Professional Documents
Culture Documents
[Tables or other self--supporting sections may be referenced. Citations should read: See
AGMA 930--A05, Calculated Bending Load Capacity of Powder Metallurgy (P/M) External
Spur Gears, published by the American Gear Manufacturers Association, 500 Montgomery Street, Suite 350, Alexandria, Virginia 22314, http://www.agma.org.]
Approved January 19, 2005
ABSTRACT
This information sheet describes a procedure for calculating the load capacity of a pair of powder metallurgy
(P/M) external spur gears based on tooth bending strength. Two types of loading are considered: 1) repeated
loading over many cycles; and 2) occasional peak loading. In a separate annex, it also describes an essentially
reverse procedure for establishing an initial design from specified applied loads. As part of the load capacity
calculations, there is a detailed analysis of gear teeth geometry. These have been extended to include useful
details on other aspects of gear geometry such as the calculations for defining gear tooth profiles, including
various fillets.
Published by
ii
AGMA 930--A05
Contents
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Definitions and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Fundamental formulas for calculated torque capacity . . . . . . . . . . . . . . . . . . . .
4
Design strength values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Combined adjustment factors for strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Calculation diameter, dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Effective face width, Fe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Geometry factor for bending strength, J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Combined adjustment factors for loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
1
1
3
4
6
7
8
8
9
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Annexes
A
B
C
D
E
F
G
13
27
37
39
44
46
50
Tables
1
2
3
iii
AGMA 930--A05
Foreword
[The foreword, footnotes and annexes, if any, in this document are provided for
informational purposes only and are not to be construed as a part of AGMA Information
Sheet 930--A05, Calculated Bending Load Capacity of Powder Metallurgy (P/M) External
Spur Gears.]
This information sheet was prepared by the AGMA Powder Metallurgy Gearing Committee
as an initial response to the need for a design evaluation procedure for powder metallurgy
(P/M) gears. The committee anticipates that, after appropriate modification and
confirmation based on application experience, this procedure will become part of a standard
gear rating method for P/M gears. As such, it will serve the same function for P/M gears as
the rating procedure in ANSI/AGMA 2001--C95 for wrought metal gears. Toward this end,
the design evaluation procedure described here closely follows ANSI/AGMA 2001--C95,
with changes made for the special properties of P/M materials, gear proportions, and types
of applications. These design considerations have made it possible to introduce some
simplifications in comparison to the above mentioned standard.
The first draft of AGMA 930--A05 was made in June 1996. It was approved by the AGMA
Technical Division Executive Committee in January 2005.
Suggestions for improvement of this document will be welcome. They should be sent to the
American Gear Manufacturers Association, 500 Montgomery Street, Suite 350, Alexandria,
Virginia 22314.
iv
AGMA 930--A05
ACTIVE MEMBERS
T.R. Bednar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T.R. Bobak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Bobby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.A. Crawford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J.A. Danaher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F. Eberle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S.T. Haye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T.M. Horne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K. Ko . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I. Laskin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.D. Osti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Reiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J.T. Rill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R. Rupprecht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Serdynski . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Wallis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AGMA 930--A05
vi
AGMA 930--A05
1 Scope
1.1 General
1.1.1 Calculation
This information sheet describes a procedure for
calculating the load capacity of a pair of powder
metallurgy (P/M) gears based on tooth bending
strength. Two types of loading are considered: 1)
repeated loading over many cycles; and 2) occasional peak loading. This procedure is to be used on
prepared gear designs which meet the customary
gear geometry requirements such as adequate
backlash, contact ratio greater than 1.0, and adequate top land. An essentially reverse procedure for
establishing an initial design from specified applied
loads is described in annex D.
1.1.3 Application
This procedure is intended for use as an initial
evaluation of a proposed design prior to preparation
of test samples. Such test samples might be
machined from P/M blanks or made from P/M tooling
based on the proposed design after it passes this
initial evaluation. Final acceptance of the proposed
design should be based on application testing and
not on these calculations. If samples made from
AGMA 930--A05
2.2 Symbols
The symbols and terms used throughout this information sheet are in basic agreement with the
symbols and terms given in AGMA 900--G00, Style
Manual for the Preparation of Standards, Information Sheets and Editorial Manuals, and ANSI/AGMA
1012--F90, Gear Nomenclature, Definitions of Terms
with Symbols. In all cases, the first time that each
NOTE: The symbols and definitions used in this information sheet may differ from other AGMA documents.
The user should not assume that familiar symbols can
be used without a careful study of their definitions.
Terms
Operating center distance
Gear pitch diameter
Operating pitch diameter of gear
Operating pitch diameter of pinion
Calculation diameter
Modulus of elasticity
Effective face width
Overlapping face width
Each face width extension, not larger than m
Effective face width extension at one end
Effective face width extension at other end
Factor relating to axis misalignment adjustment
Factor relating to manufacturing variations adjustment
Whole depth of gear teeth
Geometry factor for bending strength
Geometry factor for bending strength under repeated loading
Geometry factor for bending strength under occasional peak loading
Rim thickness factor
Stress concentration factor used in calculating bending geometry factor,
J
Stress correction factor for repeated loading
Stress correction factor for occasional overloads
Life factor
Load reversal factor
Life factor at 0.5 104 cycles
Load distribution factor for repeated loading
Load distribution factor for occasional overloads
Overload factor for repeated loads
Overload factor for occasional overloads
Reliability factor
Size factor
Temperature factor
Combined adjustment factor for bending fatigue strength
Combined adjustment factor for repeated tooth loading
Dynamic factor
Yield strength factor
Units
mm
mm
mm
mm
mm
N/mm2
mm
mm
mm
mm
mm
-- --- -mm
-- --- --- --- --- ------------------
-----------------
Reference
Eq 24
Eq 37
Eq 25
Eq 24
Eq 1
Eq 38
Eq 1
Eq 26
Eq 27
Eq 26
Eq 26
Eq 36
Eq 37
Eq 32
Eq 28
Eq 1
Eq 2
Eq 31
8.2
Eq 29
Eq 30
Eq 12
Eq 12
Eq 13
Eq 31
Eq 40
Eq 31
Eq 40
Eq 12
Eq 12
Eq 12
Eq 1
Eq 1
Eq 31
Eq 21
(continued)
AGMA 930--A05
Table 1 (concluded)
Symbol
Kys
Kyw
kut
m
mB
mct
mcy
mw
NG
NP
n
nu
qm
qv
Sb
SF
st
stG
stT
stTG
suG
suM
suT
suTG
sy
syG
syM
syT
syTG
Tt
Ty
tR
VqT
vt
Y
Terms
Combined adjustment factor for yield strength
Combined adjustment factor for occasional peak loading
Conversion factor for ultimate strength to fatigue limit
Module
Backup ratio
Modifying factor due to tooth compliance for repeated loading
Modifying factor due to tooth compliance for occasional overloads
Modifying factor due to tooth surface wear
Number of teeth of gear
Number of teeth of pinion
Number of tooth load cycles
Number of units for which one failure will be tolerated
Adjustment due to axis misalignment
Adjustment due to manufacturing variations
Bearing span
Safety factor for bending strength
Design fatigue strength
Fatigue limit, full reversal, adjusted for G--1 failure rate
G--10 failure rate fatigue limit (published data)
Adjustment in fatigue limit from G--10 to G--1
Ultimate tensile strength, adjusted for G--1
Minimum ultimate strength listed in MPIF Standard 35
Typical ultimate strength (published data)
Reduction in ultimate strength from typical to G--1
Design yield strength
Yield strength, adjusted for G--1
Minimum yield strength listed in MPIF Standard 35
Typical yield strength (published data)
Reduction in yield strength from typical to G--1
Torque load capacity for tooth bending under repeated loading
Torque load capacity under occasional peak loading
Rim thickness
Tooth--to--tooth composite tolerance (or measured variation)
Pitch line velocity
Tooth form factor
Units
-- --- --- -mm
-- --- --- --- --- --- --- --- --- --- -mm
-- -N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
Nm
Nm
mm
mm
m/s
-- --
Reference
Eq 2
Eq 2
Eq 5
Eq 1
Eq 32
Eq 35
Eq 41
Eq 35
Eq 24
Eq 24
Eq 14
Eq 20
Eq 35
Eq 35
Eq 36
Eq 31
Eq 1
Eq 3
Eq 3
Eq 3
Eq 9
Eq 10
Eq 5
Eq 9
Eq 2
Eq 6
Eq 7
Eq 6
Eq 6
Eq 1
Eq 2
Eq 32
Eq 39
Eq 39
Eq 28
AGMA 930--A05
s t K ts d c F e J t m
2000 K tw
(1)
where
Tt
is torque load capacity for tooth bending under repeated loading, Nm;
st
Kts
dc
Fe
Jt
is geometry factor for bending strength under repeated loading (see clause 8);
is module, mm;
Ty =
s y K ys d c F e J y m
2000 K yw
(2)
where
Ty
sy
factor
for
Such data for P/M materials generally meet condition (a) of 4.1.2, but not conditions (b) and (c). Values
called typical generally refer to test results with
50% of the specimens falling below and 50% above
the published value. This corresponds to a G--50
failure rate, also known as mean fatigue life.
Data published by the Metal Powder Industries
Federation (MPIF) [1] has been determined as the
90% survival stress fatigue limit, using rotating
bending fatigue testing. This fatigue limit data is also
known as the G--10 failure rate fatigue life.
Rotating bending fatigue testing imposes load
cycling of full--reversal loads. The critical location on
the test specimen is subjected to the maximums of
both tensile and compressive stresses.
