ISO15144-2: Examples 1 to 4, using Method A and B

Reviewed by U. Kissling, 10 nov 2014

Note: In the examples of ISO15144-2 the tip relief factor XCa is calculated following method B. In KISSsoft
we use Method A (which is more precise).
In order to get the same results as in 15144-2, we just set the tip relief Ca to 0.

Calculation of examples 1 to 4 with Method A and B, comparing our results

with results presented in draft ISO TR 15144-2(2014)

Example 1 : mn=10.93, =0, z=18/18

Example 2 : mn=10, =0, z=20/20
Example 3 : mn=4.5, =19.578, z=33/34
Example 4 : mn=8, =14.5, z=21/67

Resume:

What Result in 15144- Our result Comment

2
Example 1, Method B S=0.644 0.644 OK

Example 2, Method B (no tip relief S=0.353 0.353 OK

considered)

Example 3, Method A 1.124 1.208 We considered all contact

points (not only A, AB,
etc.). See note.
Example 3, Method B (no tip relief S=0.884 0.8848 OK
considered)
Example 3, Method B (tip relief 1.148 For information only
considered)

Example 4, Method A 1.158 1.282 OK

Example 4, Method B (no tip relief S= 0.894 0.8948 OK. See note.
considered)

Note: Examples using Method A (Hertzian pressure from LCA): Pressure distribution is slightly different in
KISSsoft Contact analysis than the data given as input in the examples. Furthermore any flank line
modification (or shaft bending data) is not indicated, therefore the load distribution over the face width can
not be reproduced.

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 Example 3, Method A

Example 4, Method A

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Data Overview

Example 1, Method B

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 8 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 171.6
Line load at contact point A (N/mm) [FbbRef,A] 153.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 115.9
Contact temperature (C) [theBRef,A] 198.4
Lubrication gap thickness (m) [hRef,A] 0.075
Specific film thickness in test (m) [lamGFT] 0.151
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.211

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.048
Lubricant factor [XL] 1.000
Roughness factor [XR] 1.025
Tooth mass temperature (C) [theM] 153.6
Tip relief factor [XCa (A)] 1.000
Loss factor [HV] 0.204
Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.02150
Dynamic viscosity (Ns/m2) [etatM] 4.7
Roughness average value (m) [Ra] 0.9
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.136 (hY=0.122 m)
Safety against micropitting [Slam] 0.644

Calculation Micropitting ISO TR 15144, Methode B Pair 1-2

gA = 0.000
gAB = 6.626
gB = 13.253
gC = 22.760
gD = 32.267
gDE = 38.893
gE = 45.519

Er = 226373.6
Ra = 0.900
ZE = 189.812
XL = 1.000
XS = 1.200
XCa = 1.000
mym = 0.048
theM = 153.604
etaTm= 4.652
alf38= 0.0215 *1e-6
alfTm= 0.0118 *1e-6

A:
dA,1 = 187.419
dA,2 = 221.400
rt1,A = 15.389
rt2,A = 60.908
ron,A = 12.285
XbutA = 1.000
XA = 0.333
PH,A,B = 963.371
Pdin,A,B = 1083.525
Vr1,A = 4.835
Vr2,A = 19.135

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 Vg,A = -14.300 VSig,A = 23.969
ThetaFl,A= 175.285
TheB,A = 328.889
(GM,A = 2678.6 U,A = 20.047*10^-12 W,A = 1.439*10^-4 SGF,A = 0.057)
h,A = 0.1224
lamGF,A = 0.136
Slam,A = 0.644

AB:
dAB,1 = 190.046
dAB,2 = 214.394
rt1,AB = 22.015
rt2,AB = 54.282
ron,AB = 15.663
XbutAB = 1.000
XAB = 0.500
PH,AB,B = 1044.941
Pdin,AB,B = 1175.268
Vr1,AB = 6.916
Vr2,AB = 17.053
Vg,AB = -10.137 VSig,AB = 23.969
ThetaFl,AB= 154.120
TheB,AB = 307.724
(GM,AB = 2678.6 U,AB = 15.723*10^-12 W,AB = 1.694*10^-4 SGF,AB = 0.076)
h,AB = 0.1374
lamGF,AB = 0.153
Slam,AB = 0.723

B:
dB,1 = 193.546
dB,2 = 207.998
rt1,B = 28.641
rt2,B = 47.655
ron,B = 17.890
XbutB = 1.000
XB = 1.000
PH,B,B = 1382.739
Pdin,B,B = 1555.197
Vr1,B = 8.998
Vr2,B = 14.971
Vg,B = -5.974 VSig,B = 23.969
ThetaFl,B= 145.392
TheB,B = 298.996
(GM,B = 2678.6 U,B = 13.766*10^-12 W,B = 2.966*10^-4 SGF,B = 0.086)
h,B = 0.1365
lamGF,B = 0.152
Slam,B = 0.718

C:
dC,1 = 200.000
dC,2 = 200.000
rt1,C = 38.148
rt2,C = 38.148
ron,C = 19.074
XbutC = 1.000
XC = 1.000
PH,C,B = 1339.111
Pdin,C,B = 1506.128
Vr1,C = 11.985
Vr2,C = 11.985
Vg,C = 0.000 VSig,C = 23.969
ThetaFl,C= 0.000
TheB,C = 153.604
(GM,C = 2678.6 U,C = 12.911*10^-12 W,C = 2.781*10^-4 SGF,C = 1.000)
h,C = 0.2406
lamGF,C = 0.267
Slam,C = 1.266

D:
dD,1 = 207.998
dD,2 = 193.546
rt1,D = 47.655
rt2,D = 28.641
ron,D = 17.890
XbutD = 1.000
XD = 1.000
PH,D,B = 1382.739
Pdin,D,B = 1555.197
Vr1,D = 14.971
Vr2,D = 8.998
Vg,D = 5.974 VSig,D = 23.969
ThetaFl,D= 145.393
TheB,D = 298.996
(GM,D = 2678.6 U,D = 13.766*10^-12 W,D = 2.966*10^-4 SGF,D = 0.086)
h,D = 0.1365
lamGF,D = 0.152
Slam,D = 0.718

DE:
dDE,1 = 214.394
dDE,2 = 190.046
rt1,DE = 54.282
rt2,DE = 22.015
ron,DE = 15.663
XbutDE = 1.000
XDE = 0.500
PH,DE,B = 1044.941
Pdin,DE,B = 1175.268
Vr1,DE = 17.053
Vr2,DE = 6.916
Vg,DE = 10.137 VSig,DE = 23.969

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 ThetaFl,DE= 154.120
TheB,DE = 307.724
(GM,DE = 2678.6 U,DE = 15.723*10^-12 W,DE = 1.694*10^-4 SGF,DE = 0.076)
h,DE = 0.1374
lamGF,DE = 0.153
Slam,DE = 0.723

E:
dE,1 = 221.400
dE,2 = 187.419
rt1,E = 60.908
rt2,E = 15.389
ron,E = 12.285
XbutE = 1.000
XE = 0.333
PH,E,B = 963.371
Pdin,E,B = 1083.525
Vr1,E = 19.135
Vr2,E = 4.835
Vg,E = 14.300 VSig,E = 23.969
ThetaFl,E= 175.285
TheB,E = 328.889
(GM,E = 2678.6 U,E = 20.047*10^-12 W,E = 1.439*10^-4 SGF,E = 0.057)
h,E = 0.1224
lamGF,E = 0.136
Slam,E = 0.644

Example 2, Method B without considering tip relief Ca

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 10 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 265.1
Line load at contact point A (N/mm) [FbbRef,A] 236.3
Oil temperature (C) [theOilRef] 70.0
Tooth mass temperature (C) [theMRef] 107.1
Contact temperature (C) [theBRef,A] 228.6
Lubrication gap thickness (m) [hRef,A] 0.061
Specific film thickness in test (m) [lamGFT] 0.122
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.171

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.067
Lubricant factor [XL] 1.000
Roughness factor [XR] 1.023
Tooth mass temperature (C) [theM] 126.6
Tip relief factor [XCa (A)] 1.000
Loss factor [HV] 0.206
Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.02052
Dynamic viscosity (Ns/m2) [etatM] 6.4
Roughness average value (m) [Ra] 0.8
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.060 (hY=0.048 m)
Safety against micropitting [Slam] 0.353

Calculation Micropitting ISO TR 15144, Methode B Pair 1-2

gA = 0.000
gAB = 8.219
gB = 16.439
gC = 22.980
gD = 29.521
gDE = 37.741

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 gE = 45.960

Er = 226373.6
Ra = 0.800
ZE = 189.812
XL = 1.000
XS = 1.200
XCa = 1.000
mym = 0.067
theM = 126.576
etaTm= 6.443
alf38= 0.0205 *1e-6
alfTm= 0.0130 *1e-6

A:
dA,1 = 189.274
dA,2 = 220.000
rt1,A = 11.222
rt2,A = 57.182
ron,A = 9.381
XbutA = 1.000
XA = 0.333
PH,A,B = 1476.400
Pdin,A,B = 1541.337
Vr1,A = 1.175
Vr2,A = 5.988
Vg,A = -4.813 VSig,A = 7.163
ThetaFl,A= 225.690
TheB,A = 352.266
(GM,A = 2936.2 U,A = 10.867*10^-12 W,A = 2.913*10^-4 SGF,A = 0.024)
h,A = 0.0483
lamGF,A = 0.060
Slam,A = 0.353

