AGMA 2101-C 95 MM 0687575 0003912 298 mm ERRATA January 1996 ANSUAGMA 2101-C95, Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth The following editorial correction has been made to ANS/AGMA 2101-C95 Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. This change, discovered after publication, has not been made in the printing of this document. The change is shown below. Users of ANSVAGMA 2101-C95 are encouraged to cut out this sticker and insert it in the Standard. ‘The equation can be placed over the existing equations. Page 10: 2 Pa = — 22 2 (325%) TOY x 10'KoKK. Kala \ ZeSy Vole (8) Copyright by the American Gear Manufacturers Asovaton Wed May 18 0949.24 2011Ba 0b87575 0003750 237 ANSI/AGMA 2101-C95 Metric Edition of ANS/AGMA 2001-C95, AMERICAN NATIONAL STANDARD Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth ve" AGMA STANDARDMH 0b87575 0003752 176 mm Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth ANSVAGMA 2101-C95, Metric Edition of ANSVAGMA 2001-C95 e@ (Revision of ANSVAGMA 2101-88 ) Approval of an American National Standard requires verification by ANSI that the requirements for due process, consensus, and other criteria for approval have been met by the standards developer. Consensus is established when, in the judgment of the ANS! Board of Standards Review, substantial agreement has been reached by directly and materially affected interests. Substantial agreement means much more than a simple majority, but not necessarily unanimity. Consensus requires that all views and ‘objections be considered, and that a concerted effort be made toward their resolution. ‘The use of American National Standards is completely voluntary; their existence does not in any respect, preclude anyone, whether he has approved the standards or not, from manufacturing, marketing, purchasing, or using products, processes, ar procedures not conforming ta the standards, ‘The American National Standards Institute does not develop standards and will in no circumstances give an interpretation of any American National Standard. Moreover, no person shall have the right or authority to issue an interpretation of an American National Standard in the name of the American National Standards Institute, Requeete for interpretation of this standard should be addressed to the American Gear Manufacturere Assooiation, CAUTION NOTICE: AGMA standards are subject to constant improvement, revision or withdrawal as dictated by experience. Any person who refers to an AGMA Technical Publication should be sure that the publication is the latest available from the Association on the subject metter. [Tables or other self-supporting sections may be quoted or extracted in their entirety. Credit ine should read: Extracted from ANSVAGMA Standard 2101-085, Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth with the permission of the publisher, American Gear Manufacturers. Association, 1500 King Street, Suite 201, Alexandra, Virginia 22314.) Approved January 12, 1995 American National Standards Institute, Inc. Abstract This standard specifies a method for rating the pitting resistance and bending strength of epur and helical involute gear pairs. A detailed discussion of factors influencing gear survival and calculation methods are provided. Copyright ©, October 1994 by American Gear Manufacturers Association Publiched by American Gear Manufacturers Association 1500 King Street, Suite 201, Alexandria, Virginia 22914 ISBN: 1-55580-648-0 pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011WM 0L87575 O003752 O02 mo Contents @ reeves Scope Rating formulas 1 2 Exceptions 3 References . Definitions and symbols 2.1 Definitions .. 22 Symbols. 3° Application .. 3.1. Rating practices .. 9.2 Implied accuracy Nees ow 3.3 Testing . 3.4 Manufacturing quality 35 Lubrication ......... 36 Temperature extremes - 37 Osalllatory mation 3.8 Non-uniform loading 3.9 Other considerations 4 Griteria for tooth capacity 4.1 Relationship of piting resistance and bending strength sins. 42 Pitting resistance .... 4.9 Surface conditions not covered by tis i ‘standard | 44° Bending strength 5 Fundamental rating formulas .. 5.1 Piifing resistance 5.2 Bending strength . 6 Geometry factors. Z) and Y; - 6.1 Pitting resistance geometry factor, Z; 62 Bending strength geometry factor, ¥; . 6.3 Caloulation method .... 7 Transmitted tangential oad, F. A 2 7.2 Non-uniform load 2 8 Dynamic factor, K, : R €.1. Dynamic factor considerations 2 82 Resonance ...... 13 £3 Approximate dynamic factor, ag 8 8.4 Other valuos ... 6 85 Unity dynamic factor... 218 © Overload factor, Ko . 10 Service factor ..... 11 Safety factors, Si and Sp 12 Elastic coefficient, Zp . 18. Surface condition factor, Ze Copyright by the American Gear Manufacturers Asovaton Wed May 18 0949.24 2011MH 0687575 0003753 749 mm Contents (continued) 14 Hardness ratio factor, Ziv. 14.1, Through hardened gears... 14.2 Surface hardenedithrough harden 18 Load distribution factor, Kip ..-.-2.e0-+ 15.1 Values for load distribution factor, Ky 15.2 Transverse load distribution factor, Kiva 15.3. Face load distribution factor. Kuz 16 Allowable stress numbers, cup and orp 10.1. Guide for case depth of surface hardened! gears 162 Reverse loading .. 46.3 Momentary overload 16.4. Yield strength 17 Stress oyole factor, Zy and Yy 171 Load cycles . . . 17.2 Stress cycle tactors for steel sears. 17.3. Localized yielding 18 Reliabity factor, ¥z 19 Temperature factor, Yo. o . 18.1. Moderate and low temperature operon . 19.2 High temperature operation : 20 Size factor, K, . : 201° Sizo factor... sees 20.2 Values for size factor... Tables ‘Symbole used in gear rating equations . Empirical constants; 4, 8, and C . Allowable contact stress number, oy, for steel gears Allowable bending stress number, orp, for steel gears Allowable contact stress number, dup or Iron and bronze gears Allowable bending stress number, orp, for iron and bronze gears Major metallurgical factors affecting the allowable contact stress number, op, and allowable bending stress number, opp, of through hardened steel gears ..........s6eeseeees+ . Major metallurgical factors affecting the allowable contact etrees number, op, and allowable | bending stress number, ofp, of flame or induction hardened steel gears 28 9 Major metallurgical factors affecting the allowable contact stress number, op, and allowable bending stress number, orp, of carburized and hardened steel gears 10 Major metallurgical taotors affecting the allowable contact stress number, jp, and allowable bending stress number, ofp, of nitrided steel gears . vente 3 14 Roliabilty factors, ¥z .......esesese Figures Dynamic factor. K, ... Hardness mtio factor, 7 (through hardened) Hardness ratio factor, Zy (surface hardened pinions) .. : Instantaneous contact lines in the plane of action : Pinion proportion factor, Kipy ......-. Evaluation of S and ;....... values Noasone ° ennune Copyright by the American Gear Manufacturers Asovaton Wed May 18 0949.24 2011MH 0687575 0003754 985 mm Contents (concluded) e 7 Mesh alignment factor, Kring «-++sss0sesestvevseeeeseees coceeeeecevees BB 8 Allowable contact stress number for through hardened steel gears, ove : vee 24 9 Allowable bending stress number for through hardened steel gears, orp +25 10 Allowable bending stress numbers for nied through hardened steel gears (Le.. AISI 4140, AISI 4340), orp 26 41 Allowable bending strees numbers for nitriding steel gears, orp 27 12 Minimum effective case depth for carburized gears, he min +. 32 18. Core hardness coefficient, ue «++ . 33 14 Minimum total case depth for nitrded geare, nin 34 48 Variations in hardening pettem obtainable on gear teeth with flame or induction hardening ...... 34 18 Allowable yield strength number for steel gears, op ....esse0++ 36 417 _ Pitting resistance stress cycle factor, Ziv... 37 18 Bending strength stress cycle factor, Yw 87 Annexes A Method for evaluating the rick of seating and wear B Rim thickness factor, Kp. ceeesetensenenes © Application analysis seeeeeeees D Discussion ofthe analytical face or longitudinal loed distibution factor E Gear material fatigue Ife .......eessesseees F —Controling section size considerations for through hardened gearing. G Bibllography .......... siseeesesee : soe Wed May 18-0949:24 2011 pyright by the American Gear Manufacturers AssocationMH 0L87575 OO037S5 6b) a Foreword The foreword, footnotes, and appendices in this document are provided for informational purposee only and late not to be construed to bo a part of AGMA Standard 2101-695, Fundamental Rating Factors and Caloulation Methods for Involute Spur and Helical Gear Teeth] ‘This standard presents general formulas for rating the pitting resistance and bending strength of spur and helical involute gear teeth using I80 symbology and SI units, and supersedes AGMA 2001-B88, ‘The purpose of this standard is to establish a common base for rating various lypes of gears for differing applications, and to encourage the maximum practical degree of uniformity and consistency between rating practices within the gearindustry. Itprovides the basis from which more dotalled AGMA application standards ‘are developed, and provides a basis for calculation of approximate ratings in the absence of such standards. ‘The formulas presented in this standard contain factors whase values vary significantly depending on application, system effects, gear accuracy, manufacturing practice, and definition of goar failure. Proper evaluation of these factors is essential for realistic ratings. This standard is intended for use by tho ‘experienced gear designer capable of electing reasonable values for rating factore and aware of the performance of similar designs through test results or operating experience. In AGMA 218.01 the values for Life Factor, Zy and Yy, Dynamic Factor, K,, and Load Distribution Factor, Ky, were revised. Values for factors assigned in standards prior to thet were not applicable to218.01 nor were the values assigned in 218.01 applicable to previous standards. ‘The detailed information on the Geometty Factors, Zand Yy, were removed from ANSVAGMA 2001-B88, the revision of AGMA 218.01. This material was amplified and moved to AGMA 908-B89, Geometry Factors for Determining the Piting Resistance and Bending Strength for Spur, Helical and Herringbone Gear Teeth. The values of 2 and 2 have not been changed from previous Standards. In ANSV/AGMA 2001-888 the Allowable Stress Number section was expanded. Metallurgical quality factors tor steel materials were defined, establishing minimum quality control requiremente and allowable stress numbers for various steel quality grades. Additional higher allowable stress numbers for carburized gears ‘were added when made with high quality stool. A new rim thickness factor, Ky, was introduced to reduce ‘allowable bending loads on gears with thin rims. Material on scuffing (scoring) resistance was added as an ‘annex. ANSVAGMA 2001-888 was first drafted in January, 1986, approved by the AGMA Membership in May 1988, and approved as an American National Standard on Seplember 30, 1988. This standard, ANSVAGMA 2101-C95, Is a revision of the rating method described in its superseded publications. The changes include: the Miner's nule annex was removed; the analytical method for load distribution factors, Ki, was revised and placed in an annex; rittided allowable stress. numbers were expanded to cover three grades; ntrided stress cycle factors were introduced; through hardened allowable ‘stresses were revised; application factor was replaced by overload factor; safety factors Sy and Sp were introduced; and, life factor was replaced by stress cycle factor and ite use with service feotor redefined. Caution: Tho dynamic factor has been redefined as the reciprocal of that used in previous AGMA standard and ia relocated to the denominator ofthe power equation. This AGMA Standard and related publications are based on typical or average data, conditions, or applications. The Association intends to continue working to update this Standard andito incorporate in future revisions the latest acceptable technology from domestic and international sources. The first draft of this revision was made in February, 1992. Thio version was approved by the AGMA ‘Membership in July, 1994. It was approved as an Amerioan National Standard on January 12, 1995. ‘Suggestions for the improvement ofthis Standard willbe welcome. They shouldbe sent tothe American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, Virginia 22314. Copyright by the American Gear Manufacturers Asovaton Wed May 18 0949.24 2011MB 0L87575 0003756 758 mm e@ PERSONNEL of the AGMA Gear Rating Committee Chairman: D. McCarthy ce eeeeseseeesteeseseeees Doftis Company Vice Chairman: N. Hulse General Electric ACTIVE MEMBERS K.E. Acheson .... The Gear Works — Seattle Li Lloyd ........ Lufkin Industries J!Amondola ..|) MAAG Gear Company, Lid. DIR. MeVittio ... Gear Engineers, ino. M. Antosiowicz ... The Falk Corporation A. Milburn Milburn Engineering J. Bentley Peerless-Winsmith, Inc. ©. Moyer 2.2.2: The Timken Company WA. Bradley... Consultant FA. Nay Pratt & Whitney MF. Datton ..... General Electric Company MW. Neesley ... WesTech Gear G.DeLange .... Emerson Power Transmission W.P. Pizzichil ... Philadelphia Gear JA. DeMarais’. Bison Gear JAW. Polder...) Academic Member RL. Errichello |. GEARTECH G. Smith ....... Emerson Power Transmission G.Georgalas .:. Dorr—Oliver AA. Swiglo ....! Brad Foote Goar Works H.Hagan........ Cincinnati Gear Company Je Tellman ...... Dodge ©. LaBath Cincinnati Gear Gompany F Uherek ...... Flender Corporation I Laskin Consultant CG. Wang '3E SMW & Engrg Consulting G.Llan......... Amaritlo Gear Company RLF Wasilewski . Arrow Gear Company ASSOCIATE MEMBERS EJ. Baker Gears industrial Design & Engr. DR. Houser .... Academic Member M. Bartolomeo .. New Venture Gear, Inc. V.lvers ........ Xtek, Ine. AC. Becker .... Nuttall Gear Corporation ‘A Jackson Mobil Research & Development D. Behike “Twin Diss, Inc. H, Johnson Lufkin industries, inc, E. Berndt ....... Besco RZ. Johnston... University of Maine J.D. Black Gonoral Motors Corporation JS. Korossy .... Horsburgh & Scott Company EJ. Bodensisck . Bodensiock Enginooring M. Lawrenz ..... Metal Improvement S. Bond ........ Emerson Power Trans. Corp. J. Lisiecki ...... The Falk Corporation DLL, Borden .... Gear Research Institute D. Mairet Falk Corporation E.R. Braun ..... Eaton Corporation TJ. Meiuri ...... Gleason Works G. Buzluk ...... Brad Foote Gear Works, Inc. H, Molarski Drad Foote Gear Works, Inc. RA. Calvert .... Prager, Inc. W. Nagel MAAG Gear Company, Ltd ‘A. Garou Universite Laval B.C. Newoomb .. Chicago Gear-D.0. James AS. Cohen Engranes y Mequinaria Are ©. Nguyen Philadelphia Gear Corporation ALL. Cragg Consultant AE Philips... Dodge B. Detrick Funk Manufactuting KL-Polen ...... Alliance Machine Company PR. Dickson Bay City Iron Works, Inc. E Sandber Dot Norske Vertes mpany RDiRusso Kaman Aerospace Corporation Sandberg --.- Det Norske Veritas Ru. Drago Boeing Defense RS Seine ty of Wiseoney D.W. Dudley Honorary Member ereg Iniversity of Wisconsin F. Eberle Techumsch Products Corp, DH. Senitor.... Precision Gear Company JS Eckersley .. Metal impovement Company ER. Sewall..... Sewall Gear , JIM. Escanaverino Instituto Superior Y. Sharma ...... Philadelphia Gear Corporation UFaure. CMD. EE. Shipley... Mechanical Technology, Ina C.Gay ........, CE. Gay & Company, Lid. J. Simonelli... Emerson Power Transmission RA Geary... LCI, Ine. La. Smith ...... Invincible Gear 4. Gimper United Engineoring, Ine. L Spiers ....... Emerson Power Transmission F.Giufra |...) American Bureau of Shipping --DA. Sylvester... Flender Corporation LL. Haas General Motors Corporation K. Taliaferro .... Dodge JIM, Hawkins... General Motors Corporation FA. Thoma ..... RA. Thoma, Inc C. Helberg ..... Lucas Western, Inc. D. Townsend... NASA LeRC G.Hentiot ...-.. ingenieur Conseil T. Tumbull....... Mobile Pulley & Mach, Works M. Hirt ...0000.. RenkTacke GmbH W. Wagner ..... Sewall Gear R.G. Hotchkiss .. Gleason Works H. Winter Technische Univ. Muenchen vil Copyright by the American Cea Wed May 18 0949.24 2011 nufacturers AssociationMH 0687575 000375? 654 mm Thie page is intentionelly blank. pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011WH 0687575 0003758 S20 mm ‘AMERIGAN NATIONAL STANDARD American National Standard — Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth 1 Scope 4.4 Rating formulas This standard provides a method by which different gear designs can be theoretically rated and compared. It is not Intended to assure the performance of assembled gear drive systems. ‘These fundamental rating formulas are applicable for rating the pitting resistance and bending strength of internal and external spur and helical in- volute gear teeth operating on parallel axes. The formulas evaluate gear tooth capacity as influenced by the major factors which affect geer tooth pitting ‘and geer tooth fracture at the fillet radius, The knowledge and judgment required to evaluate the various rating factors come from years of accu mulated experience in designing, manufacturing, and operating gear unlts. Empirical factors given in this standard are general in nature. AGMA applica- tion standards may use other empirical factors that ‘are more closely suited to the particular field of ap- plication. This standard is intended for use by the ‘experienced gear designer, capable of selecting reasonable values for the factors, It is not intended for use by the engineering public at large. 1.2 Exceptions ‘The formulas of this standard are not applicable to other types of gear tooth deterioration suchas plas- ticyleiding, wear, case crushing and welding. They are also not applicable when vibratory conditions exceed the limits specified for the normal operation Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011 ‘ANSVAGMA 2101-C95 of the gears (see ANSVAGMA 6000-A88, Specil cation for Measurement of Lateral Vibration on Gear Units) The formulas of this standard are nol applicable ‘when any of the following conditions exist: — Damaged gear teeth ~ Spur gears with transverse contact ratio, ea, lees than 1.0. = Spur orhelical gears with transverse contact ratio, «4, greater than 2.0. ~~ _ Interference exists between tips of teeth and. toot filets. = Teeth are pointed. = Backlash is zero. = Undorcut exists in an area above the theo- retical start of active profile. The effect of thie un- dercut isto move the highest point of single tooth ‘contact, negating the assumption ofthis calcula tion method. However, the reduction in tooth root thickness due to protuberance below the active profile Is handled correctly by this method. = The root profiles are stepped or inegular. The ¥; factor calculation uses the stress correc tion factors developed by Dolan and Broghamer [19]. These factors may not be valid for root forms which are not smooth curves. For toot pro- files which are stepped or imegular, other stress correction factors may be more appropriate. = Where root filets of the gear teeth are pro- duced by a process other than generating. - The hellx angle at the standard (reference) diameter’ is greater than 50 degrees ‘Souffing criteria are not Included In the body of the standard, but a method to evaluate scuffing risk Is included as annex A. This information is provided for evaluation by users of this standard, with the intent to include a scuffing evaluation method in a future version ofthis standard. Design considerations to prevent fractures emanat- ing from stress risers on the tooth profilo, tip [7 Wurrbers ip brackets reter to the reterence number listed in annex G, bibliography. Refer to ANSVAGMA 1012-F90 for futher discussion of standard (reference) diameters,Copyright by the American Cea Wed May 18 0949.24 2011 WH 0687575 0003759 4b? mm ANSVAGMA 2101-C05, chipping, and failures of the gear blank through the ‘web or hub should be analyzed by general machine design methods. 4.3 References The following standards contain provisions which, through reference in this text, constitute provisions of this American National Standard. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this American National Stan- dard are encouraged to investigate the possibilty of applying the most recent editions of the standards, indicated: AGMA 246.02A, Recommended Procedure for Carburized Aerospace Gearing. AGMA 427.01, Information Sheet - Systems Considerations for Critical Service Gear Drives. ‘AGMA 908-889, Information Sheet ~ Geometry Factors for Determining the Pitting Resistance and Bending Strength for Spur, Helical and Herring- bone Gear Teeth. AMS 2300G, Cleanliness, Premium Aircraft Quality, Magnetic Particle Inspection Procedure. AMS 2301, Cleaniiness, Aircraft-Quality Stee! ‘Magnetic Particle Inspection Procedure. ANSVAGMA 1012-F90, Gear Nomenclature, Def- initions of Terms with Symbols. ANSVAGMA 2000-ABB, Gear Classtication and Inspection Handbook - Tolerances and Measuring ‘Methods for Unassembled Spur and Helical Gears (Including Metric Equivatents). ANSVAGMA 2004-B89, Gear Materials and Heat Treatment Manual. ANSVAGMA 2007-B92, Surface Temper Etch Inspection After Grinding. ANSVAGMA 6000-A88, Specification for Meas- urement of Lateral Vibration on Gear Units. ANSVAGMA 6033-A88, Standard for Marine Pro- pulsion Gear Units, Part 1, Materials. nufacturers Association AMERICAN NATIONAL STANDARD ANSVAGMA 9005-D94, Industrial Gear Lubrica- tion, ASTM AdB-03a, Specification for Gray Iron Cast- ings. ASTM A388-91, Practice for Ultrasonic Examina- tion of Heavy Steel Forgings. ASTM A534-80, Specification for Carburizing ‘Steels for anti-friction Bearings. ASTM AS95-85 (1992), Specification for Special Quatity Ball and Roller Bearing Steel. ASTM A836-84 (1903), Specification for Duotile ron Castings. ASTM A609-91, Practice for Castings, Carbon, Low Alloy and Martensitic Stainless Steel, Ultra- sonie Examination Thereof. ASTM A866-92, Specification for Medium Carbon Anti-triction Bearing Stool. ASTM 8148-93, Specification for Aluminum Bronze Castings. ASTME112-88, Test Methods for Determining the Average Grain Size. ASTM 426-92, Practice for Fabrication and Control of Stee! Reference Blocks used in Utra~ sonie Inspection ASTM E709-91, Practice for Magnetic Particle Examination. 2 Definitions and symbols 24 Definitions The terms used, wherever applicable, conform to ANGVAGMA 1012-F90 and reference [2] 22 Symbols ‘The symbols used in the pitting resistance and bending strength formulas are shown In table 1 NOTE: The symbole and defintone usedin this stan- dard may ctferfrom other AGMA standards. The user ‘should not assume that familiar symbols can be used without a careful study of these definitions,ME 0687575 0003760 189 mm AMERICAN NATIONAL STANDARD ANSVAQMA2101-C88, Table 1 ~ Symbols used in gear rating equations @ First] Ret. Symbol Deseription Units Used | Clause a [Opera wonior detance mm ——}Eqz [Bat b Net face width of narrowest member mm Eqt 5.11 Ce Gear ratio factor - Eq6 514 Csr | Service factor for piting resistance _ Eq20 | 10 dy: | Operating pitch diameter of pinion mm Eqt | 544 £, | Modulue of elactioy for pinion wm? — Jeqao | 12 Ey Modulus of elasticity for gear Némm? Eq 30 12 Fa | Incremental dynamic tooth load N Eq20 | et Feax | Maximum peak tangential load N Eq4s | 16 Fe Transmitted tangential load N Eq 18 7A Ho, | Brine hardness of pinion He feqsz | 141 io | Brine hardness of gear we feqaz | tas Hemin Minimum total case depth for external nitrided gear mm Eq 44 16.4 te emsx | Maximum effective case depth mm Eq43 16.2 ‘eain [Minimum etfectve case dopth tor external| mm feqa2_| 161 carburized and induction hardened gear teeth fy | Gear tooth whe depth mn feqi?_| 628 K | Contact load factor for pitting resistance Nm |eqe | 5.1.4 Kaz | Allowable contact load factor Nimm? Eq9 5.1.4 Kp Rim thickness factor - Fq 10, 525 Kj | Stress correction factor _ Eq4s | 16.4 Ky | Load distribution factor = feqt | ast Kite |Mesh alignment correction factor = Eqa7 | 153 Ktima | Mesh alignment factor - Eq 37 153 Kime | Lead correction factor - Eq 37 15.3 Kir | Pinion proportion factor — eqa7 | 153, Kim _ | Pinion propotion modifier — — jeas7 | 153 Kus ‘Load distribution factor under overload conditions - Eq45 16.4 Kino | Transverse load dsttbuton factor — — feqss | 152 up| Face load cistrbution factor eqas | 150 Ky | Overload factor _ Eqt 9 K, | Size factor = Eq1 | 20 Kor Service factor for bending strength - Eq 29 10. K, | Dynamic factor ~ Fq1 | 524 K, | Vie etrongth factor = — evs | tes L fuite hows eaar | a7 ma | Back-up ratio — — feqiz |sas mh | Transverse metric module mm Eq 10 5.2.1 Why, Normal metric module, nominal mm Eqtt 5.24 Me Number of load cycles - Fig 17 17 Pp [Transmitted power kW Eq 18 7A (continued) 8 Wed May 18-0949:24 2011 pyright by the American Gear Manufacturers AssocationAGMA 2101-C 94 MM 0687575 000376) O15 Mm ANSVAGMA 2101-CO5- AMERICAN NATIONAL STANDARD ‘Table 1 (continued) Fist] —_Ret @ Symbol Description Units Used | Clause Pa ‘Allowable transmitied power for gear set kW Eq 25 10 Pay | Allowable transmitted power for bending strength kw Eqi4 | 523 Payu | Allowable tranemitted power for bending strength kw Eq28 | 10 at unity service factor Paz —_| Allowable transmitted power for pitting resistance KW Eqs 513 Paz | Allowable tranemitted power for pitting resistanoe kW Eq27 | 10 ‘at unity service factor Pe Axial pith mm Eqtt | 5.24 Q Transmission accuracy level number — Eq21 | as2 q Number of contacts per revolution - Eq 47 ATA Rey | Pinion surtace finish um Eqs | 142 s Bearing span mm Figé | 15.3 3 Pinion offset mm Fig 6 15.3 oF Safety factor — bending - Eq 13. a Su Safety factor — pitting = Eq4 1 San Normal tooth thickness at the top land of gear mm Eq 43 16.1 T | Transmitted pinion torque Nm Eqie | 74 R Gear rim thickness: mm Eq17 5.25 Uay | Allowable unit load for bending strength Nim Eqie | 524 U, | Core hardness coefficient - Eqaa | 16.1 | Uy |Hardening process factor =- Eq42 | 161 uy ‘Unit load for bending strength Némm? Eqg16 | 6.24 uw ‘Gear ratio (never less than 1.0) - Eq2 544 Vpa | Absolute value of pitch variation am Eqz1 | 632 1 % Pitch line velocity at operating pitch diameter ms Eqi8 | 74 vimax | Pitch line velocity maximum at operating pitch ms Eqes | 892 diameter v1 [Poisson's ratio for pinion - Eqao | 12 v2 Polsson's ratio for gear - Eq 30 12 y Geometry factor for bending strength - Eqio | 62 Yy | Stross oyolo life factor for bending strength - Eqis | 17 ¥z | Reliabiity factor — Eqs | 18 Yo —_| Temperature factor - Eq4 | 19 5 Adjusted number of pinion or gear teeth _ Eq21 8.3.2 21 | Number of testh in pinion - Eq7 | 5.14 2 Number of teeth in gear _— Eq7 5.14 Z | Geometry factor for pitting resistance — Eq1 | 64 Ze Elastic coafficiant [Nmme@ps | Eq1 12, Zy | Stress cycle life factor for piting resistance - eqs | 17. 