6 u 7 Fig. 13. Criterion in the case of PD 6457 [7] in variant given by (2), for the number of pinion teeth of 19, in function of gear ratio and the sum of shift profile coefficients in the range indicated at the point IV, A 0.95 1 2 3 4 5 6 u 7 Fig. 16. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 12, in function of gear ratio, = 0.75, and the sum of shift profile coefficients in the range indicated at the point IV, A 0.94
0.98
S F 2 1.00 S F1 0.99
0.98 0.97 0.96
report has to be less than 1 to ensure a good pinion tooth bending stress: the method DIN 3992 [2] leads to a majority of criterion report values above 1; the method PD 6457 [7] is good for the variant 2; the method ISO/TR 4467 [5] is excellent for = 0.65...0.75 .
1000
Frequency of occurrence
0.95 1 2 3 4 5 6 u 7 Fig. 17. Criterion report in the case of ISO/TR 4467 [5] for the number of pinion teeth of 19, in function of gear ratio, = 0.75, and the sum of shift profile coefficients in the range indicated at the point IV, A
Statistical frequency distributions of the criterion report were calculated for each method for all the data presented at point IV A (three data). In the statistical process, the whole variation interval of the criterion report values was divided into 20 sub-intervals, in which were counted the occurrences of the report values, which are indicated in diagrams (figures 1820).
400
1.06 S F 2 S F1 Fig. 20. Frequency of occurrence of the criterion report values in the case of ISO/TR 4467 [5], for all numbers of pinion teeth, gear ratios and profile shift coefficients in the ranges indicated at the point IV, A 1 - : = 0.5; 2 - : = 0.65; 3 - : = 0.7; 4 - : = 0.75. 0.96 0.98 1 1.02 1.04
V. Conclusion 1. The distribution of the sum of profile shift coefficients between the mating gears at cylindrical gears is recommended especially in standards, more relevant being ISO/TR 4467 [5], DIN 3992 [2] and PD 6457 [7]. 2. The criterion report of safety factors for tooth bending loading capacities of wheels (valid for the case hardening gears of general use) was applied for comparative analysis of results about different methods. This analysis was developed for ranges of numbers of pinion teeth, gear ratios and sum of profile shift coefficients. 3. The adequate methods to distribute the sum of profile shift coefficients were emphasized to better fulfill the mentioned criterion report. References
1 3 [1] AGMA 913-A98, Method for specifying the geometry of spur and helical gears, 1998. [2] DIN 3992. Profilverschiebung bei Stirnrdern mit Aussenverzahnung, 1964. [3] ISO 53, Cylindrical gears for general and heavy engineering Standard basic rack tooth profile, 1998. [4] ISO 6336, Calculation of load capacity of spur and helical gears, Part 3: Calculation of tooth bending strength, 1996. [5] ISO/TR 4467. Addendum modification of the teeth of cylindrical gears for speed-reducing and speed-increasing gear pairs, 1982. [6] Niemann, G., Winter, H. Maschinenelemente. Band II, SpringerVerlag, 1985. [7] PD 6457. Guide to the application of addendum modification to involute spur and helical gears, 1970. [8] Rdulescu, G, Dobre, G., Miric R.-F., Consideratii asupra utilizarii metodei ISO privind repartitia pe roti a sumei deplasarilor, PRASIC'90, pages 9-16, Brasov, 13-14 December 1990. [9] STAS 12268-84. Angrenaje cilindrice cu dantura n evolvent. Calcul de rezisten (Cylindrical spur gears with involute tooting. Strength calculus), 1984.
Frequency of occurrence
1.08 S F 2 1.1 S F1 Fig. 18. Frequency of occurrence of the criterion report values in the case of DIN 3992 [2], for all numbers of pinion teeth, gear ratios and profile shift coefficients in the ranges indicated at the point IV, A 1 - frequency distribution; 2 statistical mean of all values. 0.98 1 1.02 1.04 1.06 600 2
Frequency of occurrence
1.15 S F 2 S F1 Fig. 19. Frequency of occurrence of the criterion report values in the case of variants 13 of PD 6457 [7], for all numbers of pinion teeth, gear ratios and profile shift coefficients in the ranges indicated at the point IV, A
This statistical study permits a global evaluation of each method applied to all mentioned input data, by observing the localization of criterion report values and their statistical weight. The following conclusions can be stated by this analysis, taking into account that the best criterion