AB:
dAB,1 = 191.919
dAB,2 = 211.920
rt1,AB = 19.441
rt2,AB = 48.963
ron,AB = 13.916
XbutAB = 1.000
XAB = 0.500
PH,AB,B = 1484.636
Pdin,AB,B = 1549.934
Vr1,AB = 2.036
Vr2,AB = 5.127
Vg,AB = -3.091 VSig,AB = 7.163
ThetaFl,AB= 170.319
TheB,AB = 296.895
(GM,AB = 2936.2 U,AB = 7.325*10^-12 W,AB = 2.945*10^-4 SGF,AB = 0.049)
h,AB = 0.0639
lamGF,AB = 0.080
Slam,AB = 0.468

B:
dB,1 = 195.912
dB,2 = 204.844
rt1,B = 27.661
rt2,B = 40.743
ron,B = 16.475
XbutB = 1.000
XB = 1.000
PH,B,B = 1929.617
Pdin,B,B = 2014.487
Vr1,B = 2.897
Vr2,B = 4.267
Vg,B = -1.370 VSig,B = 7.163
ThetaFl,B= 119.228
TheB,B = 245.804
(GM,B = 2936.2 U,B = 6.187*10^-12 W,B = 4.976*10^-4 SGF,B = 0.102)
h,B = 0.0736
lamGF,B = 0.092
Slam,B = 0.539

C:
dC,1 = 200.000
dC,2 = 200.000
rt1,C = 34.202
rt2,C = 34.202
ron,C = 17.101
XbutC = 1.000
XC = 1.000
PH,C,B = 1893.996
Pdin,C,B = 1977.300
Vr1,C = 3.582
Vr2,C = 3.582
Vg,C = 0.000 VSig,C = 7.163
ThetaFl,C= 0.000
TheB,C = 126.576
(GM,C = 2936.2 U,C = 5.961*10^-12 W,C = 4.794*10^-4 SGF,C = 1.000)
h,C = 0.1236
lamGF,C = 0.155
Slam,C = 0.905

D:
dD,1 = 204.844
dD,2 = 195.912
rt1,D = 40.743
rt2,D = 27.661
ron,D = 16.475
XbutD = 1.000

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 XD = 1.000
PH,D,B = 1929.617
Pdin,D,B = 2014.487
Vr1,D = 4.267
Vr2,D = 2.897
Vg,D = 1.370 VSig,D = 7.163
ThetaFl,D= 119.228
TheB,D = 245.804
(GM,D = 2936.2 U,D = 6.187*10^-12 W,D = 4.976*10^-4 SGF,D = 0.102)
h,D = 0.0736
lamGF,D = 0.092
Slam,D = 0.539

DE:
dDE,1 = 211.920
dDE,2 = 191.919
rt1,DE = 48.963
rt2,DE = 19.441
ron,DE = 13.916
XbutDE = 1.000
XDE = 0.500
PH,DE,B = 1484.636
Pdin,DE,B = 1549.934
Vr1,DE = 5.127
Vr2,DE = 2.036
Vg,DE = 3.091 VSig,DE = 7.163
ThetaFl,DE= 170.319
TheB,DE = 296.895
(GM,DE = 2936.2 U,DE = 7.325*10^-12 W,DE = 2.945*10^-4 SGF,DE = 0.049)
h,DE = 0.0639
lamGF,DE = 0.080
Slam,DE = 0.468

E:
dE,1 = 220.000
dE,2 = 189.274
rt1,E = 57.182
rt2,E = 11.222
ron,E = 9.381
XbutE = 1.000
XE = 0.333
PH,E,B = 1476.400
Pdin,E,B = 1541.337
Vr1,E = 5.988
Vr2,E = 1.175
Vg,E = 4.813 VSig,E = 7.163
ThetaFl,E= 225.690
TheB,E = 352.266
(GM,E = 2936.2 U,E = 10.867*10^-12 W,E = 2.913*10^-4 SGF,E = 0.024)
h,E = 0.0483
lamGF,E = 0.060
Slam,E = 0.353

Example 3, Method A

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 8 (l:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 171.6
Line load at contact point A (N/mm) [FbbRef,A] 153.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 116.7
Contact temperature (C) [theBRef,A] 202.9
Lubrication gap thickness (m) [hRef,A] 0.040
Specific film thickness in test (m) [lamGFT] 0.080
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.112

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.054
Lubricant factor [XL] 1.000
Roughness factor [XR] 0.913
Tooth mass temperature (C) [theM] 129.9
Tip relief factor [XCa (A)] 1.488
Loss factor [HV] 0.128

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 Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.01875
Dynamic viscosity (Ns/m2) [etatM] 3.4
Roughness average value (m) [Ra] 0.5

Calculation of speeds, load distribution and flank curvature according to ISO15144 method A with contact analysis
Minimal specific film thickness (m) [lamGFY] 0.136 (hY=0.061 m)
Safety against micropitting [Slam] 1.208

Safety S

Most critical point S = 1.208

Example 3, Method B, without considering tip relief Ca

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 8 (l:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 171.6
Line load at contact point A (N/mm) [FbbRef,A] 153.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 116.7
Contact temperature (C) [theBRef,A] 202.9
Lubrication gap thickness (m) [hRef,A] 0.040
Specific film thickness in test (m) [lamGFT] 0.080
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.112

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 Intermediate results according to ISO TR 15144:2010
Coefficient of friction [mym] 0.054
Lubricant factor [XL] 1.000
Roughness factor [XR] 0.913
Tooth mass temperature (C) [theM] 149.3
Tip relief factor [XCa (A)] 1.000
Loss factor [HV] 0.128
Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.01875
Dynamic viscosity (Ns/m2) [etatM] 2.4
Roughness average value (m) [Ra] 0.5
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.099 (hY=0.045 m)
Safety against micropitting [Slam] 0.8848

Calculation Micropitting ISO TR 15144, Methode B Pair 1-2

gA = 0.000
gAB = 3.813
gB = 7.626
gC = 10.832
gD = 13.997
gDE = 17.810
gE = 21.623

Er = 226373.6
Ra = 0.450
ZE = 189.812
XL = 1.000
XS = 1.200
XCa = 1.000
mym = 0.054
theM = 149.311
etaTm= 2.440
alf38= 0.0188 *1e-6
alfTm= 0.0106 *1e-6

A:
dA,1 = 151.162
dA,2 = 171.390
rt1,A = 17.566
rt2,A = 40.090
ron,A = 12.869
XbutA = 1.300
XA = 0.841
PH,A,B = 1752.036
Pdin,A,B = 1882.929
Vr1,A = 5.518
Vr2,A = 12.224
Vg,A = -6.706 VSig,A = 17.743
ThetaFl,A= 241.698
TheB,A = 391.009
(GM,A = 2388.5 U,A = 7.431*10^-12 W,A = 4.347*10^-4 SGF,A = 0.030)
h,A = 0.0447
lamGF,A = 0.099
Slam,A = 0.885

AB:
dAB,1 = 153.115
dAB,2 = 167.957
rt1,AB = 21.379
rt2,AB = 36.277
ron,AB = 14.172
XbutAB = 1.000
XAB = 0.647
PH,AB,B = 1464.249
Pdin,AB,B = 1573.642
Vr1,AB = 6.716
Vr2,AB = 11.061
Vg,AB = -4.345 VSig,AB = 17.778
ThetaFl,AB= 124.041
TheB,AB = 273.352
(GM,AB = 2388.5 U,AB = 6.760*10^-12 W,AB = 3.036*10^-4 SGF,AB = 0.135)
h,AB = 0.0675
lamGF,AB = 0.150
Slam,AB = 1.334

B:
dB,1 = 155.417
dB,2 = 164.807
rt1,B = 25.192
rt2,B = 32.463
ron,B = 14.945
XbutB = 1.000
XB = 0.647

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 PH,B,B = 1425.909
Pdin,B,B = 1532.437
Vr1,B = 7.914
Vr2,B = 9.899
Vg,B = -1.984 VSig,B = 17.813
ThetaFl,B= 55.508
TheB,B = 204.819
(GM,B = 2388.5 U,B = 6.424*10^-12 W,B = 2.879*10^-4 SGF,B = 0.361)
h,B = 0.0859
lamGF,B = 0.191
Slam,B = 1.698

C:
dC,1 = 157.612
dC,2 = 162.388
rt1,C = 28.398
rt2,C = 29.258
ron,C = 15.183
XbutC = 1.000
XC = 0.647
PH,C,B = 1414.682
Pdin,C,B = 1520.371
Vr1,C = 8.921
Vr2,C = 8.921
Vg,C = 0.000 VSig,C = 17.843
ThetaFl,C= 0.000
TheB,C = 149.311
(GM,C = 2388.5 U,C = 6.334*10^-12 W,C = 2.834*10^-4 SGF,C = 1.000)
h,C = 0.1083
lamGF,C = 0.241
Slam,C = 2.142

D:
dD,1 = 160.002
dD,2 = 160.216
rt1,D = 31.562
rt2,D = 26.093
ron,D = 15.050
XbutD = 1.000
XD = 0.647
PH,D,B = 1420.931
Pdin,D,B = 1527.088
Vr1,D = 9.916
Vr2,D = 7.956
Vg,D = 1.959 VSig,D = 17.872
ThetaFl,D= 54.618
TheB,D = 203.928
(GM,D = 2388.5 U,D = 6.400*10^-12 W,D = 2.859*10^-4 SGF,D = 0.366)
h,D = 0.0866
lamGF,D = 0.192
Slam,D = 1.712

DE:
dDE,1 = 163.161
dDE,2 = 157.897
rt1,DE = 35.376
rt2,DE = 22.280
ron,DE = 14.403
XbutDE = 1.000
XDE = 0.647
PH,DE,B = 1452.487
Pdin,DE,B = 1561.001
Vr1,DE = 11.114
Vr2,DE = 6.794
Vg,DE = 4.320 VSig,DE = 17.907
ThetaFl,DE= 122.360
TheB,DE = 271.670
(GM,DE = 2388.5 U,DE = 6.701*10^-12 W,DE = 2.988*10^-4 SGF,DE = 0.138)
h,DE = 0.0686
lamGF,DE = 0.152
Slam,DE = 1.357