2% | Surface condition factor for piting resistance: - Eqt | 13. my Hardness ratio factor for pitting resistance _- Eq4 17. ¢ | Operating transverse pressure angie - Eqa2 | 16. 8 |Holix angle at standard pitch diameter = Equi | 521 (continued) Copyright by the American Cea Wed May 18 0949.24 2011 nufacturers AssociationCopyrigh by the American Ges Wed May 18 0949.24 2011 ME 0b87575 OO037b2 TS) a AMERICAN NATIONAL STANDARD ANSVAGMA 2101-095 Table 1 (concluded) First] Ret. Symbol Description Units Used | Clause fae [Base helix angle = Eqaz [tet | or —_| Bending stress number Nimm@ |Eqio | 5.21 oy | Contact etrees number Nimm@ — Jeq1 | 6.1.4 ore — | Allowable bending stress number Nimm? |eqis | 522 yp | Allowable contact stress number Nimm?@ Jeqa | 5.1.2 | Allowable yield stress number Mmm [eqas | 164 @ | Speed rpm Eqa7 | 474 © __ | Pinion speed rpm Eqs [519 3 Application 3.4 Manufacturing quality 8.4 Rating practices Pitting resistance and bending strength rating prac- tices for a particular field of gearing may be estab- lished by selecting proper values for the factors used in the general formulas of clause 5. ‘Where applicable AGMA application standards ex- Ist, they should be used in preference to this stan- dard, Consult AGMA Headquarters for current list of applicable standards. Where no applicable AGMA application standard existe, numerical val- tues may be estimated for the factors in the general formulas, and the approximate pitting resistance and bending strength ratings calculated. 8.2 Implied accuracy Where empirical values for rating factors are given by curves, curve fitting equations are providedto fa- clltate computer programming. The constants and Coefficients used in curve fitting often have signifi cant digits in excess of those inferred by the reiabil- ity ofthe empirioal data. Experimental data from a0- tual gear unit measurements are seldom repeatable within a plus or minus 10 percent band, Calculated gearratingsare intended tobe conservative, butthe ‘scatter in actual resuits may exceed 20 percent. 3.3 Testing ‘The preferred method to predict overall system performance is to test a proposed new design. Where sufficient oxporionce is available from similar designe, satistactory results can be obtained by extrapolation of previous tests or field deta. NOTE: Whon euitablo test roaulto or fold data are not available, values forthe rating factore chould be cho- sen conservatively. Rating factors should be evaluated en the basis of tho expacted variation of component parts in the production run. The formulas of this standard aro fonly valid for appropriate material quality and ‘georetrio quality thet conforms to the manufactur- ing tolerances. Defects such as surface cracks, 1.7, A= 0.008 98 14.2 Surface hardened/through hardened values ‘When surface hardened pinions (48HRC orharder) are tun with through hardened gears (180 to 400 Ob87575 OOO3774 773 Ml ANSUAGMA 2101-Co5, HB), a work hardening effect is achieved. The Zy factor varies with the surface finish of the pinion, 1, and the mating gear hardness, ‘Typical values are shown in figure 8, or can be cal- culated as follows: 0 +B (450 — Hp2) (83) tyes where B= 0.000 75 (2) 044840, ) (84) 2 is baso of natural or Napierian logarithms =2.71828 Re Is surface finish of pinion, micrometers, R,. 15 Load distribution factor, Ky The load distribution factor modifies the rating equations to reflect the non—tniform distribution of the load along the lines of contact. The amount of ‘non-uniformity of the load distribution is caused by, and is dependent upon, the following influences: 4.12 4.10 « : ds 5 1.08 4 © 1.06 z 3 : £ 1.04 $ § 8 1.02 1.00 8 2 14 Single reduction gear ratio Figuro 2 - Hardness ratio factor, Zr (through hardened) pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011 7MH OOb87575 ANSVAGMA 2101-Cos 0003775 GOT i AMERICAN NATIONAL STANDARD 1.16 ‘Surface finish of pinion, za in micrometers, Ra 1.44 Ly 4.08 3 Hardness ratio factor, g 1.02 00. 180200 250 "300 "350 200 Brinell hardness of the gear, HB Figure 3 - Hardness ratio factor, Zw (surface hardened pinions) Manufacturing variation of gears = _ Lead, profile, spacing and runout of both the pinion and the gear. — Tooth crowning and end reli Assembly variations of installed gears — _ Alignment of the axes of rotation of the pitch cylinders of the pinion and gear as influenced by housing accuracy and concentricily of the bearings. Defleotions due to applied loads — Elastic deflections of the pinion and gear teeth. Elastic deffections of the pinion and gear bodies. - _ Elastic deflections of shafts, bearings, hous Ings and foundations that support the gear elements. — Displacements of the pinion or gear due to clearance in the bearings. fons due to thermal Let = Thermal expansion and distortion of the geare due to temperature gt - Temperature gradients in the housing ‘causing nonperallel shafts. = Centrifugal distortion of the gears dueto high speeds, 15.1. Values for load distribution factor, Kir ‘The load distribution factor is defined as: the peak load intensity divided by the average, or uniformly distributed, load intensity; i.e., the ratio of peak to meen loading. Ite magnitude i affeoted by two componer Kp is face load distribution factor; Kia, 9 transverse load distribution factor. Ky and Kiya can be interrelated depending on the form of the instantaneous contact line in the plane of action as shown by figure 4. In functional equation form, Ku =f(Kup. Kita) (35) pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95 ‘a = Length of action, transverse plane o a (C) Helical gear with two or less axial overlaps: Figure 4 ~ Instantaneous contact lines in the plane of action For helical gears, having three or more axial over- Japs, the face load distribution factor, Kip, accounts for the non-uniformity of load sharing between instantaneous contact lines across the entire face width encompassing all teeth in contact. It is af- feoted primarily by the correctness of pinion and gearleads. Greduel lead deviation (such as results fromhelix eror, misalignment, opinion deflection), regular pattems of undulation, or random irregutar- ties in lead, are examples of causes of non-uniform load sharing among the contact surfaces of mating teeth actoss the face width (see figure 4(A)). For spur gears, where instantaneous contact lines are parallel to the axes, Kg is affected primarily by Jead and parallelism (see figure 4(B)). In this ease, Kira affected by the transverse contact ratio. For helical goars having two or less axial overlaps, the interaction of lead and profile effects are so dff- cultto separate that, for practical purposes, the load distribution subfactors, Kip and Xia, canbe consid- ered as one factor that reflects the ratio of the peak pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011 to mean load intensity along the total length of the Instantaneous contact lines (see figure 4(0)). 15.2 Transverse load distribution factor, Kira ‘The transverse load distribution factor accounts for the non-uniform distribution of load among the gear teeth which share the load. Itis affected primarily by the correctness of the profiles of mating teeth: i.e., profile modification or profile error or both, ‘Standard procedures to evaluate the influence of yg have not been established. Therefore, evalu- ation ofthe numeric value of the transverse load dis- tribution factor is beyond the scope of this standard and it can be assumed 10 be untly. Equation 35 therefore, can be modified to: Bu = Kup 18.3 Faco load distribution factor, Kirp (26) The face load distribution factor accounts for the non-uniform distribution of load across the gearing face width, The magnitude of the face load distribu- tion factor is defined as the peak load intensity di- 19 0687575 OOO377b SubCopyright by the American Cea Wed May 18 0949.24 2011 ANSVAGMA 2101-C95 Vided by the average load intensity across the face width, This factor can be determined empirically or analyt- cally. This standard provides an empirical method only, but includes a theoretical discussion for ana- lytical analysis in annex D. Either method can be Used, but when using the analytical approach, the caloulated load capacity of the gears should be ‘compared with past experience since it may be nec- ‘essaty to re-evaluate other rating factors to arrive at a rating consistent with past experience. ‘The empirical method requires a minimum amount of information. This method ie rooommonded for relatively etff gear designe which meet the following requirements: = Net face width to pinion pitch diameter ratio, bide, $2.0. (For double helical gears the gap Is nol included in the face width). — The gear elements are mounted between bearings (see following paragraph for overhung gears). - Face width up to 1020 mm. = Contact across full face width of narrowest member when loaded. GAUTION: i fay: >2.4~0.29K wherek =thecontact load factor (see Eq 6), the value of iyp determined by ‘the empirical method may notbe sufficiently conserva tive. In this case, it may be necessary to modify the lead or profile of the gaarsto arrive ata satistactory ro- ‘sult. The empirical method shall not be used whan analyzing the effect of a momentary overload, See 16.3. When gear elements are overhung, consideration must be given to shaft deflections and bearing clearances. Shafts and bearings must be stif enough to support the bending moments caused by the gear forces to the extent that resultant deflec- tions do not adversely affect the gear contact. Bear- ing clearances affect the gear contact in the same ‘way as offset straddle mounted pinions. However, _gear elements with their overhang to the same sup- port side can compound the effect. This effectis ad- dressed by the pinion proportion modifying factor, Kijpn. When deflections or bearing clearances ex- ceed reasonable limits, as determined by test or ex- perience, an analytical method must be used to e8- tablish the faoe load distribution factor, 20 nufacturers Association Mi 0L87575 0003777 482 i AMERICAN NATIONAL STANDARD When the gap in a double helical gear set is other than the gap required for tooth manufacture, for ex- ample in @ nested design, each helix should be treated as a single helical set. Designs which have high crowns to centralize tooth contact under deflected conditions may not use this method. This method will give results similar to those ob- tained in previous AGMA standards. Designs fall- ing outside the above bid,1 ranges require special consideration, For relatively stiff gear designs having gears mounted between bearings (not overhung) and relatively free from externally caused deflections, the following approximate method may be used: Kip = 1.0 + Kitme(Kitep Kitpm + Kina Kile) (37) where Kime. = lead correction factor; Ki = pinion proportion factor; Kitpn = pinion proportion modifier; Kitna = mesh alignment factor: Kize = mesh alignment correction factor. The lead correction factor, Krinc, modifies peak load intensity when crowning or lead modification is applied. Kiino. = 1.0 for gear with unmodified leads; Kime ~0.8 for geat with leads properly modified by crowning or lead correction, NOTE: For wide face gears, when methods for careful lead matching or lead corrections to compensate tor deflection are employed, may be desirableto use an analytical approach to determine the load distribution facto. The pinion proportion factor, Kyjpy, accounts for de- flections due to load. These deflections are nor- mally higher for wide faoe widths or higher b/d, re tios. The pinion proportion factor can be obtained from figure 5. For double helical gearing, the pinion proportion factor should be evaluated by considering b to be the net face width. The values for Kye a8 shown in figure § can be determined by the following equations:Copyright by the American Cea Wed May 18 0949.24 2011 AMERICAN NATIONAL STANDARD g g g 40. Pinion proportion factor, Ky © 100-200 00400 ANSVAGMA 2101-C95 ida rato nm 130 1.00 0.0 For bidyy <0.5 use Cure for bide = 08 For Determining Kine ‘Sea Eqs 38,99 and 40 500600700800. (1000 Face width, 5, mm Figure 5 Pinion proportion factor, Kir when b < 25 oe Kies God ~ 205 ~-(@8) when 25< 6 $492 bo Kg = Taagy ~ WUSTS + U0W 4928 (90) when 432 BTEHRIEN | soofigure 11 | see figure 17 | see figure 11 Nitralloy Nand 2.5% Chrome (no aluminum) NOTES ‘Hardness to be equivalent to that atthe root diameter in the center ofthe tooth space and face width. 