Adjustments to meet the conditions of 4.1.2(b) and
(c) are expressed in the following equations:
(3)
s tG = s tT s tTG
where
stG
stT
s tG
0.7
(4)
(5)
kut
where
suT
AGMA 930--A05
(6)
where
syT
steel
(martensitic
kut = 0.32
For as--sintered steel (pearlite and ferrite microstructure):
kut = 0.39
For as--sintered
microstructure):
steel
(ferrite
only
kut = 0.43
Then convert this estimated G--10 failure rate fatigue
limit, stT, to the design fatigue limit for zero--to
maximum loading using equations 3 and 4.
(7)
where
syM is minimum yield strength listed in MPIF
Standard 35, N/mm2.
The design yield strength is then set equal to this
adjusted yield strength:
s y = s yG
(8)
AGMA 930--A05
(9)
(10)
where
suM is minimum ultimate strength listed in
MPIF Standard 35, N/mm2.
The design yield strength is then set equal to this
adjusted ultimate strength:
s y = s uG
(11)
K L K LR
Ks KT KR
where
KL
is life factor;
where
suT
Ks
is size factor;
KT
is temperature factor;
KR
is reliability factor.
(12)
K L = K Ly =
0.9 s y
st
(13)
K L = 1 + 2.121 K Ly 1
0.303 K Ly 1 log n
(14)
(16)
(17)
(22)
(23)
(19)
(20)
where
nu
AGMA 930--A05
Some values from this equation, along with equivalent G values, are given in table 2.
Ky
Ks KT
(21)
where
Ky
Ks
KT
6 Calculation diameter, dc
The calculation diameter, as used in equations 1 and
2, must agree with the diameter value used in
calculating the Y factor, see annex B. For spur gears,
it is the same as the operating pitch diameter of the
gear for which the torque capacity is to be calculated.
Its value depends on the relative numbers of teeth
and the operating center distance and may be, but is
not necessarily, equal to the standard pitch diameter,
as follows:
nu units
10,000
1,000
100
Equivalent G--value
G--0.01
G--0.10
G--1.00
KR
1.50
1.25
1.00
AGMA 930--A05
where
2 CA
N
1+ G
NP
(24)
Fx
is module, mm.
where
dAP is operating pitch diameter of pinion, mm;
CA
NP
NG
2 CA
N
1+ P
NG
(25)
(28)
where
where
dAG is operating pitch diameter of gear, mm.
(26)
Fo
Fx
Fx
2m
Kf
F xe = 1
where
Fe
(27)
(29)
where
Kft
(30)
where
Kfy
(31)
where
SF
Kot
KB
Kmt
Kv
AGMA 930--A05
AGMA 930--A05
(32)
For mB 1.2
(33)
For mB <1.2
K B = 1.2916 3.682 log m B
-- misalignment of the gear axes due to manufacturing variations in the geometry of the housing,
bearings, shafts, and any other support features;
-- manufacturing variations in the geometry of the
tooth surfaces, such as axial runout (wobble) or
non--uniform tooth thickness across the face
width.
The effect of these items on non--uniform load
distribution increases with the face width of the
mating gears. In the case of gear axis misalignment,
the size of the face width in relation to the bearing
span is often significant. In the case of tooth surface
geometry, the manufacturing variations tend to
increase as face width becomes larger in relation to
gear diameter.
The common items that tend to improve load
distribution are:
KB = 1
where
tR
ht
(34)
qm
qv
mct
mw
10
(35)
AGMA 930--A05
q m = f qm
Fo
Sb
(36)
where
Typical AGMA
accuracy grade1)
Q5
Q6
Q7
Q8
Q9
Q10
fqv
1.0
0.75
0.6
0.4
0.3
0.2
NOTE:
1) See AGMA 2000--A88.
Fo
Sb
fqm
fqm = 0.1
For machined metal housing with straddle
mounted sleeve bearings:
sE
m ct = 1 5
0.5
(38)
where
fqm = 0.2
For machined metal housing with overhung
mounted sleeve bearings:
st
E
fqm = 0.5
fqm = 0.6
For as--cast or molded housing with overhung mounted sleeve bearings:
fqm= 1.0
9.1.4.2 Manufacturing variations adjustment, qv
This factor considers that P/M process variations
from ideal gear geometry are influenced by gear
proportions. This influence is expressed, for the
sake of simplicity, in terms of the ratio of face width to
pitch diameter. It also recognizes that gear geometry
may be substantially improved by a final finishing
process.
q v = f qv
Fo
d
(37)
where
Fo
fqv
11
AGMA 930--A05
Kv
0.5
(39)
where
VqT is tooth--to--tooth composite tolerance (or
measured variation), mm;
vt
is pitch line velocity, m/s.
9.2 Combined adjustment factor for occasional
overloads, Kyw
K yw = S F K oy K B K my K v
SF
Koy
KB
Kmy
12
(41)
(40)
where
is dynamic factor.
sE
m cy = 1 5
0.5
(42)
where
sy
AGMA 930--A05
Annex A
(informative)
Calculation of spur gear geometry features
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
A.1 Introduction
-- number of teeth, N;
-- outside diameter, dO;
-- tip radius, rr;
tO
tOR
rr
tOE
dOE
rC
drC
-- module, m;
-- pressure angle, .
d rC = d O 2r r
(A.1)
13
AGMA 930--A05
(A.2)
(A.3)
dB
d rC
(A.4)
OE = arctan tan rC +
2r r
dB
(A.5)
dB
cos OE
(A.6)
(A.7)
-- dedendum, bBR;
-- fillet radius, rfBR.
14
(A.9)
b BR = 0.5 Nm +
t t BR
dR
tan
(A.10)
C
L Tooth
AGMA 930--A05
C
L Space
p BR
2
gfBR
Nominal
pitch line
Generating
pitch line
t BR
2
BR
G
Gy
hfBR
yRS
hyfBR
bfBR
bBR
Start of fillet
radius curve
rfBR
H
Figure A.2 -- Generating basic rack
The third data item, basic rack fillet radius, can not be
determined from other data but must be independently specified, as noted in A.2.2. The radius may
be zero, indicating a sharp corner, but is almost
always a greater value, up to one--fourth of the basic
rack dedendum or even larger. However, it may not
exceed the size of the full round radius. A full round
basic rack fillet will produce a full round gear fillet,
leaving no part of a root circle between joined fillets.
This maximum basic rack fillet radius is:
mcos
b BR(sin )
4
r fBRX =
1 (sin )
(A.11)
(A.12)
t BR
r
+ b BR r fBR(tan ) + fBR
cos
2
(A.13)
H axis coordinate (measured from the G--axis located at the nominal pitch line):
h fBR = b BR r fBR
(A.14)
15
AGMA 930--A05
Rack shift:
y RS =
t t BR
2(tan )
(A.15)
(A.16)
(A.17)
Basic rack
Generating
pitch line on
basic rack
(A.19)
Basic rack
f = 90
(A.18)
rfBR
Generating
pitch line on
basic rack
f =
Pitch point
rfBR
Generating
circle on gear
Start of trochoid
at root circle
(point R)
(a) Start of trochoid at root circle
End of trochoid
at involute
(point F)
Generating
circle on gear
(b) End of trochoid at involute
16
AGMA 930--A05
f1 = fR = 90
(A.20)
fn = fF =
(A.21)
f =
f1 n f k + fn( k 1 )
nf 1
(A.22)
for (k = 1 to nf)
where
nf is number of points along the fillet.
h yfBR
sin f
+ r fBR
(A.23)
hyfBR
fR
Pitch point
Y
rfBR
Basic rack
Point on
trochoid
X
Gear center
Generating
circle on
gear
Generating
pitch line on
basic rack
17
AGMA 930--A05
hyfBR
fR
Pitch point
d
2
f
2
gfBR
Basic rack
C
L
(vf, f)
See fig A.4(c)
X
Generating
circle on gear
Gear center
Generating
pitch line on
basic rack
Y
Point on
trochoid
xf
Basic
rack
Gear center
yf
X
vf
18
2 g fBR +
f =
h yfBR cos f
sin f
radians (A.24)
cos f
1
NOTE: sin f is used in place of tan f to permit evaluation for f = 90.
vf =
d
2
+ f d fsin f
f cos f
f = f arcsin
vf
(A.25)
radians
(A.26)
AGMA 930--A05
(A.27)
y f = v fsin f
(A.28)
h yfBR
0.5 d + h yfBR
+ r fBR
(A.29)
dfc
Space
centerline
dR
sR
fC
f
(xfC, yfC)
F
rf
(xf, yf)
fC
F
dF
X
Tooth centerline
Figure A.5 -- Circular arc fillet
19
AGMA 930--A05
d2 d2
B
4d R
BTff =
+ d R (inv )
N dB
(A.31)
20
(A.32)
sev = sevolute =
1 inv
cos
(A.33)
dB
cos bC
(A.34)
(A.35)
AGMA 930--A05
s R = d R fC
N
(A.44)
(A.36)
fC = arccos
dB
d fC
(A.37)
(A.38)
2r f
fC = + (inv ) inv fC +
dB
(A.39)
x fC = fCcos fC
(A.40)
y fC = fCsin fC
(A.41)
2r f
dB
(A.42)
fR = fC
dB
cos F
(A.47)
(A.48)
for k = 1 to nf
where
nf
(A.45)
f =
d fC
2
F = arctan tan fC
F = + (inv ) inv F
(A.43)
x f = x fC r f cos f
(A.49)
y f = y fC r f sin f
(A.50)
21
AGMA 930--A05
ds
2
d
2
(xs, ys)
ts
2
s
2
t
2
inv
Base
circle Standard
pitch circle
Figure A.7 -- Tooth profile data
Step 1. Roll angles at the form and effective outside
diameters, which correspond to the start and end
points.