E:
dE,1 = 166.610
dE,2 = 155.916
rt1,E = 39.189
rt2,E = 18.467
ron,E = 13.225
XbutE = 1.300
XE = 0.841
PH,E,B = 1728.290
Pdin,E,B = 1857.410
Vr1,E = 12.312
Vr2,E = 5.631
Vg,E = 6.681 VSig,E = 17.942
ThetaFl,E= 237.681
TheB,E = 386.992
(GM,E = 2388.5 U,E = 7.312*10^-12 W,E = 4.230*10^-4 SGF,E = 0.031)
h,E = 0.0462
lamGF,E = 0.103
Slam,E = 0.913

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Example 3, Method B, considering tip relief Ca (for information only)

Profile and tooth trace modifications for gear 1

Symmetric (both flanks)
- Tip relief, linear Caa = 50.000m LCa = 0.960*mn dCa = 162.726mm

Profile and tooth trace modifications for gear 2

Symmetric (both flanks)
- Tip relief, linear Caa = 50.000m LCa = 0.960*mn dCa = 167.520mm

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 8 (l:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 171.6
Line load at contact point A (N/mm) [FbbRef,A] 153.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 116.7
Contact temperature (C) [theBRef,A] 202.9
Lubrication gap thickness (m) [hRef,A] 0.040
Specific film thickness in test (m) [lamGFT] 0.080
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.112

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.054
Lubricant factor [XL] 1.000
Roughness factor [XR] 0.913
Tooth mass temperature (C) [theM] 129.9
Tip relief factor [XCa (A)] 1.488
Loss factor [HV] 0.128
Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.01875
Dynamic viscosity (Ns/m2) [etatM] 3.4
Roughness average value (m) [Ra] 0.5
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.129 (hY=0.058 m)
Safety against micropitting [Slam] 1.148

Example 4, Method A

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 9 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 215.6
Line load at contact point A (N/mm) [FbbRef,A] 192.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 121.2
Contact temperature (C) [theBRef,A] 221.9

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 Lubrication gap thickness (m) [hRef,A] 0.077
Specific film thickness in test (m) [lamGFT] 0.153
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.215

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.060
Lubricant factor [XL] 1.000
Roughness factor [XR] 0.876
Tooth mass temperature (C) [theM] 77.9
Tip relief factor [XCa (A)] 1.308
Loss factor [HV] 0.131
Equivalent Young's modulus (N/mm) [Er] 230769
Compressed viscosity index (m2/N) [alf38] 0.02320
Dynamic viscosity (Ns/m2) [etatM] 43.9
Roughness average value (m) [Ra] 0.7
Calculation of speeds, load distribution and flank curvature according to ISO15144 method A with contact analysis
Minimal specific film thickness (m) [lamGFY] 0.261 (hY=0.175 m)
Safety against micropitting [Slam] 1.282

Stress pdyn

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 Specific film thickness
Most critical point = 0.261

Safety S

Most critical point S = 1.282 (at right side of facewidth and root area of pinion)

Example 4, Method B, without considering tip relief Ca

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 9 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 215.6
Line load at contact point A (N/mm) [FbbRef,A] 192.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 121.2
Contact temperature (C) [theBRef,A] 221.9

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 Lubrication gap thickness (m) [hRef,A] 0.077
Specific film thickness in test (m) [lamGFT] 0.153
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.215

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.060
Lubricant factor [XL] 1.000
Roughness factor [XR] 0.876
Tooth mass temperature (C) [theM] 80.3
Tip relief factor [XCa (A)] 1.000
Loss factor [HV] 0.131
Equivalent Young's modulus (N/mm) [Er] 230769
Compressed viscosity index (m2/N) [alf38] 0.02320
Dynamic viscosity (Ns/m2) [etatM] 40.1
Roughness average value (m) [Ra] 0.7
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.192 (hY=0.129 m)
Safety against micropitting [Slam] 0.895

Calculation Micropitting ISO TR 15144, Methode B Pair 1-2

gE = 0.000
gDE = 6.548
gD = 13.096
gC = 17.479
gB = 24.299
gAB = 30.847
gA = 37.395

Er = 230769.2
Ra = 0.670
ZE = 191.646
XL = 1.000
XS = 1.200
XCa = 1.000
mym = 0.060
theM = 80.282
etaTm= 40.071
alf38= 0.0232 *1e-6
alfTm= 0.0186 *1e-6

E:
dE,1 = 165.768
dE,2 = 576.300
rt1,E = 16.555
rt2,E = 126.062
ron,E = 15.056
XbutE = 1.300
XE = 0.845
PH,E,B = 1540.522
Pdin,E,B = 1916.619
Vr1,E = 0.920
Vr2,E = 2.197
Vg,E = -1.276 VSig,E = 3.117
ThetaFl,E= 152.432
TheB,E = 232.714
(GM,E = 4290.7 U,E = 17.975*10^-12 W,E = 4.334*10^-4 SGF,E = 0.021)
h,E = 0.1286
lamGF,E = 0.192
Slam,E = 0.895

DE:
dDE,1 = 168.872
dDE,2 = 570.692
rt1,DE = 23.102
rt2,DE = 119.514
ron,DE = 19.919
XbutDE = 1.000
XDE = 0.650
PH,DE,B = 1174.653
Pdin,DE,B = 1461.428
Vr1,DE = 1.284
Vr2,DE = 2.083
Vg,DE = -0.798 VSig,DE = 3.367
ThetaFl,DE= 69.185
TheB,DE = 149.467
(GM,DE = 4290.7 U,DE = 14.676*10^-12 W,DE = 2.520*10^-4 SGF,DE = 0.109)
h,DE = 0.2270
lamGF,DE = 0.339
Slam,DE = 1.579

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 D:
dD,1 = 172.914
dD,2 = 565.333
rt1,D = 29.650
rt2,D = 112.967
ron,D = 24.164
XbutD = 1.000
XD = 0.650
PH,D,B = 1066.497
Pdin,D,B = 1326.867
Vr1,D = 1.648
Vr2,D = 1.969
Vg,D = -0.320 VSig,D = 3.617
ThetaFl,D= 25.348
TheB,D = 105.629
(GM,D = 4290.7 U,D = 12.995*10^-12 W,D = 2.077*10^-4 SGF,D = 0.382)
h,D = 0.3414
lamGF,D = 0.510
Slam,D = 2.375

C:
dC,1 = 176.114
dC,2 = 561.886
rt1,C = 34.034
rt2,C = 108.583
ron,C = 26.660
XbutC = 1.000
XC = 0.650
PH,C,B = 1015.343
Pdin,C,B = 1263.226
Vr1,C = 1.892
Vr2,C = 1.892
Vg,C = 0.000 VSig,C = 3.784
ThetaFl,C= 0.000
TheB,C = 80.282
(GM,C = 4290.7 U,C = 12.324*10^-12 W,C = 1.883*10^-4 SGF,C = 1.000)
h,C = 0.4543
lamGF,C = 0.678
Slam,C = 3.160

B:
dB,1 = 181.821
dB,2 = 556.757
rt1,B = 40.854
rt2,B = 101.763
ron,B = 29.993
XbutB = 1.000
XB = 0.650
PH,B,B = 957.275
Pdin,B,B = 1190.981
Vr1,B = 2.271
Vr2,B = 1.773
Vg,B = 0.498 VSig,B = 4.045
ThetaFl,B= 35.368
TheB,B = 115.649
(GM,B = 4290.7 U,B = 11.708*10^-12 W,B = 1.674*10^-4 SGF,B = 0.276)
h,B = 0.3773
lamGF,B = 0.563
Slam,B = 2.624

AB:
dAB,1 = 188.071
dAB,2 = 552.104
rt1,AB = 47.402
rt2,AB = 95.215
ron,AB = 32.561
XbutAB = 1.000
XAB = 0.650
PH,AB,B = 918.752
Pdin,AB,B = 1143.053
Vr1,AB = 2.635
Vr2,AB = 1.659
Vg,AB = 0.976 VSig,AB = 4.294
ThetaFl,AB= 66.216
TheB,AB = 146.498
(GM,AB = 4290.7 U,AB = 11.451*10^-12 W,AB = 1.542*10^-4 SGF,AB = 0.118)
h,AB = 0.3378
lamGF,AB = 0.504
Slam,AB = 2.350

A:
dA,1 = 195.000
dA,2 = 547.725
rt1,A = 53.949
rt2,A = 88.667
ron,A = 34.510
XbutA = 1.300
XA = 0.845
PH,A,B = 1017.524
Pdin,A,B = 1265.938
Vr1,A = 2.999
Vr2,A = 1.545
Vg,A = 1.454 VSig,A = 4.544
ThetaFl,A= 115.846
TheB,A = 196.128
(GM,A = 4290.7 U,A = 11.433*10^-12 W,A = 1.891*10^-4 SGF,A = 0.041)
h,A = 0.2755
lamGF,A = 0.411
Slam,A = 1.916

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Full geometry data

Example 1

KISSsoft Release 03/2014 E

KISSsoft-Entwicklungs-Version KISSsoft AG CH-8608 BUBIKON
File
Name : 15144-2_Expl1
Changed by: ukissling on: 11.11.2014 at: 11:34:04

CALCULATION OF A CYLINDRICAL SPUR GEAR PAIR

Drawing or article number:

Gear 1: 0.000.0
Gear 2: 0.000.0

Calculation method ISO 6336:2006 Method B

------- GEAR 1 -------- GEAR 2 --

Power (kW) [P] 589.991

Speed (1/min) [n] 3000.0 3000.0
Torque (Nm) [T] 1878.0 1878.0
Application factor [KA] 1.00
Required service life [H] 20000.00
Gear driving (+) / driven (-) + -

1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to

DIN 3960:1987)

------- GEAR 1 -------- GEAR 2

Center distance (mm) [a] 200.000

Centre distance allowances (mm) [Aa.e/i] 0.050 / 0.050
Normal module (mm) [mn] 10.9300
Pressure angle at normal section () [alfn] 20.0000
Helix angle at reference circle () [beta] 0.0000
Number of teeth [z] 18 18
Facewidth (mm) [b] 21.40 21.40
Hand of gear Spur gear
Accuracy grade [Q-ISO 1328:1995] 5 5
Inner diameter (mm) [di] 0.00 0.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

Material
Gear 1: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28
Gear 2: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28

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 ------- GEAR 1 -------- GEAR 2

Surface hardness HRC 61 HRC 61

Material quality according to ISO 6336:2006 Normal (Life factors ZNT and YNT >=0.85)
Fatigue strength. tooth root stress (N/mm) [sigFlim] 430.00 430.00
Fatigue strength for Hertzian pressure (N/mm) [sigHlim] 1500.00 1500.00
Tensile strength (N/mm) [Rm] 1200.00 1200.00
Yield point (N/mm) [Rp] 850.00 850.00
Young's modulus (N/mm) [E] 206000 206000
Poisson's ratio [ny] 0.300 0.300
Mean roughness, Ra, tooth flank (m) [RAH] 0.90 0.90
Mean roughness height, Rz, flank (m) [RZH] 4.80 4.80
Mean roughness height, Rz, root (m) [RZF] 20.00 20.00

Gear reference profile 1:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 0.970
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Gear reference profile 2:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 0.970
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Summary of reference profile gears:

Dedendum reference profile [hfP*] 1.250 1.250
Tooth root radius Reference profile [rofP*] 0.380 0.380
Addendum Reference profile [haP*] 0.970 0.970
Protuberance height factor [hprP*] 0.000 0.000
Protuberance angle () [alfprP] 0.000 0.000
Tip form height coefficient [hFaP*] 0.000 0.000
Ramp angle () [alfKP] 0.000 0.000

Type of profile modification:

none (only running-in)
Tip relief (m) [Ca] 2.0 2.0

Lubrication type oil injection lubrication

Type of oil (Own input) Oil:
Lubricant base Mineral-oil base
Kinem. viscosity oil at 40 C (mm/s) [nu40] 210.00
Kinem. viscosity oil at 100 C (mm/s) [nu100] 18.50

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FZG test A/8.3/90 ( ISO 14635-1:2006) [FZGtestA] 12
Specific density at 15 C (kg/dm) [roOil] 0.895
Oil temperature (C) [TS] 90.000

------- GEAR 1 -------- GEAR 2

Overall transmission ratio [itot] -1.000

Gear ratio [u] 1.000
Transverse module (mm) [mt] 10.930
Pressure angle at pitch circle () [alft] 20.000
Working transverse pressure angle () [alfwt] 22.426
[alfwt.e/i] 22.460 / 22.460
Working pressure angle at normal section () [alfwn] 22.426
Helix angle at operating pitch circle () [betaw] 0.000
Base helix angle () [betab] 0.000
Reference centre distance (mm) [ad] 196.740
Sum of profile shift coefficients [Summexi] 0.3159
Profile shift coefficient [x] 0.1580 0.1579
Tooth thickness (Arc) (module) (module) [sn*] 1.6858 1.6858

Tip alteration (mm) [k*mn] 0.000 0.000

Reference diameter (mm) [d] 196.740 196.740
Base diameter (mm) [db] 184.875 184.875
Tip diameter (mm) [da] 221.400 221.400
(mm) [da.e/i] 221.400 / 221.400 221.400 / 221.400
Tip diameter allowances (mm) [Ada.e/i] 0.000 / 0.000 0.000 / 0.000
Tip form diameter (mm) [dFa] 221.400 221.400
(mm) [dFa.e/i] 221.400 / 221.400 221.400 / 221.400
Active tip diameter (mm) [dNa] 221.400 221.400
Active tip diameter (mm) [dNa.e/i] 221.400 / 221.400 221.400 / 221.400
Operating pitch diameter (mm) [dw] 200.000 200.000
(mm) [dw.e/i] 200.050 / 200.050 200.050 / 200.050
Root diameter (mm) [df] 172.869 172.867
Generating Profile shift coefficient [xE.e/i] 0.1580/ 0.1580 0.1579/ 0.1579
Manufactured root diameter with xE (mm) [df.e/i] 172.869 / 172.869 172.867 / 172.867
Theoretical tip clearance (mm) [c] 2.866 2.866
Effective tip clearance (mm) [c.e/i] 2.916 / 2.916 2.916 / 2.916
Active root diameter (mm) [dNf] 187.419 187.419
(mm) [dNf.e/i] 187.463 / 187.463 187.463 / 187.463
Root form diameter (mm) [dFf] 185.366 185.365
(mm) [dFf.e/i] 185.366 / 185.366 185.365 / 185.365
Reserve (dNf-dFf)/2 (mm) [cF.max/min] 1.049 / 1.049 1.049 / 1.049
Addendum (mm) [ha=mn*(haP*+x)] 12.330 12.330
(mm) [ha.e/i] 12.330 / 12.330 12.330 / 12.330
Dedendum (mm) [hf=mn*(hfP*-x)] 11.936 11.936
(mm) [hf.e/i] 11.936 / 11.936 11.936 / 11.936
Roll angle at dFa () [xsi_dFa.e/i] 37.753 / 37.753 37.753 / 37.753
Roll angle to dNa () [xsi_dNa.e/i] 37.753 / 37.753 37.753 / 37.753
Roll angle to dNf () [xsi_dNf.e/i] 9.620 / 9.620 9.620 / 9.620
Roll angle at dFf () [xsi_dFf.e/i] 4.176 / 4.176 4.175 / 4.175
Tooth height (mm) [H] 24.266 24.266
Virtual gear no. of teeth [zn] 18.000 18.000
Normal tooth thickness at tip cylinder (mm) [san] 7.143 7.143
(mm) [san.e/i] 7.143 / 7.143 7.143 / 7.143
Normal spacewidth at root cylinder (mm) [efn] 0.000 0.000
(mm) [efn.e/i] 0.000 / 0.000 0.000 / 0.000
Max. sliding velocity at tip (m/s) [vga] 14.300 14.300

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Specific sliding at the tip [zetaa] 0.747 0.747
Specific sliding at the root [zetaf] -2.958 -2.958
Mean specific sliding [zetam] 0.747
Sliding factor on tip [Kga] 0.455 0.455
Sliding factor on root [Kgf] -0.455 -0.455
Pitch on reference circle (mm) [pt] 34.338
Base pitch (mm) [pbt] 32.267
Transverse pitch on contact-path (mm) [pet] 32.267
Length of path of contact (mm) [ga, e/i] 45.519 ( 45.388 / 45.388)
Length T1-A, T2-A (mm) [T1A, T2A] 15.389( 15.520/ 15.520) 60.908( 60.908/ 60.908)
Length T1-B (mm) [T1B, T2B] 28.641( 28.641/ 28.641) 47.655( 47.786/ 47.786)
Length T1-C (mm) [T1C, T2C] 38.148( 38.214/ 38.214) 38.148( 38.214/ 38.214)
Length T1-D (mm) [T1D, T2D] 47.655( 47.786/ 47.786) 28.641( 28.641/ 28.641)
Length T1-E (mm) [T1E, T2E] 60.908( 60.908/ 60.908) 15.389( 15.520/ 15.520)
Length T1-T2 (mm) [T1T2] 76.297 ( 76.428 / 76.428)
Diameter of single contact point B (mm) [d-B] 193.546( 193.546/ 193.546) 207.998( 208.118/ 208.118)
Diameter of single contact point D (mm) [d-D] 207.998( 208.118/ 208.118) 193.546( 193.546/ 193.546)
Addendum contact ratio [eps] 0.705( 0.703/ 0.703) 0.705( 0.703/ 0.703)
Minimal length of contact line (mm) [Lmin] 21.400

Transverse contact ratio [eps_a] 1.411

Transverse contact ratio with allowances [eps_a.e/m/i] 1.407 / 1.407 / 1.407
Overlap ratio [eps_b] 0.000
Total contact ratio [eps_g] 1.411
Total contact ratio with allowances [eps_g.e/m/i] 1.407 / 1.407 / 1.407

2. FACTORS OF GENERAL INFLUENCE

------- GEAR 1 -------- GEAR 2

Nominal circum. force at pitch circle (N) [Ft] 19091.2

Axial force (N) [Fa] 0.0
Radial force (N) [Fr] 6948.6
Normal force (N) [Fnorm] 20316.4
Tangent.load at p.c.d.per mm (N/mm) (N/mm) [w] 892.11
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N) [Ftw] 18780.0
Axial force (N) [Faw] 0.0
Radial force (N) [Frw] 7750.4
Circumferential speed reference circle (m/s) [v] 30.90
Circumferential speed operating pitch circle (m/s)
[v(dw)] 31.42