2\See tables 7 through 10 for major metallurgical factors for each stracs grad of steel gaars. 9¥The stee! selected must be compatible with the heat treatment process selected and hardness required. 4\The allowable stress numbers indicated may be used with the case depths prescribed in 16.1. 7'1he overloadcapacty ot nitridad gears is low, Sincathe shape ofthe effective S-Ncurve flat, the sensitivity toshock 24 MH 0L87575 0003781 903 mm Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011WM 0b87575 0003782 But AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95, fotallurgical and quality control procedures required Grade2 Ory = 0.703 fp + 113, llowable bending stress numbet,q,, 150 200 250 "300 350 700 750 Brinell hardness, Hp Figure 9 — Allowable bending stress number for through hardened steel gears, orp Table 5 - Allowable contact stress number, oyp, for iron and bronze gears ‘Allowable contact Matorial Hoat | Typical minimum | ‘stress number’) Material designation!) treatment | surtace hardness®) | op Némm? ASTM AaB Gray [Class 20 7s cast = 35-415 | jeast Iron Class 30 As cast 174 HB 450-520 Class 40 As cast 207 HB 520 — 585 ASTM ASS | Grade 60-40-18 ‘Annealed T40HE, 530-635 Ductile (nodular) [Grade 60-55-06 ‘Quenched & 179 HB 530 = 635 iron tomporod ‘Grade 100-70-03 ‘Quenched & 223 HB 655-770 tempered Grade 120-80-02 ‘Quenched & 269 HB 7i0-870 {tempered Bronze Sandeast | _ Minimum tensile 205 etrongth 275 Nim? ASTM B-148 Heat treated | _ Minimum tensile “450 Alloy 954 strongth 620 Némrn? NOTES 1ISee ANSVAGMA 2004-889, Goar Matoriale and Heat Treatment Manual. 2)Hardness to be equivalent o that at the start of active profile in the cantar of the face with ®/The tower values snouts be used for genera design purposes. The upper values may De used when: High quality material is usod. =. Section size and design allow maximum response to heat treatment. Proper quality control ls effected by adequate inspection = Operating experience justifies their use, 25 Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011MH 0667575 0003783 746 a ANSVAGMA 2101-095 [AMERICAN NATIONAL STANDARD ‘s —______—_, = ‘Metallurgical and quality 2 control proosdures required 500 e Grade 2 3 400 Gp = 0.749 Hy + 110 # 900 = g [ e a ee 2 g 200 Grade 1 j ‘op =0.508 Hy + 83.8 S100 g 9 250 275 300 825 360 Core hardness, Hs Figure 10 — Allowable bending stress numbers for nitrided through hardened steel gears (Le., AISI 4140, AISI 4340), orp Table 6 ~ Allowable bending stress number, orp, for Iron and bronze gears Allowable Bending Material Heat ‘Typical Minimum | "Stress Number?) Material Designation? Treatment | Surface Hardness® | opp Nimm? ASTM AA® Gray [Class 20 [As cast = 345 cast iron Class 30 [As cast 174 HB 59 Class 40 |As cast 201 HB 90 ASTM ASS6 | Grade 60-40-18 [Annealed 740 HB 750 - 230 Ductile (nodular) [Grade 60-65-06 ‘Quenched & 179 160-230 fron tempered [Grade 10-70-08 ‘Quenched & 229 HB 185 275 tempered |Grade 120-90-02 Quenched & 269 HB 215-305 tempered Bronze ‘Sand cast Minimum tensile 39.5 strength 275 Nimm2 ASTM 8-148 Heat treated | _ Minimum tensile 165 Alloy 954 strength 620 Nimm? NOTES See ANSVAGMA 2004-B89, Gear Materials and Heat Treatment Manual. PMeasuredharcnesstobe equivaentothatwhich weuldbemeasuredattherootameterinthecenteoftheteahspece and face wich, 31The lower values should be used for general design purposes. The upper values may be used when: | High quality material is used. ‘Section eize and dosign allow maximum response to heat treatment. rope ely cntlisstectad hy adaquis inspection rating experience justifies ther use. 26 Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95, 8 “ : Grado3—26% Chrome E Metallurgical and qualiy ee e E Vechaael a hai, Grayramie ann . jp € Grade 2-2.5% Chrome: B 400 ‘pp = 0.7266Hp 1 163.63 ae ——> 2 = Grade 1 -2.5% Chrome 2 7p 9, 7255ihp + 63.98, & % 300 Grade 2—Niralloy 2 Gp = 0.7848 p+ 3 Saat 2 Gade ~My g 200 orp =0.596hp + 87.70 2 100 250 275 300 325 350 Core hardness, Hp Figure 11 — Allowable bending stress numbers for nitriding steel gears, orp Table 7 - Major metallurgical factors affecting the allowable contact stress number, cup, and allowable bending stress number, orp, of through hardened steel gears") ?)®) Metallurgical factor Grado Grado 2 ASTM E112 grain size Predominantly 6 or finer [Predominantly 5 oF finer ‘Upper transformation. prod- |Not specified Max controling Wax upper ucts. which primarily inglude section, mm transformation balnite and tine pearite.*) to 254 incl 10% Over 254 20% No blocky ferrite (due to improper austenization) (Decarburization and stock re- | NOT Spectied ‘None apparent al 400K, stock removal sufficient To moval remove any devarburization. ‘Specified hardness at_sur-|See figure 6 See figure 8 face, oup only ‘Specified hardness al rool, |See figure S See gues orp only Cleanliness®) Not specified [AMS 2307 or ASTM A806 for wrought steel (certifica- tion not required). Castings are permissible with primarily round! (Type 1) sulfide inclusions [Salar Not spectied ‘0.025% maximum for wrought (0.040% maximum for castings NOTES: S90 table 9 for values of exp and table 4 for values of erp. Criteria for grades 1 & 2 apply to both stress numbers unless gtherwise specified in the metallurgical factor column, Dall crteria in any given grade must be met to qualify forthe streas number in that grade. SUnlass otherwise specified, proper process contral with periocie verfication is an acceptable method to meet these requirements (see clause 16}, ithe microstructure requirements apply only to those portions of the gear material where the teeth willbe located to adepth qua that of 1.2 times the tooth depth 5ithe grade cleanliness requirements apply only to those portions of the gear material whre the teeth willbe located to a distance below the finished tip diameter of al least wo times the tooth depth. On external gears, this potion ofthe gear blank normally will bo lose than 25 pereont ofthe radius. CAUTION: For cold service, below 0°C, see 3.6.1 27 WE 0687575 0003784 bl2 a Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011ANSUAGMA 2101-C95 AMERICAN NATIONAL STANDARD Table 8 - Major metallurgical factors affecting the allowable contact stress number, op, and allowable bending stress number, op, of flame or induction hardened stee! gears’) ?)) Metallurgical factor Grade 1 Grade 2 ASTM E112 grain size Predominantty 5 or finer | Predominantly 5 or finer Material composition Not specified ‘Medium carbon alloy steel Prior structure Not specified ‘Quenched and tempered Material form Not specified Forgings and wrought steel; castings with ‘magnetic particle inspection of gear tooth area Cleanliness‘) Not specified ‘AMS 2301 or ASTM A866 for wrought steel cettification not required); castings are permissible with primarily round (type 1) Sufide inclusions. Satur content Not spectiod (0.025% maximum for wrought 0.040% maximum for castings Core hardness, center of tooth at root | Not specified 28 HRC minimum diameter, op only Core hardness, center of tooth at root | Not specified ‘Type A- 28 HRC minimum diameter, orp only ‘Type B — not specified Non-martensiio transformation prod: | Limited by effect on ape- | 10% maximum, no free ferta ucts in hardened zone cified hardness Surface hardness, op only See table 3 See table 3 Surface hardness at root, orp only [TypeA-sectable 4 | Type A~ See table 4 ype Bnet spectied | Type B— nol spectied — Hardness pattem (see figure 12), ory [As requted per table 4 [Type A= Contour pattem witha duct core only 'ype B — not specified Magnetic particle (method per ASTM | Not epecified Module Maximum E769 on teeth)®) My indication, mm {+ £25 16 >25to<8 24 28 32 NOTES See table for values of cup and table 4 for values of arp. Criteria for grades 1 & 2 apply to both stress numbers unless otherwise specified in the metallurgical factor colurmn. 2)al otra in any given grado must bo met to quality for tho etross numbor in that grado, S1Uniees otherwise specified, proper process control with periodic verification is an acceptable method to mest these requirements (see clause 16). The grade cleanliness requirements apply only to those portions of the gear material where the tgeth will be located toa distance bolow the tnishedtip diameter of atleast wo times the tooth depth. On extemal goare, this portion ofthe gear blank normally willbe less than 25 percent of the radius. 5INo cracks, bursts, sears of laps are permitted in the tooth area of tinished gears. regardiess of grade, Limits: maximum cf one ingication per 25 mm of fase width and maximum of five in one toath flank. No indioatione allowed below 1/2 working depth of tooth, Indications smaiier than 0.40 mm are not considered. Removal o defects which exceed the stated limits Is acceptable provided the integrity of the gear is not compromised. 28 WH 0687575 0003785 559 i Copyrigh by the American Ges Wed May 18 0949.24 2011 nufacturers AssociationAMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95, Table 9 - Major metallurgical factors affecting the allowable contact stress number, op, and eo allowable bending stress number, orp, of carburized and hardened steel! gears") 2)*) ‘Metallurgical factor)*) Grade 1 Grade Grades ‘Surface hardness (HAC or equivalent on representative surface) S5-64HAG [56-04 HAC [58-64 HAC Case hardness 55-64 HAC or equivalent '5B-G4HAC or equivalont | 68-64 HAC or equivalent [Urn cfearbides tn case ‘Samicontinuous [Asceptable par AGMA 246,02A or | Acceptable per light discontinu- ANSVAGMA 603-A00 ‘ous micro per AGMA 246.02A or ANSVAGMA 6033-A88, Tempering Recommended Required Raquired (Surface temper (por ANSVAGMA !2007-892 with swab technique per- mitted), oir only Not epocifiod Claes FBS [Class FB. Cleanliness™ Net specitiod FNS a0i_ot ASTM ABSA Tor | AE TS00 or ASTM ABBE (oor ‘wrought steel (carticaton not re- | cation required) auired); castings are permissible leh Nave primarly round (ype 1) [sulphide inclusions. Megnetie par ile in the final product to grade 3 lovela may be eubstiute in heu of AMS 2301 Ufrasonie nepestion UT) — Natapactied ‘Speatied Tor wrought per ASTM | Specified for wrought per ASTIN ‘X366_ end. castings. per ASTM | A368. Castings not applicable”) ‘48037 recommended but not ré- quired. Suggested forlarge diame- ter parts to detect flaws before the expense of machinin Magnetic pare (method par ASTM E709 on toath)® Not specified Waximam Maximam indication, Modula indication, mm Ty mm Te =25 Os 24 >28t0<8 16 32 28 24 (Doarburization incase (100.127 mm depth) cp only Nat spooled (hardness must be mat) No paral decarb apparent at|No partial decarb, apparent at 400K, except in unground roots | 400X, excepl in unground roots Decarburization n case (00.127 mm septh), orp only Net epecifiod Surface carbon Th case DE0= 1.10% DAO= 110% OO 1.00% rads, or on representative coupon, rr only Minimum ofeotive case depth at oat | Not spectiod 0% of minimum spectied case at | 66% of minimum specied case v2 tooth height recommended | al 1/2 tools height recommended Microcrecke in case (qaoke across more than ona platelet)? Nat epectfiod Net epecifed TO maximum per 0.065 mre Tala at 400X, Secondary transformation prowucls, (Upper batnite) in case. slong flank save rec, or on representative cour pont 0.26 mn deep, ep only Not specified ‘% maximum at 400K Trace at 400X Secondary transformation products, (Upper Bainte) in case along flank above roo, oF on representative cou pon to 0.26 mm deep, opr only Wot spectiog {09% maximum at 400K ‘5% maximum at 400K Tntergranular oxidation (IGO) applica ble to unground surface. Determined by motallographio inepaction of un- Jefched coupon, if used. Limits in in- jchosto bo based on case depth acfol- lows: Not epectied Casedeph mm (GO.mm | Casedenhmm 1GO.mm <0.76 20.70 0.013, o7éeket 50 o7éekee60 0.020 1505 <2.25 T50cR<2.25 0.020 225i, <3.00 225ch-300 0.025 23.00 23.00 0.051 Copyrigh by the American Ges Wed May 18 0949.24 2011 nufacturers Association (continued) 