F = tan arccos
dB
dF
d
OE = tan arccos B
d OE
(A.51)
(A.52)
F n i i + OE( i 1 )
ni 1
(A.53)
(A.54)
dB
cos i
(A.55)
22
di
cos i
2
d
y i = i sin i
2
xi =
(A.57)
(A.58)
NOTE: The coordinates at the i = 1 point should correspond exactly with the coordinates of the j = nj point on
the fillet, except for undercut trochoids, as noted in
A.6.2.
(A.59)
(A.56)
F 0
(A.60)
AGMA 930--A05
s = arccos
(A.61)
where
d AG =
2C A
d
1 + BG
d BP
(A.67)
2C A
d
1 + BP
d BG
(A.68)
is
the
selected
(d F d s d OE).
diameter
and
(A.62)
ts = ds s
ds
cos s
2
(A.64)
ys =
ds
sin s
2
(A.65)
A = arccos
d BP + d BG
2C A
(A.66)
(A.69)
(A.70)
(A.71)
23
AGMA 930--A05
Base circle
(gear)
GEAR (driven)
dAG
dBG
Operating
pitch circle
(gear)
P
pitch
point
dOEG
Line of
action
dOG
Approach action:
points 1 to P
Recess action:
points P to 4
4
3
2
1
dOP
pB
dOEP
dBP
dAP
Operating
pitch circle
(pinion)
Base circle
(pinion)
1P = A 1 +
N
NG
OEG G
NP
NP
(A.72)
(A.73)
NP
NG
4G = A
(A.77)
2G = 4G + G
N
N
1 + P OEP P
NG
NG
24
NG
NP
G = 2
NG
(A.78)
(A.74)
(A.76)
2P = 4P P
P = 2
NP
(A.79)
(A.80)
3G = 1G G
(A.81)
AGMA 930--A05
d iP =
d BP
(A.82)
cosarctan iP
d iG =
d BG
(A.83)
cosarctan iG
--
AP 1P
P
(A.84)
4P AP
P
(A.85)
(A.86)
Definition
Basic rack dedendum (for generated trochoid fillet)
Basic rack form dedendum
Effective operating center distance
Standard pitch diameter
Operating pitch diameter, pinion, gear
Base circle diameter
Diameter at center of full--fillet radius fillet
Form diameter
Diameter of gear center circle going through fillet center
Diameter at contact point
Limit diameter
Outside diameter
Effective outside diameter
Root diameter (for circular--arc fillet)
Diameter at center of tip round
Coordinate along G--axis
Coordinate along H--axis (measured from G--axis)
Coordinate along H--axis (measured from Gy--axis)
Module
Profile contact ratio
Units
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
-- --
Where
first used
A.2.2
A.4.1.2
A.2.3
A.3.1
A.7.2
A.3.1
A.5.2
A.5.4
A.5.3
A.8.2
A.8.3
A.2.2
A.3.1
A.2.2
A.3.1
A.4.1.2
A.4.1.2
A.4.2
A.2.1
A.8.4
25
AGMA 930--A05
Symbol
mpa
mpr
-- --
A.8.4
Number of teeth
-- --
A.2.2
nf
-- --
A.4.4
ni
-- --
A.6.1
RfN
mm
A.4.6
rf
mm
A.2.2
rfBR
mm
A.2.2
rfBRX
mm
A.4.1.1
rfN
mm
A.5.1
rfx
mm
A.5.2
rr
Tip radius
mm
A.2.2
sR
Bottom land
mm
A.5.5
mm
A.2.2
tBR
mm
A.4.1.1
tOR
mm
A.3.2
xfC, yfC
mm
A.5.3
yRS
Rack shift
mm
A.4.2
radians
A.3.2
radians
A.4.5
Pitch angle
radians
A.8.1
radians
A.8.1
radians
A.6.1
radians
A.4.5
OE
radians
A.6.1
radians
A.5.6
degrees
A.4.3
fC
radians
A.5.3
fF
degrees
A.4.3
fR
degrees
A.4.3
f
f
mm
A.4.5
mm
A.4.5
fC
mm
A.5.3
degrees
A.5.6
fF
degrees
A.5.6
fR
degrees
A.5.6
Pressure angle
degrees
A.2.1
bC
degrees
A.5.2
degrees
A.7.1
fC
degrees
A.5.3
OE
degrees
A.3.1
rC
radians
A.3.1
radians
A.5.4
26
Units
-- --
Where
first used
A.8.4
Definition
Approach portion of profile contact ratio
AGMA 930--A05
Annex B
(informative)
Calculation of spur gear factor, Y
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
B.1 Introduction
Tangential
tooth force, WA
B.1.1 Description
The form factor is a quantity that relates gear tooth
geometry to the capacity of the gear tooth to resist
the bending moment developed by the load applied
to the tooth. It deals only with geometry (mostly tooth
geometry, but also some aspects of gear mesh
geometry) without reference to material properties.
The role of stress concentration, which is influenced
by other factors in addition to tooth geometry, is
treated separately in bending strength calculations,
see clause 8 and annex C.
B.1.2 Definition
The definition given here relates to the definition
used in other AGMA literature. See reference 3.
This permits the comparison of form factor values as
calculated from the procedures described here with
values from the other AGMA sources.
The form factor for a gear tooth of specified outline is
the ratio of a force to a stress. When the gear
geometry is expressed in terms of unit module and
unit face width, this ratio becomes a non--dimensional quantity. The force referenced in this definition is
described below. The stress in the definition is the
bending stress at the critical section of the gear tooth
fillet. This section is located where the bending
stress is determined to be at a maximum.
Torque transmitted by a gear may be represented by
a tangential force acting at a selected radius. It is
common practice to select the radius of the operating
pitch circle. This circle derives from the view of the
gear and its mate as contacting cylinders which roll
without slipping with a speed ratio equal to the gear
ratio. See figures A.8 and B.1.
The tangential force, WA, calculated from the transmitted torque and the radius, 0.5 dA, is used as the
force in the form factor definition. The force acting at
the contact tooth surfaces differs from the force in
location and direction, as discussed below in B.2.3.1
and B.2.6.2.
Transmitted
torque, T
WA = 2 T
dA
Operating pitch
diameter, dA
27
AGMA 930--A05
Tooth
load
Critical
section
Stress
distribution
Tension
Combined stress
Stress concentration
Bending stress
at fillet
Compression
28
The critical load is the load (on the tooth flank) which
will produce the maximum tensile stress at the root
fillet. The factors which determine this critical load
are the direction of the load relative to the tooth
outline and the location of the load along the tooth
outline . The relationship between the magnitude of
this load, Wc, and the transmitted torque is described
in B.2.6.2 and B.3.6.
B.2.3.1 Load direction
The load direction is determined first by the geometry of the active portion of the tooth flank, here
understood to be an involute curve associated with
the base circle of the gear. Under certain operating
conditions common in P/M gear applications, the
sliding action between the mating gear teeth will
influence the load direction.
B.2.3.1.1 Load force normal to tooth flank
The direction of the load transmitted between gear
teeth is normal to the involute surface of the tooth
flank. If a circle (with its center at the gear axis) is
drawn through the load point, the angle between this
normal and a tangent to this circle is the involute
pressure angle, Wc, at that point. As a normal to the
involute, this direction is also tangent to the gear
base circle. See figure B.3.
This load force direction is assumed in AGMA rating
calculations. It is also used in the first set of
calculations below. See figure B.4.
AGMA 930--A05
Base circle
The AGMA gear rating calculation [3] is properly
used only for those operating conditions in which
some approximation of ideal lubricating conditions
exist.1) These operating conditions include an
adequate supply of clean lubricant at the gear teeth,
an adequate pitch line velocity, and tooth surface
geometry accurate enough to permit a well distributed contact area. When these conditions are met, a
film of lubricant is forced into the tooth contact area at
a pressure which nearly or completely separates the
contacting surfaces. The resulting friction force is
then small enough to be ignored in the gear bending
strength calculations. In many gear applications,
and especially in P/M gears with low material density
and without sealing of the pores, a full complement of
at dOE
(see B.2.3.2.1)
Tangency
dWc
Base
circle
radius, rB
at HPSTL
(see B.2.3.2.3)
Radial
line
a) No friction, normal force only,
alternate locations
Resultant
force
Normal force
c
_______________________
1) The lubrication port ion of the application clause states, The ratings determined by these formulas are only valid when
the gear teeth are operated with a lubricant of proper viscosity for the load, gear tooth surface finish, temperature, and
pitch line velocity.