Running-in value (m) [yp] 0.7

Running-in value (m) [yf] 0.9
Correction coefficient [CM] 0.800
Gear body coefficient [CR] 1.000
Reference profile coefficient [CBS] 0.975
Material coefficient [E/Est] 1.000
Singular tooth stiffness (N/mm/m) [c'] 11.832
Meshing stiffness (N/mm/m) [cgalf] 15.477
Meshing stiffness (N/mm/m) [cgbet] 13.155
Reduced mass (kg/mm) [mRed] 0.06767
Resonance speed (min-1) [nE1] 8023

User specified factor KV:

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Dynamic factor [KV] 1.150

User specified factor KHb:

Face load factor - flank [KHb] 1.100
- Tooth root [KFb] 1.068
- Scuffing [KBb] 1.100

User specified factor KHa:

Transverse load factor - flank [KHa] 1.000
- Tooth root [KFa] 1.000
- Scuffing [KBa] 1.000

Helical load factor scuffing [Kbg] 1.000

Number of load cycles (in mio.) [NL] 3600.000 3600.000

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 8 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 171.6
Line load at contact point A (N/mm) [FbbRef,A] 153.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 115.9
Contact temperature (C) [theBRef,A] 198.4
Lubrication gap thickness (m) [hRef,A] 0.075
Specific film thickness in test (m) [lamGFT] 0.151
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.211

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.048
Lubricant factor [XL] 1.000
Roughness factor [XR] 1.025
Tooth mass temperature (C) [theM] 153.6
Tip relief factor [XCa (A)] 1.000
Loss factor [HV] 0.204
Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.02150
Dynamic viscosity (Ns/m2) [etatM] 4.7
Roughness average value (m) [Ra] 0.9
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-
1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.136 (hY=0.122 m)
Safety against micropitting [Slam] 0.644

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Example 2

Here XCa calculated using Method A!

KISSsoft Release 03/2014 E

KISSsoft-Entwicklungs-Version KISSsoft AG CH-8608 BUBIKON
File
Name : 15144-2_Expl2(2014)
Changed by: ukissling on: 11.11.2014 at: 11:32:33

CALCULATION OF A CYLINDRICAL SPUR GEAR PAIR

Drawing or article number:

Gear 1: 0.000.0
Gear 2: 0.000.0

Calculation method ISO 6336:2006 Method B

------- GEAR 1 -------- GEAR 2 --

Power (kW) [P] 251.327

Speed (1/min) [n] 1000.0 1000.0
Torque (Nm) [T] 2400.0 2400.0
Application factor [KA] 1.00
Required service life [H] 20000.00
Gear driving (+) / driven (-) + -

1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to

DIN 3960:1987)
------- GEAR 1 -------- GEAR 2

Center distance (mm) [a] 200.000

Centre distance tolerance No backlash
Normal module (mm) [mn] 10.0000
Pressure angle at normal section () [alfn] 20.0000
Helix angle at reference circle () [beta] 0.0000
Number of teeth [z] 20 20
Facewidth (mm) [b] 15.00 15.00
Hand of gear Spur gear
Accuracy grade [Q-ISO 1328:1995] 6 6
Inner diameter (mm) [di] 0.00 0.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

Material
Gear 1: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28
Gear 2: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28

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 ------- GEAR 1 -------- GEAR 2

Surface hardness HRC 61 HRC 61

Material quality according to ISO 6336:2006 Normal (Life factors ZNT and YNT >=0.85)
Fatigue strength. tooth root stress (N/mm) [sigFlim] 430.00 430.00
Fatigue strength for Hertzian pressure (N/mm) [sigHlim] 1500.00 1500.00
Tensile strength (N/mm) [Rm] 1200.00 1200.00
Yield point (N/mm) [Rp] 850.00 850.00
Young's modulus (N/mm) [E] 206000 206000
Poisson's ratio [ny] 0.300 0.300
Mean roughness, Ra, tooth flank (m) [RAH] 0.80 0.80
Mean roughness height, Rz, flank (m) [RZH] 6.30 6.30
Mean roughness height, Rz, root (m) [RZF] 20.00 20.00

Gear reference profile 1:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 1.000
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Gear reference profile 2:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 1.000
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Summary of reference profile gears:

Dedendum reference profile [hfP*] 1.250 1.250
Tooth root radius Reference profile [rofP*] 0.380 0.380
Addendum Reference profile [haP*] 1.000 1.000
Protuberance height factor [hprP*] 0.000 0.000
Protuberance angle () [alfprP] 0.000 0.000
Tip form height coefficient [hFaP*] 0.000 0.000
Ramp angle () [alfKP] 0.000 0.000

Type of profile modification:

none (only running-in)
Tip relief (m) [Ca] 90.0 90.0

Lubrication type oil injection lubrication

Type of oil (Own input) Oil:
Lubricant base Mineral-oil base
Kinem. viscosity oil at 40 C (mm/s) [nu40] 150.00
Kinem. viscosity oil at 100 C (mm/s) [nu100] 14.70

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FZG test A/8.3/90 ( ISO 14635-1:2006) [FZGtestA] 12
Specific density at 15 C (kg/dm) [roOil] 0.890
Oil temperature (C) [TS] 70.000

------- GEAR 1 -------- GEAR 2

Overall transmission ratio [itot] -1.000

Gear ratio [u] 1.000
Transverse module (mm) [mt] 10.000
Pressure angle at pitch circle () [alft] 20.000
Working transverse pressure angle () [alfwt] 20.000
[alfwt.e/i] 20.000 / 20.000
Working pressure angle at normal section () [alfwn] 20.000
Helix angle at operating pitch circle () [betaw] 0.000
Base helix angle () [betab] 0.000
Reference centre distance (mm) [ad] 200.000
Sum of profile shift coefficients [Summexi] 0.0000
Profile shift coefficient [x] 0.0000 0.0000
Tooth thickness (Arc) (module) (module) [sn*] 1.5708 1.5708

Tip alteration (mm) [k*mn] 0.000 0.000

Reference diameter (mm) [d] 200.000 200.000
Base diameter (mm) [db] 187.939 187.939
Tip diameter (mm) [da] 220.000 220.000
(mm) [da.e/i] 220.000 / 220.000 220.000 / 220.000
Tip diameter allowances (mm) [Ada.e/i] 0.000 / 0.000 0.000 / 0.000
Tip form diameter (mm) [dFa] 220.000 220.000
(mm) [dFa.e/i] 220.000 / 220.000 220.000 / 220.000
Active tip diameter (mm) [dNa] 220.000 220.000
Active tip diameter (mm) [dNa.e/i] 220.000 / 220.000 220.000 / 220.000
Operating pitch diameter (mm) [dw] 200.000 200.000
(mm) [dw.e/i] 200.000 / 200.000 200.000 / 200.000
Root diameter (mm) [df] 175.000 175.000
Generating Profile shift coefficient [xE.e/i] 0.0000/ 0.0000 0.0000/ 0.0000
Manufactured root diameter with xE (mm) [df.e/i] 175.000 / 175.000 175.000 / 175.000
Theoretical tip clearance (mm) [c] 2.500 2.500
Effective tip clearance (mm) [c.e/i] 2.500 / 2.500 2.500 / 2.500
Active root diameter (mm) [dNf] 189.274 189.274
(mm) [dNf.e/i] 189.274 / 189.274 189.274 / 189.274
Root form diameter (mm) [dFf] 188.201 188.201
(mm) [dFf.e/i] 188.201 / 188.201 188.201 / 188.201
Reserve (dNf-dFf)/2 (mm) [cF.max/min] 0.537 / 0.537 0.537 / 0.537
Addendum (mm) [ha=mn*(haP*+x)] 10.000 10.000
(mm) [ha.e/i] 10.000 / 10.000 10.000 / 10.000
Dedendum (mm) [hf=mn*(hfP*-x)] 12.500 12.500
(mm) [hf.e/i] 12.500 / 12.500 12.500 / 12.500
Roll angle at dFa () [xsi_dFa.e/i] 34.866 / 34.866 34.866 / 34.866
Roll angle to dNa () [xsi_dNa.e/i] 34.866 / 34.866 34.866 / 34.866
Roll angle to dNf () [xsi_dNf.e/i] 6.842 / 6.842 6.842 / 6.842
Roll angle at dFf () [xsi_dFf.e/i] 3.027 / 3.027 3.027 / 3.027
Tooth height (mm) [H] 22.500 22.500
Virtual gear no. of teeth [zn] 20.000 20.000
Normal tooth thickness at tip cylinder (mm) [san] 6.949 6.949
(mm) [san.e/i] 6.949 / 6.949 6.949 / 6.949
Normal spacewidth at root cylinder (mm) [efn] 0.000 0.000
(mm) [efn.e/i] 0.000 / 0.000 0.000 / 0.000
Max. sliding velocity at tip (m/s) [vga] 4.813 4.813

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Specific sliding at the tip [zetaa] 0.804 0.804
Specific sliding at the root [zetaf] -4.095 -4.095
Mean specific sliding [zetam] 0.804
Sliding factor on tip [Kga] 0.460 0.460
Sliding factor on root [Kgf] -0.460 -0.460
Pitch on reference circle (mm) [pt] 31.416
Base pitch (mm) [pbt] 29.521
Transverse pitch on contact-path (mm) [pet] 29.521
Length of path of contact (mm) [ga, e/i] 45.960 ( 45.960 / 45.960)
Length T1-A, T2-A (mm) [T1A, T2A] 11.222( 11.222/ 11.222) 57.182( 57.182/ 57.182)
Length T1-B (mm) [T1B, T2B] 27.661( 27.661/ 27.661) 40.743( 40.743/ 40.743)
Length T1-C (mm) [T1C, T2C] 34.202( 34.202/ 34.202) 34.202( 34.202/ 34.202)
Length T1-D (mm) [T1D, T2D] 40.743( 40.743/ 40.743) 27.661( 27.661/ 27.661)
Length T1-E (mm) [T1E, T2E] 57.182( 57.182/ 57.182) 11.222( 11.222/ 11.222)
Length T1-T2 (mm) [T1T2] 68.404 ( 68.404 / 68.404)
Diameter of single contact point B (mm) [d-B] 195.912( 195.912/ 195.912) 204.844( 204.844/ 204.844)
Diameter of single contact point D (mm) [d-D] 204.844( 204.844/ 204.844) 195.912( 195.912/ 195.912)
Addendum contact ratio [eps] 0.778( 0.778/ 0.778) 0.778( 0.778/ 0.778)
Minimal length of contact line (mm) [Lmin] 15.000