29 0687575 OO0378b 45S mmANSVAGMA 2101-C95 AMERICAN NATIONAL STANDARD Table 9 (concluded) Metallurgical factor 5) Grade 4 Grade? ‘Grade 3 fagrandlar oxdation (1SO} applica | Net epaotia ‘excessive salvage Ts allowed by controlled shotpeening, with the bie to unground surtace. Determined agreement of the customer ‘metallographic inspection of un- esd coupe used, Ls Jchoato bo basod on case depthasfol- ows: faximum retained austente im case | Not epectied [30% maNTTURT Tania (determined matallographically) Hardenebiy band Notepeatiod | Rocoraing to T-Band require: | According to upper halt of = ments, Recommended but nat e- | Band requirements ui [Gare hardnass (at canter of toth at [Nat epecTied 21 HAG minimum TTC minima Toot dlameter or on representatWe leoupon), our only'? [Coro Rardnosa (et canter of tooth at [ST HAC mint | 35 NC minimum SOTIAC minima root diameter or on representative | mum. jeoupon), arp oniytt) [ASTMETi2 grein size | Predominantly | Predeminantly 6 orfiner | Predominantly © or finer] ortiner [Satur content Not specified [0.040% maximum COTES MeL [Materialform Not specified [Not spaciiad ‘Sisal forgings and har stool [Shot peering. orp only Not specified | Recommended tthe roatis pround | Required in tooth roat area [OTES: NEE be 2 for valuo of pond table 4 for vauoo of apn Crea or rads 1,2 and ep to beth stress numbers unless atherwise epectied in the metalurgcal factor column lll ortria in any given grade must be met to qualify for the stress number in that grede. pues tere sce, poparprnes crim tm parade vatican an acoptale matte meet thane equa (g00 clause 16). Microstructure, microhardness and core hardness considerations may be determined fromtest coupons. Test coupons shall be fromthe eame aicy eteel (not necessarily eame heet) es the production parts. Coupon shouldbe sizedto produce a similar cooling Tate to that obtained in the gear teeth of the actual gear. Coupon proportions of minimum diameter 6m, andmnimaum length 12 m, Jaro used in ISO 6936-5, Microhardness is tobe measured on the test coupon at a depth net more than 0.70 mm below the depth {gorresponding othe tihished tooth surtace.. For low temperature service, below O°C, consider low temperature Charpy V-notch impact strength, fracture eppeerance ransition temperature (FATT) requirements and use ot nickel allay steel, Consideration must be given tothe loss of hardness and gtrongth of some materials dus to the tempering effect of temperatures over 175°C. ®yThe grade cleaniiness requirements appiy only to hose portions ofthe gear material where the teeth willbe locatedto a distance below the finished tip diameter of atleast two times the tooth depth. On external gees, this portion of the gear biank normally wall be less than 2b percent of the radius, ?Speotied for wrought gearing per ASTM A386, using ether the back reflection or reference blocktechnique. Use 9.18 mm FBH (0800) per ASTM E426 (also desorbed In ANSVAGMA G083-Al6), A cstance ampitude correction cue is no intend inspection is fromthe 0.D. tomic-redius and a 360 degree scanis required. Other UT specications which ensure the sarre quality lovalare permitted, Speciec orcas gears (rage? eniy) per ANIM ARDG ave nZone 1 (OD 0 28mm rots) and Laval 2 in Zone 2 (remainder of rim) using 8.18 mm FBH; or approved equivalent using back rellection technique (also described in |ANSVAGMA 6033-A88). ®)No cracks, bursts, seams or lps are permitted in the tooth area of finished gears, regardless of grade, Limits: maximum of one indication per2s mm offace width and maximum tive in one toothflank. No indeations alowed below 1/2 working depth af tooth, Indications emalter than 0.40 mm are not considered. Removal of defects which exceed the stated limits is acceptable provided he intearty ofthe gear is not compromised. *Mecimum iit ‘of microcracks for Grade 8 gearing may be dificult to achieve with sub-zero treatment to transform retained 1 Sub-zero trestmen, if required, should be preceded by tempering at 150°C minimum, to minimize formation of microcracks, followed by retempering. ‘The purpose of the sub-zero treatment should be to pick up an addtional ono to two Hockwal hardness points. Sub-Zero treatment should not be employed to transform large amounis of relained austenite (e.9,,50%) 0 gein amatic improvements n hardness, even wih prior tempering, or mcroeracking may occu Tore hardness requirements for ping resistance and bending stength are considered independert. The allowable stress numbers ara established for the grade selected based on hardness. Because higher contact stresses are allowed for carburized andhardgned gers, the reguting higher bending esses must also be accommodated. Therelore, or geuinigo this ype, higher ‘ore hardnesses aré specttad for the bending strength. The gear rating may be imed by eihet piting resistance or Bonding sipgnath fr the golocted grado and score hardness equrament {2)minimum hardness of 30 HI for grade 3 may be dificult o achieve on gears coarser than 4.23 m,. Therefore, a minimum hardness of 25 HRC is acceptable in such cases. *S)Requires a minimum reduction of 71o 1 for strand or continuous cast baretook; or minimum reduction of 4to 1 for forged goare. mm 0687575 0003787 32) Copyright by the American Gear Manufacturers Asovaton Wed May 18 0949.24 2011MH 0687575 OO03788 2bs AMERICAN NATIONAL STANDARD ANSVAGMA 2101-CO5 Table 10 - Major metallurgical factors affecting the allowable contact stress number, ous and allowable bending stress number, orp, for nitrided steel gears") 2)2) Wotallurgical factor Grade t Grade 2 Grade 3 ASTM E112 grain size Predominant | Predominanty § or ter Predominantly 5 or finer or finer Hardanability HeBand HoBand HeBand [Sulfur content (0.040% max [0.025% meximum (0.015% maximum mum Cleaniiness® Not specified | AMS 2301 or ASTM A866 (certifica- |AMS. 2300 or ASTM A866 tion not required) cerfcation required ‘Surface hardness Pertables _|Pertables Por table 3 Core hardness: [28 HAC mint [28 HAC minimum [32 HRC minimum mum White layer (maximum) (0.025 mm __| 0.020 mm 0.012 mm Upper vanstormation products [Notspeciied [Max controling _ Maxcupper | Trace at 400X which primary gclude bainite section, mm_~ transformation fndtine pearl to 254 inc. 10% Over 254 Ro becky ferite (due 10 improper austenization) —_____} Ultrasonic inspection Notspeciied [Not specified Specified for wrought per ASTM A888) Wiagnelis parcle (mejnod per [Not specified [Not spectied ‘Maximum ASTM E700 on tooth)? Module | indication, Me min 25 08 >2510<8 16 28 24 Grinding burns Notspectied | See nota @ NOTES ‘See table 8 for values of aur, end table 4 for velues of orp 2)Al criteria in eny given grade must be met to quality forthe stress number in that grade. inlees otherwise speciied, proper prooess control with period verification is an soceptable method to mest these requirements (588 clause 16). “\The grade cleanliness requirements apply only to those portions of the gear material where the teeth willbe located to a ciatance below the finished tip diameter of at oaat two timoa the tooth depth. On external goar, this portion of the gear blank normally wil be less than 25 percent of the radlus. 5/The microstructure requirements apply only to those portions of the gear material where the teeth willbe located 1 @ depth ‘equal to thet of 1.2 times the toath dopth. ®\Spectiad for wrought gaaring por ASTM A388, using eithor the back reflection or reference block technique. Usea3.18mm FBH (8-0400) per ASTM E428 (also described in ANSVAGMA 6033-88). A distance amplitude correction curve is not intended, Inspection is from the 0.0. to mid-radius an a 260 degres scan is required. Other UT specifications which oncure {ho same quaity lavel are ported. Spectied for cast gears (rade 2 only) per ASM ABUS Level 1 in Zone 1 (OD to 25 mm. below rote and Level in Zane 2 (raider offen) using 3.18 wm FB or approved equivalent using beck refection technique (also described in ANSVAGMA 6033~AA) FrNo cracks, bursts, seams or aps are permed inthe tooth area of hished gears, regardless of grade, Limits: maximum of cone indication per 25 mm offace width and maximum of five in one tooth lank. No indications allowed beiow 1/2 working depth af tooth, Indications smaller than 0.40 mmare notconsidared. amoval of defects which exceed tne statedlimis is acceptable provided the inteurily of the gear is not compromise. grinding burns are possible on ritrided materials. The normal ingpection methods, as definedin ANSVAGMA 2007-B92, are not applicable to iting, Care must be taken when grinding nitided surfaces to ensure that no harmful surface conditions are produced in the grinding process Copyrigh by the American Ges Wed May 18 0949.24 2011 nufacturers AssociationANSUAGMA 2101-C05 AMERICAN NATIONAL STANDARD ‘Spin hardening Inductor coil Induction coil Induction orflame head or flame head AAR SDSZKA RASA oY — Type A ‘Type A Type B (Contour) (Non-contour) Flank hardoning {tooth to tooth) Inductor or lame head Inductor or flame head KW WY} Type B Type B Flank and root hardening (tooth to tooth) Inductor or flame head NOTE: Type A indicate flanks and roots are hardened, contour or non-contour pattern. ‘Type B indicates only hardening of flanks extending to the form diameter Figure 12 — Variations In hardening pattarn obtalnabla on gear testh with flame or induction hardening ‘The effective case depth for carburized and hard- ‘ened gears Is defined as the depth below the sur- face at which the Rockwell'C’ hardness, HRC, has ‘dropped to 50 HRC or equivalent. ‘The effective case depth for Induction and flame hardened gears is defined as the depth below the surface at which the hardness is equivalent to 10 Rockwell ‘C’ points below the specified minimum surface hardnesa, A guide for minimum effective oase depth, Fe min, at the pitch line for carburized and induction hardened external (not internal) teeth based on the depth of 32 maximum shear from contact loading is given by the formula: = ity Sit py vx(42) Pewia = T008B gy 6 whe Ae ninis minimum effective case depth at pitching, mm; oy scontactstress number Nimm?, The max- imum value recommended is 1400 Nim? {or this equation; ys operating transverse pressure angle; Uy _ is hardening process factor, Nimm?; MH 0b87575 0003789 174 mm pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011MH 0687575 0003790 Ib AMERICAN NATIONAL STANDARD ANSVAGMA 2101-c95, =4.4x10'Nimm?for carburized andhard- If Aemin from Eq 42 (with heat treat tolerance consid- oe ened: ered) exceeds fe max, & Careful review of the pro- ’ . poseddesignis required. Changingthe profile shift, FOR Nin fortooth-to-tooth induc: Jowaring the operating pressure angle, oF using @ tion hardened larger module will increase h. mex Bub is base helix angle. For nitrided gears, caso dopth is specified as total Anethor guideline for dotorining case dpi is £280 depth and is defined aa the depth below the ‘shown in figuro 12. These case depthe have hada surface at which the hardness has dropped to 110 long history of successful use on carburized gears, Percent of the core hardness. ‘They are not based on equation 42. A guide for minimum case depth for nitrided external (not internal) teath based on the depth of Care should be exercised when choosing case aximumshear romcontact loadings given by the depth, such that adequate case depths prevail at formula: the tooth root fillet, and that tooth tips are not over hardened and brittle. A suggested value of maxi- b= LSet Nye 6 (44) ‘mum effective case depth at the pitch line. fe max. is 'emin THE 105C05B ny he max = the les8er Of 0.4 Me OF 0.58 Son where (48) Jepin'i8 minimum total case depth for nitrided where gears, mm; jemanis suggested maximum effective case 1U, Iscorehardness coefficient, from figure 14. ‘depth at pitchline, mm; Ifthe value Of femin from Eq 44 Is less than the value Son iSnormaltooth thicknessatthe top land of for normal case depth from figure 15, then the the gear in queetion, mm. minimum value from figure 15 should be used “986103 Effective case depth is defined as depth of case: = 3.046 349 x (25) _whigh has a minimum hardness of 6 HAC. Total case dap to coro carbon is approximate- Normal anna depth risx efouracase depth 1 b emia | "Tho valuoe and ranges shown on the Case dapih curves are to be used as guides, For gearing In which maximum performance is required, detailed studies must be made of the “| pplication, loading, and manufacturing procedures to obtain desirable gradients of both hardness and internel stress. —] Furthermore, tha method of measuring the case as well as the allowable tolerance in case depth may be a matter of} ‘agreement botwoon the customar and the manufacturer. ———ee 05 10 15 20 25 30 35 40 45 50 55 60 65 ‘Minimum effective case depth, fy zi, Mm Figure 12 - Minimum effective case depth for carburized geare, He min Normal module, 7 Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011ANSUAGMA 2101-Co5 AMERICAN NATIONAL STANDARD. Temas bay 1 oon + dan Sueno, gq __‘p" "ig |__| 1 BEA2G07 “1425 47ExT0? BSB 5TOxIO® —2080618x10> 2 “7 9e66s 1775498102 —1.104.475 10-5 2.577 960% 10-9 3 Baer 585 ZoOREBOXIO® —1zs084axI0 _2706z216X10° 4 16.02 182 8.247 710x102 —ZoasavExt0-S 4.474 087% 10-2 54064486 8.094 568x102 5201 TAD 10-5 _ 1.190.604 10-8 — — —— INOTE: Use upper portion of core hardness band (which yields Heavier case ]dopths) for goneral design purpose and lower portion for high quality material 2s detined in 16.1). : Curve 1 Curve 2| mn eS Curve 3 . Curve 4| no Curve 5) 16 12 08 600 00 7000 1200 7400 7600 Contact stress number, oy, Nemme Figure 14 Core hardness coefficient, t/, "Tha vies shown have Boon niccsasly used ov Wd gears nd can bo used ana poe For rg maxirur performance, especially sos, coarea pithes, an high work SEeeahe tl set no raf ppm, ecg ad aay poses doe termine he dosed gracensofharsneso, rong, endinomal residual sbosses trougbou te tooth 1 hemin = 168 ~ HBS + x Heavy case depth 2 gs Ba gs 5 6 8 10 Ne lormal case depth 2 2 . Ot 02 0304 060810 20 Minimum effective case depth, mm. Figure 15 - Minimum total cago depth for nitrided goars, Amin MH 0687575 0003791 852. mm Copyrigh by the American Ges Wed May 18 0949.24 2011 nufacturers AssociationAMERICAN NATIONAL STANDARD 16.2 Reverse loading Use 70 percent of the opp values foridler gears and other gears where the teeth are completely reverse Joaded on every cycle. 