29
AGMA 930--A05
Compressive
load
Translated
load
Critical
load, Wc
Bending
load
Wc
dWc
Constant
stress
parabola
hfc
Wc
Radial
line
Critical
section
(xfc, yfc)
at critical fillet
wfc
30
(B.1)
(B.2)
AGMA 930--A05
and
d WcG = d 2G
(B.3)
(B.4)
and
d WcG = d 1G
(B.5)
(B.6)
where
Wc
Wc
(B.7)
yWc
Wcy
Wc
Wc
Wc
Wcx
hfc
xWc
xWcC
sBS
st
wfc
sCS
Wc
(B.8)
where
Wc
31
AGMA 930--A05
W cx = W c sin Wc
(B.9)
32
(B.11)
Bending Moment
Section Modulus
hf
(B.12)
wf2
hf
wf2
(B.13)
(B.10)
s BS
h
= 6 cos Wc f2 = 6cos Wc [BT ]
Wc
wf
(B.14)
where
[BT ] =
hf
wf2
(B.15)
AGMA 930--A05
1
6cos Wch fc
w fc 2
sin
w Wc
fc
(B.19)
h fc
(B.16)
w fc 2
s CS = W c
The combined tensile stress is the difference between the bending tensile and the compressive
stresses, see figure B.6:
h fc
w fc
Wc
sin Wc
w fc
(B.18)
cos A
6cos Wc
h fc
w fc
(B.21)
sin Wc
w fc
s t = 6W c cos Wc
(B.17)
w fc
WA
d
= B = cos A
Wc
dA
(B.20)
sin Wc
Adjustment ratio, m cA =
A WsA
m
(B.22)
33
AGMA 930--A05
(B.23)
34
AGMA 930--A05
Table B.1 -- Selection of critical load location points for Y--factor calculation under friction
conditions
Gear to be
evaluated
Tooth--to-tooth
accuracy
level
Driver
Both driver
and driven
meet or exex
ceed Q8
requirements
Either driver or driven
do not
meet or exceed Q8
requirements
Driven
Critical
load
location to
be
evaluated
(see A.8.1)
Sign of c
in equation B.23
for 2nd
location
evaluation
Effect of
action on
bending
stress
Sign of c
in equation B.23
3P A
Approach
Reduces
NA
3P > A
Recess
Increases
--
NA
4P A
Approach
Reduces
NA
4P > A
Recess
Increases
--
NA
2G > A
Approach
Reduces
2G A
Recess
Increases
--
1G > A
Approach
Reduces
1G A
Recess
Increases
--
2nd
location
to be
evaluated1)
Point 3
Point 4
Both driver
and driven
meet or exex
ceed Q8
requirements
Either driver or driven
do not
meet or exceed Q8
requirements
Pitch point
--
Point 2
NA
Pitch point
--
Point 1
NA
NOTE:
1)
If the evaluation point on the driver happens to be in approach zone, then the secondary calculation is not required for
the driven gear since the recess condition will not be present near the pitch point.
of
Y--factor
for
friction
(B.24)
where
c
35
AGMA 930--A05
cos Wc + c
d
WA
= Wc cos Wc + c
Wc
dA
cos A
=
cos Wc
where
dA
B.4 Symbols
(B.25)
36
Definition
Form factor force--stress ratio
Diameter at critical load location
Highest point at which full load is transmitted by single pair
Bending stress factor
Maximum bending stress factor
Height of translated load force above fillet section
Module
Tooth force adjustment ratio
Bending tensile stress at fillet section
Compressive stress
Combined tensile stress
Tangential force acting at operating pitch circle
Critical load
Force component parallel to tooth axis
Force component normal to tooth axis
Width of fillet section
Distance from gear center of translated critical tooth force
Coordinates of critical load point
Non--dimensional Y--factor
Half tooth thickness angle
Load deviation angle
Direction angle of critical tooth force
Pressure angle at critical load point
Involute pressure angle
Coefficient of friction
Units
-- -mm
mm
-- --- -mm
mm
-- -N/mm2
N/mm2
N/mm2
N
N
N
N
mm
mm
mm
-- -degrees
degrees
degrees
degrees
degrees
-- --
Where first
found
B.2.6
B.2.3.2.2
B.2.3.2.3
B.2.4.2
B.2.4.3
B.2.4.2
B.2.7
B.2.6.2
B.2.4.2
B.2.5.2
B.2.5.3
B.2.6.2
B.2.3
B.2.3.4.2
B.2.3.4.1
B.2.4.2
B.2.3.3
B.2.3.3
B.2.7
B.2.3.3
B.3.2
B.2.3.3
B.2.3.3
B.2.3.1.1
B.3.2
AGMA 930--A05
Annex C
(informative)
Calculation of the stress correction factor, Kf
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
C.1 Introduction
The stress correction factor, Kf, which considers the
effect of stress concentration at the sharply changing
cross--section of the tooth at its root fillet, is another
component for determining the bending strength
geometry factor, J. The geometry element in stress
concentration is the curvature (radius) at the fillet in
relation to the overall tooth size and shape and the
location of the load. The calculation presented here
for this element is the Dolan and Broghamer method
as used in other AGMA gear rating calculations.
In calculating the influence of stress concentration
on gear tooth bending strength, elements other than
geometry must also be considered. These non--geometry elements are the type of loading (repeated or
occasional) and the material condition (degree of
ductility or brittleness). Together, they can influence
the long term sensitivity of the gear to the initial level
of stress concentration.
These elements are also considered in the AGMA
gear rating calculations. Their treatment here
follows a different format.
C.2 Elastic stress concentration factor, Kfs
This factor is based on the assumption of purely
elastic conditions in the material. The empirical
equation used in the calculation is derived from
photoelasticity experiments.
(C.1)
(C.2)
w
K fs = H + r fc
fc
w fc
h fc
(C.3)
where
H
= 0.331 -- 0.436 ;
= 0.324 -- 0.492 ;
= 0.261 + 0.545 ;
a) the actual effect of a notch (sharp change in outline) on the strength of a material; to
b) the effect that might be predicted solely on the
basis of elastic theory.
If the actual effect is represented by the stress
correction factor, Kf, and the elastic theory prediction
by the elastic stress concentration factor, Kfs, then
the notch sensitivity index, q, is defined as follows:
q=
Kf 1
K fs 1
(C.4)
37
AGMA 930--A05
Heat--treated
(brittle)
Repeated
0.5
1.0
Occasional
overload
0.0
0.8
38
(C.5)
Type of material
As--sintered
(ductile)
AGMA 930--A05
Annex D
(informative)
Procedure for initial design
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
D.1 Introduction
This information sheet is elsewhere devoted to
calculating bending load capacity for a completed
design of a pair of P/M gears. However, there is often
a need for a reverse of this process. For this, the
objective of a specified bending load capacity has
already been established. The required procedure
then consists of finding the design of the pair of P/M
gears which will meet this objective. This annex
describes such a design procedure. Like the other
parts of this information sheet, it is limited to
consideration of tooth bending strength and does not
deal with issues of wear or other potential limits on
gear performance.
The general method for this design procedure
consists of the following:
1) select the appropriate equation from clause 3,
which relates all the elements that determine
tooth bending torque capacity;
2) introduce a value for desired torque;
3) introduce an approximate strength value for the
selected material;
4) introduce estimated values for adjustment and
geometry factors;
5) using appropriate guidelines, establish relationships among the remaining geometric elements
in the equation: calculation diameter, effective
face width, and module;
6) assign preliminary values to these elements, applying appropriate rounding and preferred
values;
7) reevaluate this preliminary design by replacing
estimated values with those calculated by the
various procedures in this information sheet, to
arrive at a calculated load capacity;
8) for small differences between this load capacity
and the original specified load, introduce minor
changes to the design geometry;
9) for major differences between the two load values, use the newly calculated factors in place of
the original estimates and repeat the remainder
of this initial design procedure;
10)if the initial design dimensions exceed space limits or are otherwise inappropriate, repeat the process with a new material selection or other
changes in the basic selections.
D.1.1 Iterative design process
This design procedure can develop into an iterative
process. Design results from one set of calculations
may lead to changes which call for a new round of
calculations. As noted in step 9, initial simplified
design assumptions, when checked at design
completion, may prove to be significantly inappropriate, thereby requiring revision of some or all of the
design process. Also, as noted in step 10, an initial
design selection, such as the P/M material, may lead
to a design of gears which are simply too large, or
otherwise inappropriate, for the application. This will
require a new design selection and a new set of
design calculations.
D.1.2 Guidance from previous designs
Since the design process will make use of some
initial assumptions, it will be advantageous if these
assumptions can be based on data from previous
designs of P/M gears for similar applications. Where
such guidance is not available, the designer will be
able to use estimates provided in this annex.
However, as new designs are completed, some
results should replace the data calculated here.
Such changes will aid in future work.
D.2 Operating conditions
As with any gear design procedure, it is necessary to
start with information on the operating conditions
and associated performance requirements.
D.2.1 Loads
Two types of loading are considered in this information sheet, repeated loading and occasional peak
loading. When starting with completed gear designs, each has its own load capacity calculation
including separate strength properties for the selected material. It may not be obvious from the start
which load condition will control a new design. The
more common design control is from repeated
loading and this type of loading is given priority in the
39
AGMA 930--A05
40
(D.1)
(D.2)
(D.3)
(D.4)
(D.5)
d GX d PX m G
(D.6)
AGMA 930--A05
(D.8)
41
AGMA 930--A05
42
(D.9)
(D.10)
(D.11)
(D.12)
(D.13)
(D.14)
m1
= d c m Fm K RS
(D.15)
AGMA 930--A05
(D.16)
43
AGMA 930--A05
Annex E
(informative)
Calculation of inverse functions for gear geometry
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
E.1 Purpose
Some of the calculations in annex A refer to new
trigonometric functions, namely the involute function, defined in A.3.2 as:
inv = tan (where in radians) (E.1)
and the sevolute function, defined in A.5.2 as:
sev =
cos1 inv
(E.2)
13
0.374 I
(E.3)
(E.4)
Second approximation, 2:
2 = 1 +
I inv 1
tan 1
(E.5)
(E.6)
where
S
44
1 = 0.8 ( S 1 ) + 1.4 ( S 1 )
where
I
NOTE: This equation is suitable for values of the sevolute function up to 1.57. This corresponds to values of
the pressure angle approaching 90. A 45 angle is unlikely to be exceeded in any calculations for spur gears.