Transverse contact ratio [eps_a] 1.557

Transverse contact ratio with allowances [eps_a.e/m/i] 1.557 / 1.557 / 1.557
Overlap ratio [eps_b] 0.000
Total contact ratio [eps_g] 1.557
Total contact ratio with allowances [eps_g.e/m/i] 1.557 / 1.557 / 1.557

2. FACTORS OF GENERAL INFLUENCE

------- GEAR 1 -------- GEAR 2

Nominal circum. force at pitch circle (N) [Ft] 24000.0

Axial force (N) [Fa] 0.0
Radial force (N) [Fr] 8735.3
Normal force (N) [Fnorm] 25540.3
Tangent.load at p.c.d.per mm (N/mm) (N/mm) [w] 1600.00
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N) [Ftw] 24000.0
Axial force (N) [Faw] 0.0
Radial force (N) [Frw] 8735.3
Circumferential speed reference circle (m/s) [v] 10.47
Circumferential speed operating pitch circle (m/s)
[v(dw)] 10.47

Running-in value (m) [yp] 0.8

Running-in value (m) [yf] 1.1
Correction coefficient [CM] 0.800
Gear body coefficient [CR] 1.000
Reference profile coefficient [CBS] 0.975
Material coefficient [E/Est] 1.000
Singular tooth stiffness (N/mm/m) [c'] 11.487
Meshing stiffness (N/mm/m) [cgalf] 16.285
Meshing stiffness (N/mm/m) [cgbet] 13.842
Reduced mass (kg/mm) [mRed] 0.06597
Resonance speed (min-1) [nE1] 7502

User specified factor KV:

Dynamic factor [KV] 1.038

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User specified factor KHb:
Face load factor - flank [KHb] 1.050
- Tooth root [KFb] 1.034
- Scuffing [KBb] 1.050

User specified factor KHa:

Transverse load factor - flank [KHa] 1.000
- Tooth root [KFa] 1.000
- Scuffing [KBa] 1.000

Helical load factor scuffing [Kbg] 1.000

Number of load cycles (in mio.) [NL] 1200.000 1200.000

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 10 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 265.1
Line load at contact point A (N/mm) [FbbRef,A] 236.3
Oil temperature (C) [theOilRef] 70.0
Tooth mass temperature (C) [theMRef] 107.1
Contact temperature (C) [theBRef,A] 228.6
Lubrication gap thickness (m) [hRef,A] 0.061
Specific film thickness in test (m) [lamGFT] 0.122
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.171

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.067
Lubricant factor [XL] 1.000
Roughness factor [XR] 1.023
Tooth mass temperature (C) [theM] 109.9
Tip relief factor [XCa (A)] 1.420
Loss factor [HV] 0.206
Equivalent Young's modulus (N/mm) [Er] 226374
Compressed viscosity index (m2/N) [alf38] 0.02052
Dynamic viscosity (Ns/m2) [etatM] 9.5
Roughness average value (m) [Ra] 0.8
Calculation of speeds, load distribution and flank curvature according to method B following ISO 15144-1:2010
With modifications following ISO TR CD 15144-2:2013
Ca taken as optimal in the calculation (0=no, 1=yes) 0 0
Minimal specific film thickness (m) [lamGFY] 0.079 (hY=0.063 m)
Safety against micropitting [Slam] 0.461

9. DETERMINATION OF TOOTHFORM

Profile and tooth trace modifications for gear 1

Symmetric (both flanks)
- Tip relief, linear Caa = 90.000m LCa = 0.822*mn dCa = 212.004mm

Profile and tooth trace modifications for gear 2

Symmetric (both flanks)
- Tip relief, linear Caa = 90.000m LCa = 0.822*mn dCa = 212.004mm

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Example 3

KISSsoft Release 03/2014 E

KISSsoft-Entwicklungs-Version KISSsoft AG CH-8608 BUBIKON
File
Name : 15144-2_Expl3(No Opt Ca)
Changed by: ukissling on: 11.11.2014 at: 11:20:04

CALCULATION OF A HELICAL GEAR PAIR

Drawing or article number:

Gear 1: 0.000.0
Gear 2: 0.000.0

Calculation method ISO 6336:2006 Method B

------- GEAR 1 -------- GEAR 2 --

Power (kW) [P] 1256.637

Speed (1/min) [n] 3000.0 2911.8
Torque (Nm) [T] 4000.0 4121.2
Application factor [KA] 1.00
Required service life [H] 20000.00
Gear driving (+) / driven (-) + -

1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to

DIN 3960:1987)
------- GEAR 1 -------- GEAR 2

Center distance (mm) [a] 160.000

Centre distance tolerance No backlash
Normal module (mm) [mn] 4.5000
Pressure angle at normal section () [alfn] 20.0000
Helix angle at reference circle () [beta] 19.5780
Number of teeth [z] 33 34
Facewidth (mm) [b] 44.00 44.00
Hand of gear right left
Accuracy grade [Q-ISO 1328:1995] 4 4
Inner diameter (mm) [di] 0.00 0.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

Material
Gear 1: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28
Gear 2: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28

------- GEAR 1 -------- GEAR 2

Surface hardness HRC 61 HRC 61

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Material quality according to ISO 6336:2006 Normal (Life factors ZNT and YNT >=0.85)
Fatigue strength. tooth root stress (N/mm) [sigFlim] 430.00 430.00
Fatigue strength for Hertzian pressure (N/mm) [sigHlim] 1500.00 1500.00
Tensile strength (N/mm) [Rm] 1200.00 1200.00
Yield point (N/mm) [Rp] 850.00 850.00
Young's modulus (N/mm) [E] 206000 206000
Poisson's ratio [ny] 0.300 0.300
Mean roughness, Ra, tooth flank (m) [RAH] 0.45 0.45
Mean roughness height, Rz, flank (m) [RZH] 3.75 3.75
Mean roughness height, Rz, root (m) [RZF] 20.00 20.00

Gear reference profile 1:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 1.000
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Gear reference profile 2:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 1.000
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Summary of reference profile gears:

Dedendum reference profile [hfP*] 1.250 1.250
Tooth root radius Reference profile [rofP*] 0.380 0.380
Addendum Reference profile [haP*] 1.000 1.000
Protuberance height factor [hprP*] 0.000 0.000
Protuberance angle () [alfprP] 0.000 0.000
Tip form height coefficient [hFaP*] 0.000 0.000
Ramp angle () [alfKP] 0.000 0.000

Type of profile modification:

for high load capacity gearboxe
Tip relief (m) [Ca] 50.0 50.0

Lubrication type oil injection lubrication

Type of oil (Own input) l:
Lubricant base Mineral-oil base
Kinem. viscosity oil at 40 C (mm/s) [nu40] 76.50
Kinem. viscosity oil at 100 C (mm/s) [nu100] 8.00
FZG test A/8.3/90 ( ISO 14635-1:2006) [FZGtestA] 12
Specific density at 15 C (kg/dm) [roOil] 0.895
Oil temperature (C) [TS] 90.000

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 ------- GEAR 1 -------- GEAR 2

Overall transmission ratio [itot] -1.030

Gear ratio [u] 1.030
Transverse module (mm) [mt] 4.776
Pressure angle at pitch circle () [alft] 21.122
Working transverse pressure angle () [alfwt] 21.122
[alfwt.e/i] 21.122 / 21.122
Working pressure angle at normal section () [alfwn] 20.000
Helix angle at operating pitch circle () [betaw] 19.578
Base helix angle () [betab] 18.354
Reference centre distance (mm) [ad] 160.000
Sum of profile shift coefficients [Summexi] -0.0001
Profile shift coefficient [x] 0.0000 -0.0001
Tooth thickness (Arc) (module) (module) [sn*] 1.5708 1.5708