16.3 Momentary overload ‘When the gear is subjected to infrequent (less than 100 cycles during tho design life) momentary high ‘overloads approaching yield, the maximum allow- able stress is determined by the allowable yiold properties rather than the bending fatigue strength ‘ofthe material. This stress is designeted.as o,. Fig: ure 16 shows suggested values for allowable yield strength for through hardened steel. Forcase hard- ened gears, the core hardness should be used in conjunction with figure 16. In these cases, the de- sign should be checked to make certain that the ANSVAGMA2101-C95, the gear blank configuration and ite besring eup- port. Special consideration, euch as an approach similar to annex D, must be given to this condition when analyzing overloads. The empirical method of 15.3 shall not be used. 16.4 Yield strength For through hardened gears up to 400 HB the factor ,, shown in equation 45, can be appliedtothe yield strength of the material. These values must be ap- plied at the maximum peak load to which the gears are subjected FmaxK ys Be Ky ok, = (48) where © isellowable yield strength number from fig- teeth are not permanently deformed. When yield is ure 16, Nimm?; the governing stress, the stress correction factor, i Kj, is considered ineffective for ductile materials; % vies orenath factor from the following henoe, the stress corroction factor can be taken as ations, unity Requirements of application ky ‘A momentary overload can cause an unusual face Conservative practice 080 load distribution factor which will be influenced by Industrial practice 0.75 ,1200-—17-—t 21100} So—— Amesied or Normal 1000) 7 900 i 800 © 700 = 3.324HHp ~ 226.2 $ ont £ % 500 4 sco 2 B 900 — 2 sol = 2.069 +2138 = 200 i+ 100 + ° | 150 200 250 300 350 400 450 500 Brinell hardness, Hp Figure 16 — Allowable yield strength number for steel gears, «, 35 Mi 0687575 0003792 795 a Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011Copyright by the American Cea Wed May 18 0949.24 2011 ANSUAGMA 2101-C95 Fax. 18 maximum peak tangential load, N; Ky is stress correction factor (see AGMA 908-B89); Kyy_ is load distribution factor under overload conditions. CAUTION: This equation is based on a ductie mater: al, Forpurposes ofthis standard, a materials consi ‘ered ductilifthe tensile elongation ofthe core material ist least 10%. For non-ductile materiale, the effects ‘of stress concentration should be considered, For a straddle mounted gear or pinion in an en- closed drive, Kz, may be calculated from equation 46. Kite =0.000 5670+1.07 (46) Equation 46 has been used as a design guide; a more detailed approach may give more accurate resuits. Fora case hardened gear. the analysis of allowable yleld properties should Include a stress calculation through @ cross section of the material. In lieu of a cross section analysis, the use of material core hardness values can be used. For additional information, see [20] 17 Stress cycle factors, Zy and ¥y The stress cycle factors, Zy and Yy, adjust the allowable stress numbers for the required number of oyoles of operation. For the purpose of this standard, n,, the number of stress cycles is defined a the number of mesh contacts, under load, of the geartooth being analyzed. AGMA allowable stress, numbersare established for 10? unidirectionaltooth load cycles at 99 percent reliablty. The stress cycle factor adjusts the allowable stress numbers for design lives other than 107 cycles. The stress cyclo factor accounts for the S-N char- acteristics of the gear material as well as for the gradual increased tooth stress which may occur from tooth weer, resulting in increased dynamic ef- fects and from shifting load distributions which may ‘occur during the design ife of the gearing. Whenusinga service factor, the determination of Zy and Yy shall be in accordance with clause 10. 174 Load cycles When evelueting gearing, it is important to know how many stress cycles the individual gears wil ex- 36 AMERICAN NATIONAL STANDARD perience during the intended fe of the equipment. ‘Some machines will run twenty four hours per day and operate for twenty or more years, Other ma- chines have goars that have a stross cycle equiva- lent to a few hours. The gear designer should de- sign forthe stress oyoles that are appropriate for tho application. The number of stress oycles, nz, is used to determine the stress cycle factoras follows: 0 Ling (a7) nm, isthe number of stress cycles; L elif (houre); @ is speed (rpm); @ _ isnumber of contacts per revolution. 17.2 Stross cycle factors for stool gears ‘At the present time there is insufficient data to pro- vide accurate stress cycle curves for all types of gears and gear applications. Experience, however, suggests stress cycle curves for pitting resistance and bending strongth of steel gears as shown in fig- lures 17 and 18, These figures do not include deta for stainless steel gears. The shaded zones on the figures represent the influence of such items as pitch ine velocity, material cleanliness, ductity and {fracture toughness. The upper portions for general applications. The lower portion is typically used for crftical service where pitting and tooth wear must be ‘minimal and low vibration levels are required. 17.3 Localized ylelding Ifthe product of orp Yy exceeds the allowable yield stress, g,, offigure 16, localized yiekding of the teeth. may occur. In some applications this is not acceptable. In others where profile and motion transmission accuracies are not critical, this may be acceptable for limited life. The use of this standard at bending stress levels above those permissible for 10% cycles requires careful analysis. Stresses inthis range may exceed the elastic limit of the gear tooth in bending stress. Depending on the material and the load imposed, a single stross cycle above the level limit at < 104 cycles could result in plastic yielding of the gear tooth. WH 0687575 0003793 425 mm nufacturers AssociationStress cycle factor, Zy Tw ‘Stress cycle factor, Copyrighl by the hi Wed May 18 0949.2 AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95 Wo chow ay tw uated coT influenced by: Lubrication regime Fal ofteria ‘Smootness of operation required Pichlne velosty Gut tei ears Material dctity and facture toughness. ABE m,-0.988 Residual stoee load 10 cycles, m, 107 108 Ince stress cycle factor, Zyy ROVE The Shots Ty ine shaded aa Te influenced by: Pitchine velocity Gear material clantiness Residual tress Matertal ucaty and tracrure toughness eae au my in tt tM 1517 m0 0817 _ Nitrided 10% 10° 108 107 108 Number of load cycles, m, Figure 18 - Bonding strength stross cycle factor, ¥yy 18 Reliability factor, ¥z The reliebilty factors account for the effect of tho normal statistical distribution of failures found in ma- terials testing. The allowable stress numbers given in tablas 3 through 6 are based upon a statistical probability of one failure in 100 at 107 cycles. Table ineriean Gear Manufacturers Association 42011 11 contains reliability factors which may be used to modify these allowable stresses to change that probabilty. These numbers are based upon data developed for bending and pitting failure by the U.S. Navy, Other values may be used if specific data is available, MH 0L87575 000379" SLL mmCopyrigh by the American Ges Wed May 18 0949.24 2011 ANSVAGMA 2101-CO5 ‘Table 11 - Reliability factors, ¥z [_ Requirements ofapplication ___¥z0_] ‘awor than ono failure in 10 000 150 Fewer than one failure in 1000 1.25 Fewer than one failure in 100 1.00 Fewer than one failure in 10 0.852) Fewer than one failure in 2 0.70213) NOTE ‘Tooth breakage is sometimes considered a greater hazard than pitting, In such cases a greater value of ¥z ig eelected for bending. iat this value plastic flow might occur rather than 4 Som test data extepoatn, When strength rating is based on yield strength, o,, the values of K; from 16.4 should be used instead of Ye. 19 Temperature factor, Yo 18.1 Moderate and low temperature operation ‘The temperature factor is generally taken as unity when gears operate with temperatures of oil or gear blank not exceeding 120°C. When operating tom: peratures result in gear blank temperatures below 0°C, special care must be given, see 3.6.1. 18.2 High temperature operation ‘When operating at oil or gear blank temperature above 120°C, Yois given a value greaterthan 1.0t0 AMERICAN NATIONAL STANDARD allowforthe effect of temperature on oil flmandma- terlal properties. Consideration must be given to the loss of hardness and strength of some materials due to the temper- ing effect of temperatures over 150°C. 20 Size factor, K; 20.1 Size factor The size factor reflects non-uniformity of material properties. Il depends primarily on: - Tooth size — Diameter of parte, = Ratio of tooth size to diameter of part - Face width — Area of stress pattern — Ratio of case depth to tooth size - Hardenability and heat treatment of materials Standard size factors for goar teeth have not yet been established for cases where there is a dett- mental size effect. In such cases, some size factor greater than unity should be used. 20.2 Values for size factor The size factor may be taken as unity for most gears, provided a proper choice of steel is made for the size of the part and its heat treatment and hardening process. MH 0687575 0003795 4TS nufacturers AssociationCopyrigh by the American Ges Wed May 18 0949.24 2011 AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95 Annex A (informative) Method for evaluating the risk of scuffing and wear This annexis for information only and shouldnot be construedto be apart of ANSVAGMA 2101~C95, Fundamentalrating factors and catculation methods for involute spur and helical gear teeth. A.1 Purpose ‘standard method for evaluating the riskof scuffing and wear of spur and helical gearsets is described ‘The term scoring has been used in the past in the USA, while the term scuffing is used in Europe and in ISO standards to desenbe the severe form of ad- hesive wear which involves welding and tearing of the surfaces of gear teeth, Tobe consistent with cur- rent usage, the term scuffing is used in this annex where scuffing Is defined as the localized damage caused by the occurrence of solid-phase welding between sliding surfaces. Its accompanied by the transfer of metal from one surface to another due to welding and tearing, and may occur in any sliding and rolling contact where the oil film is too thin to separate the surfaces. Its symptoms are a micro- scopically rough, matte, tom surface. Surface analysis that shows transfer of metal from one surface to the other is proof of scuffing, NOTE: Ihetermscorng implies scratching andis de- fined as the formation of scratches in the direction of sliding. The word ecoring le used inthis annex to de- scribe the clean-cut, paralal scratches inthe direction of sliding that occur on gear teeth due to abrasion or rricro-cutting caused by abrasives in the lubricant, or looee or attached, work-hardened particles. Tho scuffing risk evaluation is based on Blok’ [1] critical temperature hypothesis, and the woar risk evaluation is based on Dowson and Higgineon's [2.3.4.5] equation for elastohydrodynamio (EHD) film thioknose. This annex is a supplement to ANSVAGMA 2401-C95. Ik has beer introduced to enable field experience data to be accumulated and evaluated relative to the calculation methods given. Such data will serve to enhance the future development of i proved methods for evaluating scuffing and wear tisk, A.1.1 Lubrication regime The specific fim thickness, 2, defined as the ratio of the central film thickness to composite surface roughness, is a useful measure of the lubrication regime. For 2.