AGMA 930--A05
Exact angle
Degrees
Radians
8.2406242
0.1438260
10.3656916
0.1809154
14.0166548
0.2446368
17.5767722
0.3067725
21.9811018
0.3836426
29.3377203
0.5120398
36.1914219
0.6316595
44.1379468
0.7703525
55.8643701
0.9750172
64.8741619
1.1322677
Error (approximate
First
Second
--0.0001000
0.0000001
--0.0001088
0.0000001
--0.0000992
0.0000000
--0.0000585
0.0000000
0.0000250
0.0000000
0.0001291
0.0000000
--0.0002065
0.0000001
--0.0024506
0.0000121
--0.0182947
0.0007329
--0.0652677
0.0115850
Second approximation, 2:
2 = 1 + S sev 1 1 +
sin 1
(E.7)
For successive approximations, use equation E.7
after replacing 1 by the value of the angle found in
the prior approximation.
-- exact), radians
Third
Fourth
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
0.0000012
0.0000000
0.0003466
0.0000003
Exact angle
Degrees
Radians
2.60090125
0.04539429
3.70111645
0.06459667
5.92462045
0.10340413
8.49638966
0.14828997
12.25623610
0.21391167
20.16288171
0.35190867
29.83660174
0.52074694
45.05369301
0.78633528
81.87368867
1.42896544
45
AGMA 930--A05
Annex F
(informative)
Test for fillet interference by the tooth of the mating gear
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
F.1 Introduction
This annex is provided as an aid to the gear designer,
to be used to determine if interference at the fillet of
one gear by the tip of the tooth of the mating gear
exists.
Annex A provides means for calculating the point by
point shape of the fillet of a gear. This shape may be
a trochoid generated by the fillet of a generating
basic rack or it may be a circular--arc of specified
radius tangent to the root circle and to the involute
tooth flank.
This annex provides means for calculating the
nearby path, point by point, followed by the tip of the
mating gear tooth. Interference is indicated if the
combined graphical plot of the fillet and tip path
shows an overlap between the two curves. Clearance is indicated if there is a gap between the two
curves along their entire corresponding length. If the
fillet is a circular--arc, a calculation method showing
interference or clearance is provided, avoiding the
need for graphical plots.
F.2 Input data for the graphical plots
(F.1)
d MG = N MG m
(F.2)
(F.3)
pc = m
(F.4)
T = inv 1 (inv) +
46
2C
(F.5)
pc tG t MG
CT =
C (cos )
cos T
(F.6)
(F.7)
2 N G C AN
(F.8)
NG + NMG
d AMG =
2 N MG C AN
(F.9)
NG + NMG
A = arccos C
(cos )
C AN
(F.10)
Furthermore, the two gears will operate with backlash. Dealing with this backlash in the analysis is
avoided by adjusting the tooth thickness value in the
mating gear. This backlash adjusted tooth thickness
is:
t BMG = p c t G + 2 C inv A (inv)
(F.11)
Figure F.1 shows the two gears positioned without
any relative rotation, with the centerline of the mating
gear tooth space in line with the centerline of the
tooth of the gear. It also shows the tip radius of the
mating gear and its points of tangency to the
involute, point OEMG, and to the remaining top land,
point ORMG, also shown in figure F.2. The center of
the tip radius is located on the mating gear by its
radial distance from the gear center, rrCMG, and by its
angular location relative to the adjusted tooth
centerline, rCBMG. These may be calculated as
shown in A.3.1 and A.3.2. Using the new subscripts,
equations A.1, A.3, A.4, A.5, A.7 and A.8 become:
d rCMG = d OMG 2 r rMG
(F.12)
d BMG = d MG (cos )
(F.13)
AGMA 930--A05
rCMG = arccos
d BMG
d rCMG
t BMG
d MG
(F.14)
2 r rMG
d BMG
(F.15)
(F.16)
(F.17)
F.4 Path of tip of mating gear
In figure F.2, the gear is represented as fixed in
position while the mating gear is shown in a rotated
position. This arrangement is for convenience, since
the analysis is concerned with relative position only.
The figure also shows the pitch point, PP, the point
where the operating pitch circles of the two gears
come together. A line drawn from this pitch point
through the center of the tip radius, point RCMG,
establishes a point on the tip radius, point RMG. This
point becomes a point on the path of the tip of the
mating gear. This path is a curve made up from a
collection of such points, plotted as if they were fixed
on the gear and located near its fillet. These points
are similarly defined as the mating gear continues its
rotation around the gear.
F.4.1 Limits of the path
The end points of the path are defined by the end
points of the tip round on the mating gear, points
OEMG and ORMG, shown in figure F.2. For each
point, the corresponding path point appears when
the mating gear has rotated until the pitch point is
correspondingly positioned. At this position, a
straight line connects three points:
-- the pitch point, PP;
-- the center of the mating gear tip radius center,
point RCMG; and
-- the selected point on the mating gear tip round,
RMG.
The rotation angle of the mating gear, MG, that
corresponds with each of the points can be determined from this requirement.
F.4.1.1 Limit for point OE
The conditions for this limit are based on the mating
gear contacting the fixed gear at the point OEMG at a
slightly rotated position compared to figure F.2. A
straight line connects the three points as noted
above.
47
AGMA 930--A05
Point ORMG at
remaining top land
Tip radius, rrMG
Point OEMG at effective
outside diameter
Point RCMG -- Center
of tip round
Tooth CL
(gear)
To mating
gear center
rrCMG
rCBMG
To mating
gear center
Tooth pitch
angle, MG
Space C
L (mating gear)
Circular tooth
thickness (mating
gear), tBMG
Standard pitch
circle (mating gear)
Operating pitch
circle (gear), dAG
Figure F.1 -- Gear and mating gear (with tooth thickness increased) in tight mesh at specific center
distance
Pitch point
PP
MG
Rotation angle,
MG
Point
RCMG
Tooth CL
(mating gear)
Tooth CL MG
To mating
gear center
rCBMG
Point
ORMG
G Common centerline rotation
angle (G)
To mating
gear center
MG
2
Point
RMG
Space C
L MG
Point OEMG
Tooth C
L
(gear)
Operating pitch
diameter (gear)
Operating pitch
diameter (mating
gear)
48
(F.18)
where
OEBMGis the half tooth thickness angle at the effective outside diameter such that:
OEBMG = BMG + inv inv OEMG
(F.19)
(F.27)
(F.28)
(F.29)
AGMA 930--A05
(F.20)
(F.21)
drCMG
x PPj x rCMGj
x rj = x PPj
(F.22)
r1MG ( n j ) + rnMG ( j 1 )
(F.23)
(n 1 )
for (j = 2 to n -- 1)
F.4.3 Calculation of path points projected on the
fixed gear
Step 1. For each rjMG, calculate the corresponding
value of the rotation angle on the gear, rjG, using the
following equation:
rjG = rjMG +
MG
2
N MG
NG
(F.24)
where
MG is the tooth pitch angle at the mating gear.
MG = 360
N MG
+ y PPj y rCMGj
rPPj + r rMG
rPPj
x PPj x rCMGj
(F.33)
y rj = y PPj
(F.32)
(F.31)
where
(F.30)
(F.25)
rPPj + r rMG
rPPj
y PPj y rCMGj
(F.34)
x rj x fC + y rj y fC
(F.35)
49
AGMA 930--A05
Annex G
(informative)
Calculation examples
[This annex is provided for informational purposes only and should not be construed as a part of AGMA 930--A05,
Calculated Bending Load Capacity of Power Metallurgy (P/M) External Spur Gears.]
G.1 Purpose
The calculation examples in this annex serve the
dual purpose of helping to clarify the procedures
explained in this document and providing a test case
for any computer programs prepared for these
procedures. The following sections begin with a flow
diagram illustrating the various steps and their
proper order to determine the load capacity of a P/M
gear. This is followed with a detailed example
problem using a gear mesh assuming friction in the
system. The final example describes the calculations to test for fillet interference.
G.1.1 Sequence of calculations
Due to the multiple steps required in determining the
load capacity, the following sequence outlines these
steps in a preferred order to ensure all elements of
the calculation are considered. The goal is to
calculate all seven factors required for determining
the result of equation 1 or 2.
Before any calculations begin, list all pertinent gear
data as illustrated by the data entries in table G.1.
A -- calculate gear geometry per annex A,
equations A.1 through A.85.
A--1 Tip radius geometry (see G.2.1)
A--2 Generated trochoid fillet points (see
G.2.2)
A--3 Circular--arc in place of trochoid (see
G.2.3)
A--4 Involute profile data (see G.2.4)
A--5 Operating line of action and pitch circle
data (see G.2.5)
A--6 Contact conditions (see G.2.6)
B -- calculate form factor, Y, equations B.1
through B.19.
B--1 Critical load location (see G.3.1)
B--2 Critical fillet section (see G.3.2)
B--3 Maximum bending stress (see G.3.3)
B--4 Non--dimensional Y factor (see G.3.4)
C -- calculate the stress concentration factor, Kf,
equations C.1 through C.5.