Tip alteration (mm) [k*mn] 0.000 0.000

Reference diameter (mm) [d] 157.612 162.388
Base diameter (mm) [db] 147.023 151.479
Tip diameter (mm) [da] 166.610 171.390
(mm) [da.e/i] 166.610 / 166.610 171.390 / 171.390
Tip diameter allowances (mm) [Ada.e/i] 0.000 / 0.000 0.000 / 0.000
Tip form diameter (mm) [dFa] 166.610 171.390
(mm) [dFa.e/i] 166.610 / 166.610 171.390 / 171.390
Active tip diameter (mm) [dNa] 166.610 171.390
Active tip diameter (mm) [dNa.e/i] 166.610 / 166.610 171.390 / 171.390
Operating pitch diameter (mm) [dw] 157.612 162.388
(mm) [dw.e/i] 157.612 / 157.612 162.388 / 162.388
Root diameter (mm) [df] 146.362 151.138
Generating Profile shift coefficient [xE.e/i] -0.0031/ -0.0031 -0.0031/ -0.0031
Manufactured root diameter with xE (mm) [df.e/i] 146.335 / 146.335 151.110 / 151.110
Theoretical tip clearance (mm) [c] 1.126 1.124
Effective tip clearance (mm) [c.e/i] 1.140 / 1.140 1.138 / 1.138
Active root diameter (mm) [dNf] 151.162 155.916
(mm) [dNf.e/i] 151.162 / 151.162 155.916 / 155.916
Root form diameter (mm) [dFf] 150.427 155.147
(mm) [dFf.e/i] 150.411 / 150.411 155.131 / 155.131
Reserve (dNf-dFf)/2 (mm) [cF.max/min] 0.376 / 0.376 0.393 / 0.393
Addendum (mm) [ha=mn*(haP*+x)] 4.499 4.501
(mm) [ha.e/i] 4.499 / 4.499 4.501 / 4.501
Dedendum (mm) [hf=mn*(hfP*-x)] 5.625 5.625
(mm) [hf.e/i] 5.639 / 5.639 5.639 / 5.639
Roll angle at dFa () [xsi_dFa.e/i] 30.544 / 30.544 30.327 / 30.327
Roll angle to dNa () [xsi_dNa.e/i] 30.544 / 30.544 30.327 / 30.327
Roll angle to dNf () [xsi_dNf.e/i] 13.691 / 13.691 13.970 / 13.970
Roll angle at dFf () [xsi_dFf.e/i] 12.371 / 12.371 12.658 / 12.658
Tooth height (mm) [H] 10.124 10.126
Virtual gear no. of teeth [zn] 38.880 40.058
Normal tooth thickness at tip cylinder (mm) [san] 3.421 3.429
(mm) [san.e/i] 3.411 / 3.411 3.418 / 3.418
Normal spacewidth at root cylinder (mm) [efn] 0.000 0.000
(mm) [efn.e/i] 0.000 / 0.000 0.000 / 0.000
Max. sliding velocity at tip (m/s) [vga] 6.681 6.706
Specific sliding at the tip [zetaa] 0.543 0.549
Specific sliding at the root [zetaf] -1.215 -1.186
Mean specific sliding [zetam] 0.546
Sliding factor on tip [Kga] 0.270 0.271

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Sliding factor on root [Kgf] -0.271 -0.270
Pitch on reference circle (mm) [pt] 15.005
Base pitch (mm) [pbt] 13.997
Transverse pitch on contact-path (mm) [pet] 13.997
Lead height (mm) [pz] 1392.241 1434.431
Axial pitch (mm) [px] 42.189
Length of path of contact (mm) [ga, e/i] 21.623 ( 21.623 / 21.623)
Length T1-A, T2-A (mm) [T1A, T2A] 17.566( 17.566/ 17.566) 40.090( 40.090/ 40.090)
Length T1-B (mm) [T1B, T2B] 25.192( 25.192/ 25.192) 32.463( 32.463/ 32.463)
Length T1-C (mm) [T1C, T2C] 28.398( 28.398/ 28.398) 29.258( 29.258/ 29.258)
Length T1-D (mm) [T1D, T2D] 31.562( 31.562/ 31.562) 26.093( 26.093/ 26.093)
Length T1-E (mm) [T1E, T2E] 39.189( 39.189/ 39.189) 18.467( 18.467/ 18.467)
Length T1-T2 (mm) [T1T2] 57.656 ( 57.656 / 57.656)
Diameter of single contact point B (mm) [d-B] 155.417( 155.417/ 155.417) 164.807( 164.807/ 164.807)
Diameter of single contact point D (mm) [d-D] 160.002( 160.002/ 160.002) 160.216( 160.216/ 160.216)
Addendum contact ratio [eps] 0.771( 0.771/ 0.771) 0.774( 0.774/ 0.774)
Minimal length of contact line (mm) [Lmin] 70.578

Transverse contact ratio [eps_a] 1.545

Transverse contact ratio with allowances [eps_a.e/m/i] 1.545 / 1.545 / 1.545
Overlap ratio [eps_b] 1.043
Total contact ratio [eps_g] 2.588
Total contact ratio with allowances [eps_g.e/m/i] 2.588 / 2.588 / 2.588

2. FACTORS OF GENERAL INFLUENCE

------- GEAR 1 -------- GEAR 2

Nominal circum. force at pitch circle (N) [Ft] 50757.5

Axial force (N) [Fa] 18052.0
Radial force (N) [Fr] 19607.8
Normal force (N) [Fnorm] 57329.4
Tangent.load at p.c.d.per mm (N/mm) (N/mm) [w] 1153.58
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N) [Ftw] 50757.6
Axial force (N) [Faw] 18052.0
Radial force (N) [Frw] 19607.6
Circumferential speed reference circle (m/s) [v] 24.76
Circumferential speed operating pitch circle (m/s)
[v(dw)] 24.76

Running-in value (m) [yp] 0.4

Running-in value (m) [yf] 0.4
Correction coefficient [CM] 0.800
Gear body coefficient [CR] 1.000
Reference profile coefficient [CBS] 0.975
Material coefficient [E/Est] 1.000
Singular tooth stiffness (N/mm/m) [c'] 12.744
Meshing stiffness (N/mm/m) [cgalf] 17.951
Meshing stiffness (N/mm/m) [cgbet] 15.259
Reduced mass (kg/mm) [mRed] 0.04377
Resonance speed (min-1) [nE1] 5860

User specified factor KV:

Dynamic factor [KV] 1.050

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User specified factor KHb:
Face load factor - flank [KHb] 1.100
- Tooth root [KFb] 1.077
- Scuffing [KBb] 1.100
User specified factor KHa:
Transverse load factor - flank [KHa] 1.000
- Tooth root [KFa] 1.000
- Scuffing [KBa] 1.000

Helical load factor scuffing [Kbg] 1.238

Number of load cycles (in mio.) [NL] 3600.000 3494.118

9. DETERMINATION OF TOOTHFORM

Profile and tooth trace modifications for gear 1

Symmetric (both flanks)
- Tip relief, linear with transition radius Caa = 50.000m LCa = 0.960*mn dCa = 162.767mm

Profile and tooth trace modifications for gear 2

Symmetric (both flanks)
- Tip relief, linear Caa = 50.000m LCa = 0.960*mn dCa = 167.565mm

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Example 4

KISSsoft Release 03/2014 E

KISSsoft-Entwicklungs-Version KISSsoft AG CH-8608 BUBIKON
File
Name : 15144-2_Expl4(No Opt Ca) Updated as Part2-2012
Changed by: ukissling on: 11.11.2014 at: 10:41:58

CALCULATION OF A HELICAL GEAR PAIR

Drawing or article number:

Gear 1: 0.000.0
Gear 2: 0.000.0

Calculation method ISO 6336:2006 Method B

------- GEAR 1 -------- GEAR 2 --

Power (kW) [P] 934.953

Speed (1/min) [n] 530.9 166.4
Torque (Nm) [T] 16817.0 53654.2
Application factor [KA] 1.22
Required service life [H] 20000.00
Gear driving (+) / driven (-) - +

1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to

DIN 3960:1987)
------- GEAR 1 -------- GEAR 2

Center distance (mm) [a] 369.000

Centre distance allowances (mm) [Aa.e/i] 0.050 / 0.050
Normal module (mm) [mn] 8.0000
Pressure angle at normal section () [alfn] 20.0000
Helix angle at reference circle () [beta] 14.5000
Number of teeth [z] 21 67
Facewidth (mm) [b] 185.00 185.00
Hand of gear right left
Accuracy grade [Q-ISO 1328:1995] 5 5
Inner diameter (mm) [di] 0.00 0.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

Material
Gear 1: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28
Gear 2: (Own input) 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Bild 9/10 (MQ), Kernfestigkeit >=25HRC Jominy J=12mm<HRC28

------- GEAR 1 -------- GEAR 2

Surface hardness HRC 61 HRC 61

Material quality according to ISO 6336:2006 Normal (Life factors ZNT and YNT >=0.85)

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Fatigue strength. tooth root stress (N/mm) [sigFlim] 430.00 430.00
Fatigue strength for Hertzian pressure (N/mm) [sigHlim] 1500.00 1500.00
Tensile strength (N/mm) [Rm] 1200.00 1200.00
Yield point (N/mm) [Rp] 850.00 850.00
Young's modulus (N/mm) [E] 210000 210000
Poisson's ratio [ny] 0.300 0.300
Mean roughness, Ra, tooth flank (m) [RAH] 0.67 0.67
Mean roughness height, Rz, flank (m) [RZH] 5.31 5.31
Mean roughness height, Rz, root (m) [RZF] 20.00 20.00

Gear reference profile 1:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 1.022
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Gear reference profile 2:

Reference profile (Own input)
Dedendum coefficient [hfP*] 1.250
Root radius factor [rhofP*] 0.380
Addendum coefficient [haP*] 1.025
Tip radius factor [rhoaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping

Summary of reference profile gears:

Dedendum reference profile [hfP*] 1.250 1.250
Tooth root radius Reference profile [rofP*] 0.380 0.380
Addendum Reference profile [haP*] 1.022 1.025
Protuberance height factor [hprP*] 0.000 0.000
Protuberance angle () [alfprP] 0.000 0.000
Tip form height coefficient [hFaP*] 0.000 0.000
Ramp angle () [alfKP] 0.000 0.000

Type of profile modification:

for high load capacity gearboxe
Tip relief (m) [Ca] 25.0 40.0

Lubrication type oil injection lubrication

Type of oil (Own input) Oil:
Lubricant base Mineral-oil base
Kinem. viscosity oil at 40 C (mm/s) [nu40] 320.00
Kinem. viscosity oil at 100 C (mm/s) [nu100] 24.50
FZG test A/8.3/90 ( ISO 14635-1:2006) [FZGtestA] 12
Specific density at 15 C (kg/dm) [roOil] 0.899
Oil temperature (C) [TS] 70.000