> 1, the contact between the tooth surfaces has an intermittent character with a per- nufacturers Association centage of contact time that decreases gradually as 2 increases. As an approximate guide, b> 2 indicates full EHD lubrication, while 2. < 1 indicates partial EHD or boundary lubrication regimes. ‘The specific film thickness cannot be usedto predict the probebilty of scuffing, since thin EHD films area necessary but insufficient condition for scuffing to ‘occur. However, a thin film together witha high con- tact temperature suggests a high probability of scuffing in the absence of extreme pressure (EP) additives. 4.2 Mechanism of scuffing and wear When gear teeth are completely separated by a thick fllm of lubricant, there Is no contact between the aspertties of the tooth surfaces, and usually there Is no scutfing or wear. For thinner elastohydrodynamic films, the degree of esperily conlact increases and abrasive wear, au hesive wear or scuffing becomes possible. Abra- sive wear may oocur due lo the rubbing action of the ‘gear teeth or the presence of abrasive particles in the lubricant. Adhesive wear occurs by localized welding and subsequent detachment and transfer of particles from one or both of the gears. Abrasive oradhesive wear may not be harmful if itis mild and it subsides with time, as in a normal break-in proc 35, Scuffing on the other hand, is a severe form of adhesive wear thal Gan resull in catastrophic dam age to the gear tell The basic mechanis of ‘scuffing is not clearly understood, but there is gen- eral agreement that itis caused by intense frictional heat that is generated by the combination of high sliding velocity and intense surface pressure. Scuff- ing occurs under thin film, boundary-lubricated ‘conditions where the phenomenon is controlled by physical and chemical properties of the lubricant, oxide films and gear tooth materials. A4.3 Flash temperature and probability of scuffing BloK’s [1] contact temperature theory states that scuffing will occurin gear teeth that are siding under boundary—lubricated conditions, when the maxi- ‘mum contact temperature of the gear teeth reaches 39 MM 0687575 GO03796 334 aCopyrigh by the American Ges Wed May 18 0949.24 2011 ANSVAGMA2101~C95 @ ofitical magnitude. The contact temperature ie conoeived as the sum of two components: the flash tomporature and the bulk temperature. Usually, the meshing position most ortical in re- Gear - ‘Bearings & shafts Friction power Figure A.9 - Example of thermal network ‘The bulk temperature is determined by the heat flow balance in the gear box. There are several sources Of frictional heat, of which the most important ones. are the tooth friction and the bearing friction. Other heat sources, like seals and the oil flow, may con- tribute to some extent. For gear pitchline velocities above 80 m/s, the churning loss, the expulsion of the lubrication oil between the meshing teeth, and the windage loss become important heat sources ‘which should be considered. The heat is conducted and transferred to the environment by conduction, convection and radiation. AQ Contact temperature A..1 Contact temperature at any point At any point on the line of action (see figure A.10) the contact temperature Is: 5 = Op + Op AZT) where ant) ©u is the bulk temperature (see A.8): 81 isthe flash temperature (see A.7). A Bc oD E Figure A.10- Contact temperature along the line of action 4.9.2 Maximum contact temperature ‘The maximum contact temperature is: Uomax = Or + Bomex where Oy isthe bulk temperature (see A.8); Shmax 8 the maximum flash temperature (see ATS). A.10 Scutting temperature ‘The scuffing temperature is the contact tempera- ture at which scuffing is likely to occur with the cho- en combination of lubricant and gear materials. The scuffing temperature is assumed to be a char- acteristic value for the material-lubricant-material system of a gear pair, to be determined by gear tests with the same materiallubricant-material system. AA0.4 Scutfing tomporaturo for low-additive minoral oils, (a72) When using a low-additive mineral oil, the scuffing temperature is assumed tobe independent of oper- ating conditions ina faily wide range. For such an cil and steel combination, the scuffing temperature may be correlated with the composition of the oil. ‘The viscosity grade has been chosen as a conven ient representative index of that composition, and thus of the scuffing temperature. Viscosity grade is suitably expressed terms of kinematic viscosity. It is emphasized that viscosity grade is introduced as a readily available index of the different chemical composition of the various low-additive mineral oils, and is not to be conceived as an elas- tohydrodynamically influential characteristic. = 118 +33 In-vyy °C (A.73) wis 33 In yao (A73) ‘Yao is kinematic viscosity at 40°C, mm?/s. A.102 Scuffing risk evaluation AGMA 217.01 [9] correlated the total contact tem perature with the probability of scuffing for 49 WH 0687575 000380b O03 mw Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011ANSVAGMA2101-C95 MIL-L-7808 and MIL-L-6081, grade 1005 oils. The data were gathered from a survey of the aero- space industry and includes data forcarburizedand ground gears (predominantly made of SAE 9310 steel) from field applications and test rigs. The data were reduced using a Gaussian probability func- lion. Table A.2 gives the mean scuffing temperature (60 percent chance of scuffing) and standard devia tion of temperatures for MIL-L~7608 and MIL-L-6081 oils from AGMA 217.01. [9] Table A.2 - MIL Lubricant moan scuffing tem- peratures Copper-plated steel! 1.50 Mean Bath or gas ritrided stool 1.50 sou perature Hardened carburized stool Lubricant temperature q Cc on |— Less than 20% retained austenite 1.16 = 786 314 — 20 to 30% retained austenite 1.00 MIL-1-6081 129 MNS | |— Greater than 30% retained austenite | 0.85 rade 1005) Austenite steel (stainless steel) 0.45, AMERICAN NATIONAL STANDARD = Xv Oomay tat * OM, tat (A74) where Xw Is welding factor (see table A.4); Qrmas.tes._ is maximum flash temperature of test gears fhyeu i bulk temperature of test gears Table A.4- Welding factors, Xv "Through hardened steel x Phosphated steel 125 Table A.9 can be used as an approximate guide for rnonadditive mineral oils and steels typical ofthe IAE and FZG test machines. The mean scuffing tern- perature (50 percent chance of scuffing) was de- rived from data published by Blok[11}. The standard deviation temperature was assumed to be 15 per- cent of the mean value. Table A.9 ~ Mineral oil mean scuffing tempere- ros Mean Standard AGMA | souffing | temperature Iso | lube | temperature | deviation ve | no. “C ap —— 17 4] 4 180 es} 2 202 100] 3 214 150| 4 227 z0| 5 240 so] 6 252 460) 7 264 620 8 27 1000] 8A 280 1500] - 3203 A.10.3 Combination of mineral oil with gear stool Tho scuffing temperature of low-additive mineral olla that ie determined from test geare may be ox- tended to different gear steels, heat treatments or surface treatments by introducing an empirical welding factor. 60 Table A.5 gives the evaluation of scuffing riskbesed Table A.5 - Scuffing risk Probability of scuffing —[Sourfing risk <10% Tow 10 to 30% Moderate 30% High ‘A104 Scutfing temperature for high-additive mineral oil When usinga high-adkitive, extreme pressure min- eral oil or a synthetic ol, extended research is still needed lo determine the nature of a possible non ‘constancy of the scuffing temperature for the mate- fials and operating conditions concemed. Special attention has to be paid to the correlation between {est conditions and actual or design conditions. For instance, the operating conditions of a gear trans- mission are quite diferent from the operating condi- tions of disk tests. AAOS Safety factor ‘A ately factor has to be introduced to account for inaccuracies in the caloulation and to avoid unnec- ‘escary risks. In contrast to pitting and fatigue broak- age, which chow a dietinct incubation period, a sin- gle chort overload can load to scuffing and failure of gears, Tho cafety factor is dofined as a quotient of oil temperature differences to establish a dimen- sionloes factor indepondont of the temperature soale, Tho caloulated safety factor shall not be less than the minimum demanded safoty factor for con- tact temperature. MH 0b87575 0003807 THT Mm pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011Copyrigh by the American Ges Wed May 18 0949.24 2011 AMERICAN NATIONAL STANDARD where Sp = pantul > s, 9 pmax = Boat 2 where i. iS oil temperature; fs is seutfing temperature: Ssmux is maximum contact temperature (see ATS); Spmin i9 minimum demanded safety factor. A.11 Alternative scuffing risk evaluation Tho Integral Temperature Method [14] has been proposed as an alternative to Blok’s method for as- sessing the risk of scuffing. While Blok’s method is based on a critical maximum temperature, the Inte- gral Temperature Method proposes acritical energy level, and is based on integrating the temperature distribution along the path of contact. For purposes of comparison, the integral tempera- ture may be obtained by numerically integrating (e.g. using Simpson's Fulle) the total conjunction temperature given by Eq A.71. Such comparisons have shown the following: = _Blok’s method and the Integral Temperature Method give essentially the same assessment of ‘scuffing risk for most geersets. = _ Blok method and the Integral Temperature Method give different assessments of scuffing risk for those cases where there are local tem- perature peaks. These cases usually ocour in gearsets that have low contact ratio, contact near the base circle or other sensitive geome- tries = _Blok’s method is sensitive to local tempera: ture peaks because itis concemed with the maxi- mum instantaneous temperature, while the Inte- gral Temperature Method is insensitive to these peaks because it averages the temperature dis- tribution, A.12 Film thickness equation The central EHD film thickness is based on the Doweon and Toyoda [5] equation: Dimensionless central film thickness: ANSVAGMA 2101-095 E036 089 aya where the following are dimensionless parameters: Me 06 -(A.70) materials parameter, G G ab, AT ‘speed parameter, U v= Be any load parameter, W w = Xpta ATO) & _ ispressure — viscosity coefficient, (mm?/N) ranges from 0.726102 mm2N to 2.910% mmZN for typical gear lubri- cants. Data for pressure — viscosity coeff- cients versus temperature for typical gear lubricants is given in figure A.11. It has been based on data given in reference [13]. He ISabsolute viscosity, cP. Figure A.12 gives average values of viscosity versus tem- perature for typical mineral gear olls with a viscosity Index of 95. It has been adapted from reference [12]; {tis important that the film thickness calculation be mado using values of viscosity and pressure — vis- cosity coefficients that correspond to the gear bulk temperature, ‘The central film ness is given by: fe = Hen (A860) ‘Tho specific film thickness [17] is given by: -(A81) where © Iscomposite surface roughness glven by: = (012 + ofS o(A82) L isthe filter cutoff wavelenulh used in mea suring surface roughness. Ideally, the cutoff wavelengths of the surface meas- uring instrument should be comparable to the width of the Hertzian contact band, 2y. However, this may not be practical because many surtace meas- uring instruments have fixed cutotf wavelengths (usually 0.8 mm), 51 WS 0L87575 0003808 986 mm nufacturers AssociationANSVAGMA 2101-C95, AMERICAN NATIONAL STANDARD 2.90 | = e Zz = 250 £ 2 pas 3 = 2.00 5 € a5 Te AGMA TUBENO. 