C--1 Elastic stress concentration factor (see
G.4.1)
50
(A.1)
= 85.3440 2 (0.7620)
= 83.8200 mm
AGMA 930--A05
Symbol
N
m
dO
dR
rr
t
rf
CA
F
VqT
tR
Pinion
24
3.1750
20.000
85.3440
69.9262
0.7620
5.7277
1.3513
Gear
40
3.1750
20.000
131.2418
116.5352
0.7620
4.2469
1.6993
12.0000
stT
suT
12.7000
25.4 micrometers
9.9441
FL--4405--125HT
290 N/mm2
930 N/mm2
E
n
135,000 N/mm2
5.0 106
nu
10,000
Mesh
101.7270
Qv
d B = d (cos )
(A.3)
= 76.2000 cos(20.0000)
= 71.6046 mm
rr
d/2
drc
dO
Figure G.1
dB/2
Figure G.2
51
AGMA 930--A05
a = r B tan rC
dB
d rC
rC = arccos
tan OE =
(A.4)
=
= arccos 71.6046
83.8200
(a + r r )
rB
rB tan rC + rr
rB
r
= tan rC + r r
2r
= tan rC + r
dB
= arccos(0.85427)
= 31.3213 degrees
OE = arctan tan rC +
= 0.5467 radians
rC
2r r
dB
r
cos rC = r B
rC
d
cos rC = B
d rC
rrC
rB
rC = arccos
rC
dB
d rC
d OE =
=
2 rr
dB
cos OE
(A.6)
71.6046
cos(32.2028)
= 84.6222 mm
Figure G.3
OE = arctan tan rC +
dB
= arctan tan(31.3213) +
= arctan (0.62980)
= 32.2028 degrees
(A.5)
2(0.762)
71.6046
(A.7)
OE
a
rC
OE
t OR = d O + (inv ) tan OE + rC
(A.8)
= 85.3440 [0.07517 + inv (20.0000)
tan (32.2028) + 0.5417]
= 0.5913 mm
52
rB
Figure G.4
NOTE: The example gear selected for these calculations has a circular--arc fillet. The following trochoid fillet calculations are used to demonstrate the use of the
formulas in this section and are not used elsewhere in
the example calculations.
AGMA 930--A05
r fBRX =
t BR = m
2
(3.1750)
=
2
(A.9)
cos
b BR sin
4
1 sin
3.1750
(A.11)
cos 20.0000
4.1540(sin 20.0000)
4
1 sin 20.0000
= 2.3433 1.4208
0.6580
= 4.9873 mm
Basic rack dedendum, bBR
= 1.4020 mm
t t BR
b Br = 0.5 N m +
dR
tan
(A.10)
69.9262
(A.12)
= 3.2649 mm
t BR
2
b=
t t BR
2 tan
bBR
t
2
c=
dR
2
a = d = Nm
2
2
Figure G.5
Nominal
pitch line
Generating
pitch line
bfBR
bBR
rfBRX
rfBR
Figure G.6
Figure G.7
AGMA 2005 ---- All rights reserved
53
AGMA 930--A05
= 5.7277 4.9873
2 tan (20.0000)
= 1.0171 mm
t BR
2
gfBR
t BR
2
yRS
t
2
rfBR
b
a
Figure G.10
Figure G.8
t BR
+a+b
2
a = b BR r fBR tan
r
b = fBR
cos
t
r
g fBR = BR + b BR r fBR tan + fBR
cos
2
Coordinate along the H--axis, hfBR (figure G.9)
g fBR =
h fBR = b BR r fBR
(A.14)
hfBR hyfBR
= 4.1540 1.3513
= 2.8027 mm
Nominal pitch line
bBR
Figure G.11
hfBR
undercutting.
rfBR
If
Figure G.9
54
undercutting.
there
there
is
is
no
(A.17)
= 2.2478
therefore, there is no undercutting.
G.2.2.4 Fillet point selection (see A.4.4)
f =
f1 n f k + fn( k 1 )
nf 1
AGMA 930--A05
h yfBR
sin f
+ r fBR
(A.23)
f1:
(A.22)
f1 =
f5:
For k = 1 to nf
f15 =
nf = 10
f1 = 90.0000 degrees
(A.20)
fn = = 20.0000 degrees
(A.20)
k = 1:
f10:
1.7856 + 1.3513 = 6.5720 mm
sin(20.0000)
Step 2. Generating roll angle, f (figure G.13)
f10 =
90.0000(10 1) + 20.0000(1 1)
10 1
= 90.0000 degrees
f1 =
2 g fBR +
f =
k = 5:
h yfBR cos f
sin f
(A.24)
f1:
90.0000(10 5) + 20.0000(5 1)
f5 =
10 1
= 58.8889 degrees
2 4.9518 + 1.7856
k = 10:
f1 =
cos90.0000
sin90.0000
76.2000
= 0.1300 radians
= 7.4466 degrees
hyfBR
Pitch point
Y
f
rfBR
Point on
trochoid
Basic rack
Generating
pitch line on
basic rack
X
Generating
Gear center circle on gear
Figure G.12
55
AGMA 930--A05
hyfBR
Pitch point
d
2
d
f
Basic
rack
f
2
gfBR
C
L
X
Generating
pitch line on
basic rack
Generating
circle on gear
Gear
center
Figure G.13
f1:
f5:
2 4.9518 + 1.7856
f5 =
cos58.8889
sin58.8889
v f1 =
76.2000
2
+ 3.1369 2 76.2000
1/2
(3.1369)(sin 90.000)
76.2000
= 0.1583 radians
= 9.0672 degrees
f1 = 7.4466 arcsin
f10:
= 34.9631
3.1369 cos(90.0000)
34.9631
= 7.4466 degrees
2 4.9518 + 1.7856
f3 =
cos20.0000
sin20.0000
76.2000
= 0.2587 radians
= 14.8243 degrees
vf =
d
2
+ 2f d f sin f
cos
f = f arcsin f v f
f
NOTE:
arcsin f
cos f
vf
f5:
v f5 =
76.2000
2
+ 3.4369 2 76.2000
1/2
(3.4369)(sin 58.8889)
f5 = 9.0672 arcsin
= 35.2023
3.4369 cos(58.8889)
35.2023
= 6.1756 degrees
12
(A.25)
f10:
v f10 =
(A.26)
76.2000
2
+ 6.5720 2 76.2000
(6.5720)(sin 20.0000)
calculates a value in
56
f5 = 14.8243 arcsin
1/2
= 36.3802
6.5720 cos20.0000
36.3802
= 5.0507 degrees
AGMA 930--A05
d
2
a
v 2f = a 2 + b 2
v f = a 2 + b 2
Basic rack
vf
f
Gear
center
b
f
Pitch point
X
Generating
circle on gear
Generating
pitch line on
basic rack
12
a= dx
2
x = f sin f
a = d f sin f
2
b = f cos f
a 2 + b 2 = d f sin f + 2 cos 2 f
2
2
2
d
d
=
d + 2f sin 2 f + 2f cos 2 f
2
2 sin f 2 sin f
vf =
d
2
2
= d d f sin f + 2fsin 2 f + cos 2 f
2
2
= d + 2f d f sin f
2
+ 2f d f sin f
f = f f
f = arcsin f cos v f
f
f = f arcsin f cos v f
f
12
Figure G.14
57
AGMA 930--A05
x f = v f cos f
(A.27)
y f = v f sin f
(A.28)
R fN =
=
f1:
h yfBR
0.5 d + h yfBR
(A.29)
+ r fBR
1.7856 2
+ 1.3513
0.5(76.2) + 1.7856
= 1.4312 mm
f5:
x f5 = 35.2023 cos(6.1756) = 34.9980 mm
r fN =
d2 d2
B
(A.30)
4d R
2
= 71.6046 69.9262
4(69.9262)
= 0.8493 mm
f10:
x f10 = 36.3802 cos(5.0507) = 36.2390 mm
BTff =
Y
yf
+ d R inv
N dB
(A.31)
Point on
trochoid Basic
rack
xf
Gear center
vf
bC = arc sev BT ff
(A.32)
Figure G.15
Table G.2
f (deg)
f (rad)
f (deg)
f (rad)
vf
f (rad)
f (deg)
xf
yf
90.0000
1.570796
3.136900
0.129969
7.446647
34.96310
0.129969
7.446647
34.66822
4.531320
82.2222
1.435048
3.153479
0.136370
7.813418
34.97814
0.124169
7.114339
34.70884
4.332036
74.4444
1.299300
3.204792
0.143015
8.194134
35.02314
0.118473
6.788001
34.77764
4.139596
66.6667
1.163553
3.295940
0.150185
8.604941
35.09790
0.112981
6.473354
34.87413
3.956977
58.8889
1.027805
3.436874
0.158252
9.067192
35.20228
0.107784
6.175596
34.99800
3.786917
51.1111
0.892057
3.64534
0.167770
9.612497
35.33678
0.102959
5.899133
35.14965
3.631826
43.3333
0.756309
3.953301
0.179644
10.292830
35.50372
0.098563
5.647224
35.33141
3.493678
35.5556
0.620562
4.422018
0.195538
11.203490
35.71030
0.094624
5.421567
35.55055
3.374018
27.7778
0.484814
5.182699
0.218942
12.544430
35.97804
0.091143
5.222084
35.82871
3.274593
20.0000
0.349066
6.572045
0.258732
14.824260
36.38024
0.088152
5.050726
36.23898
3.202832
58
Imaginary involute
through fillet center
Base
circle
Root
diameter
bC
AGMA 930--A05
(A.35)
(A.36)
= 69.9262 + 2(1.3513)
= 72.6288 mm
Figure G.16
First approximation:
1 = 0.8( S 1 ) + 1.4( S 1 )
12
rf
(E.4)
= 0.8(1.01739 1) + 1.4(1.01739 1)
12
1
sin 1
Figure G.17
Step 2. Pressure angle along imaginary involute
through fillet center, fC (figure G.18)
Second approximation:
2 = 1 + S sev 1 1 +
(E.5)
fC = arccos
1+
1
inv (0.198532 rad)
cos 0.198532 rad
= 73.0396 mm
(A.37)
= 9.6336 degrees