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 ------- GEAR 1 -------- GEAR 2

Overall transmission ratio [itot] -0.313

Gear ratio [u] 3.190
Transverse module (mm) [mt] 8.263
Pressure angle at pitch circle () [alft] 20.604
Working transverse pressure angle () [alfwt] 22.737
[alfwt.e/i] 22.755 / 22.755
Working pressure angle at normal section () [alfwn] 22.064
Helix angle at operating pitch circle () [betaw] 14.707
Base helix angle () [betab] 13.608
Reference centre distance (mm) [ad] 363.581
Sum of profile shift coefficients [Summexi] 0.7115
Profile shift coefficient [x] 0.3200 0.3915
Tooth thickness (Arc) (module) (module) [sn*] 1.8037 1.8557

Tip alteration (mm) [k*mn] 0.000 0.000

Reference diameter (mm) [d] 173.527 553.635
Base diameter (mm) [db] 162.428 518.223
Tip diameter (mm) [da] 195.000 576.300
(mm) [da.e/i] 195.000 / 195.000 576.300 / 576.300
Tip diameter allowances (mm) [Ada.e/i] 0.000 / 0.000 0.000 / 0.000
Tip form diameter (mm) [dFa] 195.000 576.300
(mm) [dFa.e/i] 195.000 / 195.000 576.300 / 576.300
Active tip diameter (mm) [dNa] 195.000 576.300
Active tip diameter (mm) [dNa.e/i] 195.000 / 195.000 576.300 / 576.300
Operating pitch diameter (mm) [dw] 176.114 561.886
(mm) [dw.e/i] 176.138 / 176.138 561.963 / 561.963
Root diameter (mm) [df] 158.647 539.898
Generating Profile shift coefficient [xE.e/i] 0.3200/ 0.3200 0.3915/ 0.3915
Manufactured root diameter with xE (mm) [df.e/i] 158.647 / 158.647 539.898 / 539.898
Theoretical tip clearance (mm) [c] 1.551 1.526
Effective tip clearance (mm) [c.e/i] 1.601 / 1.601 1.576 / 1.576
Active root diameter (mm) [dNf] 165.768 547.725
(mm) [dNf.e/i] 165.820 / 165.820 547.809 / 547.809
Root form diameter (mm) [dFf] 165.202 544.515
(mm) [dFf.e/i] 165.202 / 165.202 544.515 / 544.515
Reserve (dNf-dFf)/2 (mm) [cF.max/min] 0.309 / 0.309 1.647 / 1.647
Addendum (mm) [ha=mn*(haP*+x)] 10.736 11.333
(mm) [ha.e/i] 10.736 / 10.736 11.333 / 11.333
Dedendum (mm) [hf=mn*(hfP*-x)] 7.440 6.868
(mm) [hf.e/i] 7.440 / 7.440 6.868 / 6.868
Roll angle at dFa () [xsi_dFa.e/i] 38.061 / 38.061 27.875 / 27.875
Roll angle to dNa () [xsi_dNa.e/i] 38.061 / 38.061 27.875 / 27.875
Roll angle to dNf () [xsi_dNf.e/i] 11.770 / 11.770 19.635 / 19.635
Roll angle at dFf () [xsi_dFf.e/i] 10.634 / 10.634 18.481 / 18.481
Tooth height (mm) [H] 18.176 18.201
Virtual gear no. of teeth [zn] 22.962 73.260
Normal tooth thickness at tip cylinder (mm) [san] 4.551 5.749
(mm) [san.e/i] 4.551 / 4.551 5.749 / 5.749
Normal spacewidth at root cylinder (mm) [efn] 0.000 5.634
(mm) [efn.e/i] 0.000 / 0.000 5.634 / 5.634
Max. sliding velocity at tip (m/s) [vga] 1.454 1.276
Specific sliding at the tip [zetaa] 0.485 0.581
Specific sliding at the root [zetaf] -1.387 -0.941
Mean specific sliding [zetam] 0.530
Sliding factor on tip [Kga] 0.297 0.261

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Sliding factor on root [Kgf] -0.261 -0.297
Pitch on reference circle (mm) [pt] 25.960
Base pitch (mm) [pbt] 24.299
Transverse pitch on contact-path (mm) [pet] 24.299
Lead height (mm) [pz] 2107.946 6725.352
Axial pitch (mm) [px] 100.378
Length of path of contact (mm) [ga, e/i] 37.395 ( 37.265 / 37.265)
Length T1-A, T2-A (mm) [T1A, T2A] 53.949( 53.949/ 53.949) 88.667( 88.797/ 88.797)
Length T1-B (mm) [T1B, T2B] 40.854( 40.983/ 40.983) 101.763( 101.763/ 101.763)
Length T1-C (mm) [T1C, T2C] 34.034( 34.064/ 34.064) 108.583( 108.682/ 108.682)
Length T1-D (mm) [T1D, T2D] 29.650( 29.650/ 29.650) 112.967( 113.096/ 113.096)
Length T1-E (mm) [T1E, T2E] 16.555( 16.684/ 16.684) 126.062( 126.062/ 126.062)
Length T1-T2 (mm) [T1T2] 142.617 ( 142.746 / 142.746)
Diameter of single contact point B (mm) [d-B] 181.821( 172.914/ 172.914) 556.757( 565.436/ 565.436)
Diameter of single contact point D (mm) [d-D] 172.914( 181.938/ 181.938) 565.333( 556.757/ 556.757)
Addendum contact ratio [eps] 0.820( 0.818/ 0.818) 0.719( 0.715/ 0.715)
Minimal length of contact line (mm) [Lmin] 285.450

Transverse contact ratio [eps_a] 1.539

Transverse contact ratio with allowances [eps_a.e/m/i] 1.534 / 1.534 / 1.534
Overlap ratio [eps_b] 1.843
Total contact ratio [eps_g] 3.382
Total contact ratio with allowances [eps_g.e/m/i] 3.377 / 3.377 / 3.377

2. FACTORS OF GENERAL INFLUENCE

------- GEAR 1 -------- GEAR 2

Nominal circum. force at pitch circle (N) [Ft] 193825.5

Axial force (N) [Fa] 50126.7
Radial force (N) [Fr] 72867.7
Normal force (N) [Fnorm] 213050.9
Tangent.load at p.c.d.per mm (N/mm) (N/mm) [w] 1047.71
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N) [Ftw] 190979.0
Axial force (N) [Faw] 50126.7
Radial force (N) [Frw] 80031.6
Circumferential speed reference circle (m/s) [v] 4.82
Circumferential speed operating pitch circle (m/s)
[v(dw)] 4.90

Running-in value (m) [yp] 0.6

Running-in value (m) [yf] 0.8
Correction coefficient [CM] 0.800
Gear body coefficient [CR] 1.000
Reference profile coefficient [CBS] 0.975
Material coefficient [E/Est] 1.019
Singular tooth stiffness (N/mm/m) [c'] 14.624
Meshing stiffness (N/mm/m) [cgalf] 20.535
Meshing stiffness (N/mm/m) [cgbet] 17.455
Reduced mass (kg/mm) [mRed] 0.10294
Resonance speed (min-1) [nE1] 6423

User specified factor KV:

Dynamic factor [KV] 1.015

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User specified factor KHb:
Face load factor - flank [KHb] 1.250
- Tooth root [KFb] 1.223
- Scuffing [KBb] 1.250

User specified factor KHa:

Transverse load factor - flank [KHa] 1.000
- Tooth root [KFa] 1.000
- Scuffing [KBa] 1.000

Helical load factor scuffing [Kbg] 1.299

Number of load cycles (in mio.) [NL] 637.080 199.682

4b. MICROPITTING ACCORDING TO ISO TR 15144-1:2010

Calculation of permissible specific film thickness

Lubricant load according to FVA Info sheet 54/7 9 (Oil:)
Reference data FZG-C Test:
Torque (Nm) [T1Ref] 215.6
Line load at contact point A (N/mm) [FbbRef,A] 192.7
Oil temperature (C) [theOilRef] 90.0
Tooth mass temperature (C) [theMRef] 121.2
Contact temperature (C) [theBRef,A] 221.9
Lubrication gap thickness (m) [hRef,A] 0.077
Specific film thickness in test (m) [lamGFT] 0.153
Material coefficient [WW] 1.00
Permissible specific film thickness (m) [lamGFP] 0.215

Intermediate results according to ISO TR 15144:2010

Coefficient of friction [mym] 0.060
Lubricant factor [XL] 1.000
Roughness factor [XR] 0.876
Tooth mass temperature (C) [theM] 77.9
Tip relief factor [XCa (A)] 1.308
Loss factor [HV] 0.131
Equivalent Young's modulus (N/mm) [Er] 230769
Compressed viscosity index (m2/N) [alf38] 0.02320
Dynamic viscosity (Ns/m2) [etatM] 43.9
Roughness average value (m) [Ra] 0.7
Calculation of speeds, load distribution and flank curvature according to ISO15144 method A with contact analysis
Minimal specific film thickness (m) [lamGFY] 0.261 (hY=0.175 m)
Safety against micropitting [Slam] 1.282

9. DETERMINATION OF TOOTHFORM

Profile and tooth trace modifications for gear 1

Symmetric (both flanks)
- Tip relief, linear with transition radius Caa = 25.000m LCa = 0.818*mn dCa = 188.096mm

Profile and tooth trace modifications for gear 2

Symmetric (both flanks)
- Tip relief, linear Caa = 40.000m LCa = 0.818*mn dCa = 570.726mm
- End relief I CbI = 50.000m LCI = 0.189*b
- End relief II CbII = 50.000m LCII = 0.189*b

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