8 175 + z i g 5 mL. 29600 é 4.00 087 "a 20 3040606070 80 80 100 110120130 140 150 160 170 Bulk temperature, (°C) Figure 8.11 ~ Pressure-viscostty coefficient versus temperature "9383 600 400 200 F100 S180 2 00 : 40 @ 20 $s 8g 2 10 8 6 44 3 40~C«CCSCSCHSCHSC«RO Buk temperature, (°C) Figure A.12— Absolute viscosity versus temperature 52 mH 0087575 0003809 812 mm Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011AMERICAN NATIONAL STANDARD AA3 Wear risk evaluation Inthe boundary lubrication regime, some wear is in- evitable. Many gears, because of practical liits on lubricant viscosity, speed and temperature, must ‘operate under boundary lubricated conditions. Mild adhesive wear oocure: during running-in and usually subsides with time, resulting in a tolerable wear rate anda satisfactory lifetime forthe gearset. The wear that occurs during running-in may be beneficialif it smoothes the tooth surfaces (increas- ing the epecific film thickness) and increases the area of contact by removing minor imperfections through looal wear. The amount of wear thatistoler- able depends on the expected lifetime for the gear- set, and on requirements forthe control of noise and vibration. The wear rate may become excessive if the tooth profiles are wornto the extent that high dy- namic loads are encountered. Excessive wear may also be caused by contamination ofthe lubricant by abrasive particles. When woar becomes aggres- sive andis not preempted by sculfing (orbendingfa- tigue), wear and pitting will ikely compete for the predominate failure mode. ‘The boundary lubrication regime consists of ex- 30 2.0 a £02 025 05 25 «6.0 ANSVAGMA 2101-C95 ceedingly complex interactions between the addi- tives in the lubricant, metal, and atmosphore mak- ing t impossible to assess accurately the chance of wear of scuffing from a single parameter such as the specific film thickness. However, the empirical data of figure A.13 has heen used as an approxi- mate guide to the probability of wear-related dis- tress. Figure A.13 is based on data published by Wellauer and Holloway [6] which were obtained from several hundred laboratory tests and field ap- plications. The curves of figure A.13 apply to through hardened steel! gears ranging in size from ‘25 mm to 4600 mm in diameter that were lubricated with mineral gear lubricants, The authors [6] defined tooth surtace distress as surtace pitting or wear which might be destructive or could shorten the ‘grardrive fe. Mostoofthe data of figure A.13 pertain 10 gears that experienced lives in excess of 10 mi lion cycles. The curves of figure A.13 were adjusted to reflect the root-mean-square surface rough- ess. Reference (6] used the arithmetic average to determine composite surface roughness. They were also adjusted by assuming that the minimum film thicknesses calculated by reference [6] were 76% of the values given by Eq A.80 [5] 5%. 40% 80% Probabilty of wear related distress. 25.0 60.0 "250.0 Pitch line velocity, m/s Figure A.19 - Probability of wear distress, percent @™ 0b87575 0003810 534 mm Copyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011| ANSI/AGMA 2101-C95 AMERICAN NATIONAL STANDARD Annex A References 1. Blok, H., Les temperatures de Surface dans les Conditions de graissage Sans Pression Extreme, Sec- e | ‘ond World Petroleum Congress, Paris, Juno, 1937. 2. Dowson, D., and Higginson, G. R., New Roller - Bearing Lubrication Formula, Engineering, (London), Vol. 192, 1967, pp. 158-159, . 9. Dowson, D., aid Higginson, G.R., Elastohydrodynamic Lubrication ~ The Fundamentals of Roller and Gear Lubrication, Pergamon Press (London), 1966. 4. Dowson, D. Elastohydradynamies, Paper No. 10, Proc., Inst. Mech. Engrs. Vol. 182, Pt. 3A, 1957, pp. 151-167. 5. Dowson, D., and Toyoda, S., A Central Film Thickness Formula for Elastohydrodynamic Line Contacts, 5th Leeds-Lyon Symposium Proceedings, Paper 11. (Vil), 1978, pp. 60-65. 6. Wellauer, E. J. and Holloway, G.A., Application af EHD Oil Film Theory to industrial Gear Drives. Trans ASME, J. Eng,, Ind., Vol 98,, series B., No 2. May 1976, pp 626-634. 7. Kelley, B.W., A New Look at the Scoring Phenomena of Gears, SAE trans, Vol. 61, 1953, pp 175-188. 8. Kelley, B.W., The Importance of Surface Temperature to Surface Damage, Chapter in Engineering Ap- proach to Surface Damage, Univ. of Michigan Press, Ann Arbor, 1958. 9. AGMA217.01, AGMA Information Sheet - Gear Scoring Design for Aerospace Spur and Helical Power Gears, October, 1965. 10. Benedict G. H. and Kelley B. W., Instantaneous Cooffioionts of Gear Tooth Friction, ASLE trans., Vol 4., 1961, pp 59-70. 11. Blok, H., The Postulate About the Constancy of Scoring Temperature, Interdisciptinary Approach to the Lubrication of Concentrated Contacts, NASA SP-237, 1970, pp. 153-248. 12, Neale, M. J., Tribology Handbook, Butterworths, (London), 1973. 13. Mobil Oil Corporation, Mobil EL Guidebook, 1979. 14. Winter, H., and Michaelis, K., Scoring Load Capacity of Gears Lubricated with EP-Oils, AMA Paper No. P219.17, October, 1983. 15. Blok, H., The Thermal-Network Method for Predicting Bulk Temperatures in Gear Transmissions, Proc. 7h Round Table Discussion on Marine Reduction Gears held in Finspong Sweden, 9-10 September 1969 16. BlokH., Thermo-Tribology — Fifty Years On, keynote address to the Int. Conf. Tribology; Friction, Lubri- calion and Wear — 50 Years On, Inst. Mech. Engrs., London, 1-3 July 1987, Paper No. C 248/67. 17. Moyer, C.A., and Bahney, LL, Modifying the Lambda Ratio to Funotional Line Contacts, STLE Preprint No. 89-TC-6A-1, pp. 1-7. 54 MH 0687575 0003811 470 mm Copyright by the American Gear Manufacturers Asovaton Wed May 18 0949.24 2011Copyrigh by the American Ges Wed May 18 0949.24 2011 AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95 Annex B (informative) Rim thickness factor, Ke ‘This annexis for Information only and should not be construed to be apart of ANSVAGMA 2101-095 Fundamental rating fectors and calculation methods for involute epur and helical gear teeth. B.1 Purpose This annex provides a method for considering the effects of gear blank rim thickness on the load carry- ing capacity of the gear tooth. It is based on Drago’s! analysis of gear tooth bending fatigue strength. ‘This analysis shows that bending stresses in gear teeth are adversely affected when the rim thickness below the tooth root, tis relatively thin aa com- pared to the tooth height, . Drago's analysis con- sisted of photo elastic models where the resulting ‘ourves were extrapolated from a limited number of test samples at backup ratlos of 0.5 and 2.0 of greater. The study also included finite element analysie and data points from other research. A backup ratio of 2.0 indicated no effect on bending stress, but, an effect beganto occur somewhere bo. tween 1.0and2.0, The curve inthis annexis based ‘onthis analysis. But in view of the limited data, presented as two straight lines with a knee at 1.2. ‘The knee wae established based on experience of manufacturero who have successfully operated gears at rated loads with this backup ratio. The rim thickness factor, Kp, ie not sufficiently con- servative for components with notches, hoop ‘stresses or keyways. This is based on data for ex- ternal gears with smooth bores and no notches or keyways. The concen with notches (such as splines) or Keyways In the bore of a gear is an increase in stress concentration which may lead 10 a fracture through the gearrim. Using large radiiinthe comers of the keyway (or spline) will help reduce the stress concentration and using a ductile (not britle) mato- rial with good fracture toughness will aloo help. An- atherconcemispress itingthe gear onto shaftas this will induce stresses in the gear rim. The amount of effect af all of these items is beyond the scope of this standard B.2 Rim thickness factor, Kp Where the rim thickness is not sufficient to provide {ull support forthe tooth roo, the location of bonding fatigue failure may be through the gear rim, rathor than at the tooth fillet. In such cases, the use of a stress modifying factor, Ka. is recommended, This factor, entitled rim thickness factor, Xp, adjusts the calculated bending stress number for thin immed gears. tt is @ function of the backup ratio, ‘mp, oF the ratio of the rim thickness below the tooth root, fe, 88 compared to the tooth whole depth. 4 ™ 1) tg isrim thickness below the tooth root, min; he — Iswhole depth, mm. Figure B.1 provides recommended values ot Kp for backup ratios above 0.5. The effects of webs or stif- eners can be an improvement but are not ao- ccountedifor. The effect of tapered rims has not been investigated, Ratios less than 0.5 require special analysis and Is beyond the scope of this standard. ‘When previous experience justifies, lower values of Kp may be used. The rimthickness factor, Ka. is applied in addition to the 0.70 reverse loading tactor where itis applicable (c00 16.2). 1) Drago, Rw. An Improvement in the Conventional Analysis of Gear Tooth Bending Fatigue Strength. AGMA P229.24, October 1982. 86 M@™ 0L87575 0003812 307 a nufacturers AssociationANSVAGMA 2101-C95 AMERICAN NATIONAL STANDARD 06 06 08 1.0 12 2 8 4 6 678910 Backup ratio, mg Figure B.1 — Rim thickness factor, Ke 56 M™ 0687575 0003823 243 ml pyright by the American Gear Manufacturers Assocation Wed May 18-0949:24 2011Copyrigh by the American Ges Wed May 18 0949.24 2011 AMERICAN NATIONAL STANDARD ANSVAGMA 2101-C95 Annex © (informative) Application analysis ‘This annexis for information only and should not be construed to be a part of ANSVAGMA 2101-C86 Fundamentat rating factors and calculation methods for invotute spur and helical gear teeth. C1 Purpose This annex discusses the use of factors of safety, overload factors, service factors and other considerations for geared systems. C.2 Background Many influence factors are used to determine the calculated load capacity of gears to account for various designe, manufacturing methods and uses of gears. Many of these factors have been ‘empirically developed from accumulated experi- ence. Therefore, tis critical that they be used inthe ‘manner otiginally intended. The influence factors are normally used as modifiersto eithera calculated stress from part configuration and applied load or ta an allowable stress number based on material properties. The gear designer can then compare tho modified calculated stress to the modified allowable stress numbor for a specific design. In any design it is critical to make allowances for unknown variables in materials, machining toler- ances, loading. ete. Various terms (factor of safely, sorvice factor, and overload factor) are used in the gear industry to describe this important concept. The designer, manufacturer, buyer, and user must all have a clear understanding of the meaning and implications of these terms when comparing gear capacity using different standards. The following definitions are glven to explain the differences between these terms as appled to gearing: €.3 Factor of safety The term “actor of safety" has historically been used in mechanical design to describe a general erating factor to limit the design stress in propor- tion to the material strength. A factor of safety accounts for uncertainties in — Design analysis — Material characteristics = Manufacturing quality Factor of safety also must consider human safety tisk and the economic consequences of failure, The greater the uncertainties or consequences of these considerations, the higher tho factor of safety should be. As the extent of these factors become known with more certainty, the value of the factor of safety can be more accurately determined. For ex: ample, a product such as an automobile transmis- slon which is subjected to ful size, full load proto- type testing and rigorous quality control of dimen- sions, materials and processes during mannufac- ture, could have a more precise safety factor than a hoist made in smal! quantities to normal commercial practices, ‘As design practices become more comprehensive, some influence factors have been removed from the unknown area of “safety factor” and introduced ‘3 predictable portions of the design method. The reliability factor, ¥z, is an example, NOTE: Factor of safety has alsobeen usedhistorically to account for uncertainties in “applied loading” or unknown overloads. In gear design, however, service factore or overload feotore have boan used for this uneartainty. C4 Overload factor ‘An overload factor makes allowance for any exter- nelly epplied loads in oxocss of the nominal trane- mitted load, Overload fectore are established only efter considerable field experience is gained. In do- termining the overload factor, consideration should be given to the fact that systeme develop momen- tary peek torques appreciably greater than those determined by the nominel ratings of the prime mover or driven equipment. Also, there are many possible sources of other overloads that should be considered, such as system vibrations, accelera tion torques, overspeeds, variations in system op- eration, split-path load sharing among muttiple prime movers, and changes in process applied load conditions. C5 Sorvice factor Aservice factoris traditionally appliedas.a mutiplier ofthe nominal application loadto determine catalog selections of pre-designed gear units. In AGMA {gear rating the service factor has been used to in- clude the combined ettects ot required ite cycles, ‘material reliability, and overloadfactorsin an empiri- cally determined single influence factor. The spe- cific mathematical contribution of each of these items has not been satisfactorily established. In ad- 87 BS OLS7575 OOOISLY 13T mm nufacturers Association