6.070233
= 0.198552 radians = 11.3762 degrees
dB
d fC
= arccos 71.6046
72.6288
1
sin 11.3750
= 0.198532 + (1.017390
rf
(A.34)
fC = + inv inv fC +
2r f
dB
(A.39)
2(1.3513)
71.6046
59
AGMA 930--A05
Imaginary involute
through fillet center
Base
circle
Root
diameter
fC
(A.45)
Figure G.18
fR = fC = 7.2314 degrees
Step 5. Coordinates at fillet center, xfC, yfC
x fC = fCcos fc
(A.41)
2 (1.3513)
= arctan tan (9.6336)
71.6046
7.2314(10 1) + 87.5977(1 1)
10 1
= 7.2314 degrees
7.2314(10 5) + 87.5977(5 1)
10 1
= 42.9498 degrees
(A.42)
dB
dF =
= 71.6046 = 72.2257 mm
cos F
cos 7.5194
(A.43)
k = 10:
7.2314(10 10) + 87.5977(10 1)
10 1
= 87.5977 degrees
Step 5. Coordinates of spaced points along fillet, xf,
yf (table G.3)
f1 =
x f = x fC r fcos f
(A.49)
y f = y fC r fsin f
(A.50)
f1:
x f1 = 36.0256 1.3513(cos 7.2314) = 34.6850 mm
s R = d R fC
N
(A.44)
60
k = 5:
f5 =
(A.48)
f1 =
nf 1
k = 1:
fR n f k + fF( k 1 )
For k = 1 to nf, nf = 10
2 r f
F = arctan tan fC
dB
(A.47)
f5:
x f5 = 36.0256 1.3513cos 42.9498 = 35.0365 mm
AGMA 930--A05
i5:
f10:
0.1320(10 5) + 0.6298(5 1)
10 1
= 0.3532 radians
1 =
i10:
Table G.3
f
7.2314
16.1610
25.0906
34.0202
42.9498
51.8794
60.8090
69.7385
78.6681
87.5977
f
1
2
3
4
5
6
7
8
9
10
xf
34.6850
34.7276
34.8018
34.9055
35.0365
35.1914
35.3665
35.5576
35.7600
35.9689
yf
4.4010
4.1950
3.9981
3.8151
3.6504
3.5081
3.3915
3.3035
3.2462
3.2210
1 =
(A.54)
i1:
i = arctan (0.1320) = 7.5195 degrees
i5:
5 = arctan (0.3532) = 19.4555 degrees
i10:
10 = arctan (0.6298) = 32.2028 degrees
Step 4. Diameter at the i--th point, di
F = tan arccos
dB
dF
dB
d OE
71.6046 = 75.9407 mm
cos(19.4555)
71.6046 = 84.6222 mm
cos(32.2028)
Step 5. Polar (or half tooth) angle at the i--th point,
i
i = t + inv inv i
d
= 5.7277 + inv (20) inv i
76.2000
(A.56)
= 0.0752 + 0.0149
tan i i radians
ni 1
di =
di =
= 0.6298 radians
i =
71.6046 = 72.2257 mm
cos(7.5195)
i5:
(A.52)
F n i 1 + OE( i 1 )
di =
(A.55)
i10:
= 0.1320 radians
OE = tan arccos
dB
cos i
i1:
(A.51)
di =
= 0.0901 tan i + i
(A.53)
i1:
1 = 0.0901 tan(7.5195) + 0.13124
For i = 1 to ni, ni = 10
i1:
0.1320(10 1) + 0.6298(1 1)
1 =
10 1
= 0.1320 radians
i5:
5 = 0.0901 tan(19.4555) + 0.33956
= 0.0764 radians = 4.3768 degrees
61
AGMA 930--A05
i10:
10 = 0.0901 tan(32.2028) + 0.56204
S = arccos
xi =
(A.57)
(A.58)
i1:
dB
dS
(A.61)
S 1:
S1 = arccos 71.6046 = 7.5196 degrees
72.2257
S 2:
S2 = arccos 71.6046 = 19.4554 degrees
75.9407
S 3:
S3 = arccos 71.6046 = 32.2027 degrees
84.6222
Step 2. Half--tooth thickness angle at the selected
point, S
S = t + inv inv S
d
i5:
x 5 = 75.9407 cos 4.3768 = 37.8596 mm
2
75.9407
sin 4.3768 = 2.8977 mm
y5 =
2
i10:
(A.62)
tan S S radians
= 0.0901 tan S + S
S 1:
S1 = 0.0901 tan (7.5196) + 0.13124
= 0.0893 radians = 5.1772 degrees
S 2:
S2 = 0.0901 tan (19.4554) + 0.33956
= 0.0764 radians = 4.3768 degrees
S 3:
d S2 = 75.9407 mm
d S3 = 84.6222 mm
Table G.4
f
1
2
3
4
5
6
7
8
9
10
62
f (rad)
0.1320
0.1873
0.2426
0.2979
0.3532
0.4086
0.4639
0.5192
0.5745
0.6298
f
7.5195
10.6091
13.6377
16.5905
19.4555
22.2227
24.8850
27.4374
29.8769
32.2028
df
72.2257
72.8499
73.6820
74.7150
75.9407
77.3501
78.9332
80.6798
82.5796
84.6222
f (rad)
0.0893
0.0879
0.0855
0.0817
0.0764
0.0694
0.0605
0.0498
0.0370
0.0223
f (deg)
5.1172
5.0378
4.8972
4.6809
4.3768
3.9749
3.4681
2.8513
2.1218
1.2785
xf
35.9689
36.2842
36.7065
37.2329
37.8596
38.5820
39.3943
40.2900
41.2615
42.3006
yf
3.2210
3.1986
3.1450
3.0486
2.8977
2.6809
2.3874
2.0067
1.5287
0.9441
(A.63)
AGMA 930--A05
S 1:
t S1 = 72.2257 0.0893 = 6.4506 mm
S 2:
t S2 = 75.9407 0.0764 = 5.8010 mm
S 3:
t S3 = 84.6222 0.0223 = 1.8883 mm
Step 4. Coordinates of the selected point, xS, yS
d
x S = S cos S
2
d
y S = S sin S
2
S 1:
(A.64)
(A.65)
(A.2)
= 40 (3.175)
= 127.0000 mm
d BG = d G cos
(A.3)
= 127.0000 cos 20
G.2.5.1 Operating pressure angle (see A.7.1)
(A.68)
2(101.7270)
1 + 71.6046
119.3410
= 127.1588 mm
(A.66)
(A.69)
(A.70)
= 0.6298 radians
Determine OEG
Step a. Diameter at center of tip round for the
gear, drC
d rC = d O 2 r r
= 119.3410 mm
2(101.7270)
1 + 119.3410
71.6046
= 76.2953
2 CA
d AG =
d
1 + BP
d BG
=
(A.67)
d + d BG
A = arccos BP
2 CA
2 CA
d
1 + BG
d BP
(A.1)
= 131.2418 2(0.7620)
= 129.7178 mm
Step b. Pressure angle at center of tip round,
rC
rC = arccos
dB
d rC
(A.4)
63
AGMA 930--A05
2r r
dB
(A.5)
2(0.7620)
119.3410
= 23.6896 degrees
OEG = tan OEG
(A.71)
N
NG
OEG G
NP
NP
(A.72)
= 0.2497 radians
But not smaller than zero; Remains the same
(0.2497)
(A.73)
A 1 +
NP
NG
(A.74)
(A.79)
= 0.5115 radians
But not greater than 4P (0.6298); Remains the same
(0.5115)
3G = 1G G = 0.4388 0.1571
(A.81)
= 0.2817 radians
But not smaller than 4G (0.2107); Remains the
same (0.2817)
0.3678 1 + 40 = 0.98083
24
Remains the same (0.6298)
4G = A 1 +
(A.82)
d BG
(A.83)
cosarctan iP
cosarctan iG
Point 1:
71.6046
= 73.8023 mm
cos (arctan 0.2497)
119.3409
d 1G =
= 130.3226 mm
cos(arctan 0.4388)
Point 2:
d BP
d 1P =
NP
N
OEP P
NG
NG
71.6046
= 76.2992 mm
cos(arctan 0.3680)
119.3409
d 2G =
= 127.1548 mm
cos (arctan 0.3677)
Point 3:
d 2P =
(A.75)
= 0.2107 radians
But not smaller than zero; Remains the same
(0.2107)
71.6046
= 84.6222 mm
cos(arctan 0.6298)
119.3409
d 4G =
= 121.9604 mm
cos(arctan 0.2107)
d 4P =
71.6046
= 80.4264 mm
cos(arctan 0.5115)
119.3409
d 3G =
= 123.9849 mm
cos(arctan 0.2817)
Point 4:
d 3P =
= 0.3678 1 + 24 0.6298 24
40
40
64
2G = 4G + G = 0.2107 + 0.1571
d iG =
(A.78)
= 0.3680 radians
But not smaller than 1P (0.2497); Remains the
same (0.3680)
d iP =
2P = 4P P = 0.6298 0.2618
0.3678 1 + 24 = 0.58850
40
Remains the same (0.4388)
A 1 +
3P = 1P + P = 0.2497 + 0.2618
= 0.36781 + 40 0.4388 40
24
24
(A.77)
= 0.3677 radians
But not greater than 1G (0.4388); Remains the
same (0.3677)
G = 2 = 2 = 0.1571 radians
NG
40
(A.76)
AGMA 930--A05
(A.62)
= 0.0752 + 0.0149
tan Wc Wc(radians)
= 0.05139 (radians)
AP 1P
P
(A.84)
(A.85)
(A.86)
(B.2)
= 80.4264 mm
d WcG = d 2G
(B.3)
= 127.1548 mm
G.3.1.1 Translation to tooth centerline (see
B.2.3.3)
Step 1: Determine coordinate points, xWc, yWc:
Pressure angle at dWc; Wc:
d BP
d Wc
= arccos 71.6046
80.4264
= 0.4728 radians = 27.0876 degrees
t Wc = d Wc Wc
(A.63)
= 80.4264 (0.05139)
= 4.1328 mm
Coordinates at dWc; xWc, yWc:
x Wc =
d Wc
cos Wc
2
(A.64)
= 80.4264 cos(2.9442)
2
y Wc =
d Wc
sin Wc
2
(A.65)
= 80.4264 sin(2.9442)
2
= 2.0655 mm
If considering the effects of friction, see G.12.
Step 2: Direction angle of critical tooth force, Wc:
Wc = Wc Wc
(B.6)
= 27.0876 2.9442
= 24.1433 degrees
Step 3: Distance of translated critical tooth force,
xWcC
x WcC = x Wc y Wctan Wc
(B.7)
(A.61)
= 40.1601 mm
Wc = arccos
= 2.9442 degrees
(B.8)
= W c cos(24.1433)
= 0.9125 W c
65
AGMA 930--A05
W cx = W c sin Wc
f BS = 6 cos Wc
(B.9)
= W c sin(24.1433)
hf
= 6(cos(24.1433))
= 0.4090 W c
= 5.4752
(B.14)
w 2f
hf
hf
w 2f
w 2f
h f = x WcC x f
(B.10)
= 39.2343 x f
xf
Select f = 30
x f = x fC r f cos f
= 3.8955 mm
h f = x WcC x f
= 4.3790 mm
wf = 2 yf
= 6 W c (cos(24.1433))
= 5.4752 W c
hf
(B.11)
= 2 (3.8955)
(B.13)
w 2f
(B.10)
= 39.2343 34.8553
(A.50)
hf
(A.49)
= 7.7910 mm
Step 3: Calculate the bracketed term, BT:
BT =
hf
w 2f
hf
(B.15)
w 2f
= 4.37902
7.7910
w 2f
= 0.0721
Table G.5
f
1
2
3
4
5
6
7
8
9
10
66
xf
34.6850
34.7276
34.8018
34.9055
35.0365
35.1914
35.3665
35.5576
35.7600
35.9689
yf
4.4011
4.1950
3.9981
3.8151
3.6504
3.5081
3.3915
3.3035
3.2462
3.2210
hf
4.5493
4.5067
4.4325
4.3288
4.1978
4.0429
3.8678
3.6767
3.4743
3.2654
wf
8.8021
8.3901
7.9963
7.6302
7.3009
7.0161
6.7829
6.6069
6.4924
6.4421
sBS
0.3215 Wc
0.3505 Wc
0.3796 Wc
0.4071 Wc
0.4312 Wc
0.4497 Wc
0.4603 Wc
0.4612 Wc
0.4513 Wc
0.4308 Wc
fBS
0.3215
0.3505
0.3796
0.4071
0.4312
0.4497
0.4603
0.4612
0.4513
0.4308
AGMA 930--A05
f = 35
x f = 36.0255 1.3513 (cos 35.0000)
= 34.9186 mm
(B.14)
h f = 39.2343 34.9186
s BS = 6 W c cos Wc
= 4.3157 mm
w f = 2 (3.7961)
= 7.5921 mm
= f BSX W c
h fc
(B.16)
w 2fc
= 0.4621 W c
BT = 4.31572
7.5921
= 0.0749
(B.17)
= W c sin 24.1433
6.6733
Yes.
Step 5: Repeat steps 2--4 with successively larger
angles until BT changes from increasing to
decreasing (table G.6).
sin Wc
w fc
= 0.0613 W c
Combined tensile stress, st:
(B.18)
h
sin Wc
s t = 6 W ccos Wc fc
Wc
w fc
2
w
fc
Table G.6
f
35
40
45
50
55
60
65
70
xf
34.9186
34.9904
35.0700
35.1570
35.2505
35.3499
35.4545
35.5634
yf
3.7961
3.7025
3.6156
3.5360
3.4642
3.4009
3.3465
3.3013
hf
4.3157
4.2439
4.1643
4.0774
3.9838
3.8844
3.7798
3.6709
wf
7.5921
7.4051
7.2313
7.0720
6.9285
6.8018
6.6929
6.6027
BT
0.074872
0.077394
0.079636
0.081526
0.082990
0.083962
0.084381
0.084204
Decreasing?
No
No
No
No
No
No
No
Yes
wf
6.6929
6.6830
6.6733
6.6639
BT
0.084381
0.084391
0.084394
0.084392
Decreasing?
No
No
No
Yes
Table G.7
f
65.0
65.5
66.0
66.5
xf
35.4545
35.4652
35.4759
35.4867
yf
3.3465
3.3415
3.3367
3.3319
hf
3.7798
3.7691
3.7584
3.7476
67
AGMA 930--A05
w
K fs = H + r fc
fc
(B.20)
= cos 20.1956
= 0.9385
Adjusted force--stress ratio, AWsA:
A WsA = A Wsc m cA
(B.21)
= 2.3417
A WsA
m
(B.22)
(C.5)
K fy = 1 + 0.8 (1.8312 1)
= 1.6650 for occasional peak overloading
G.5 Fundamental formulas for calculated
torque capacity
Tooth bending under repeated loading (see
3.1):
= 1.3513 mm
or
r fc = r f
0.15226
= 1 + 1 (1.8312 1)
= 0.7375
r fc = R fN
0.45124
= 2.4951 (0.9385)
= 2.3417
3.1750
68
(C.3)
6.6733
3.7584
= 1.8312
H = 0.331 0.436
= 0.331 0.436 (0.34907)
= 0.17881
L = 0.324 0.492
= 0.324 0.492 (0.34907)
= 0.15226
M = 0.261 + 0.545
= 0.261 + 0.545 (0.34907)
= 0.45124
G.4.2 Stress correction factor (see C.3)
= 2.4951
w fc
h fc
= 0.17881 + 6.6733
1.3513
(B.19)
Wc
0.4008 W c
(C.2)
s t K ts d c F e J t m
(1)
2000 K tw
Tooth bending under occasional peak loading
(see 3.2):
Tt =
Ty =
s y K ys d c F e J y m
2000 K yw
(2)
s tG
0.7
= 276
0.7
= 394 Nmm 2
st =
(4)
(5)
= 0.32 (930)
(3)
s uG = s uM = 860 Nmm 2
(10)
S y = S uG = 860 Nmm 2
(11)
= 1.090
For n > 1 107:
(15)
NOTE: The above load cycle is used for the demonstration of the use of the formula example and is not
used elsewhere in the example.
Unidirectional loading
(16)
KS = 1
(18)
(19)
(20)
K ts =
(12)
= 0.727
Ky = 0.75 (hardened material)
(23)
sy
K L = K Ly = 0.9 s
t
Ky
K ys =
KS KT
= 1 + [2.121(1.96467 1)]
K LR = 1.0
K L K LR
KS KT KR
(14)
K ts =
KL = 1
= 298 14
= 284 Nmm 2
s
s t = tG
0.7
= 284
0.7
= 406 Nmm 2
0.303 K Ly 1 log n
= 298 Nmm 2
s tG = s tT s tTG
s tT = k ut s uT
AGMA 930--A05
Ky
KS KT
(21)
= 0.75
(1)(1)
= 0.75
G.7 Calculation diameter (see clause 6)
d C = d AP
(24)
69
AGMA 930--A05
since m B 1.2, K B = 1
F xe1 = 1
Fx
Fx
2m
(27)
K mt = 1 + (q m + q v)m ct m w
qm =
= 1 0.3500
0.3500
(2)(3.175)
= 0.331 mm
Effective face width, Fe:
(26)
f qm F o
Sb
(28)
0.2(12.0000)
24.0000
= 0.100
f qv F o
qv =
d
0.3(12.0000)
=
76.2000
= 0.047
m ct
s
= 1 5
E
(30)
K tw = S F K ot K B K mt K V
(31)
K yw = S F K oy K B K my K V
(40)
=15
0.5
m w = 1.0
= 1.107
Dynamic factor, Kv:
K v = 1 + 0.0055 V qTv t
9.9441
0.5 (85.3440 69.9262)
= 1.290
12
(39)
12
12
= 1.177
Load distribution factor for occasional overloads,
Kmy:
=15
0.5
135860000
(42)
0.5
K my = 1 + (q m + q u) m cy
(32)
0.5 d O d R
= 0.6009
tR
12
(35)
70
(38)
135394000
Sy
m cy = 1 5
E
0.5
K mt = 1 + (q m + q v)m ct m w
= 0.7375
1.6650
= 0.443
G.10 Combined adjustment factors for loading
(see clause 9)
(37)
= 0.7375
1.8312
= 0.403
Jy = Y
K fy
tR
ht
(36)
= 0.730
Jt = Y
K ft
mB =
(35)
= (1 0.055) 0.3500
= 0.331 mm
F xe2 = F xe1
F e = F O + F xe1 + F xe2
(33)
(41)
(31)
(40)
(1)
(394)(0.727)(76.2953)(12.662)(0.403)(3.175)
2000(1.303)
= 135.9 Nm
Step 2.
c = arctan 0.25
860 0.7576.295312.6620.4433.175
2000 1.281
= 342.1 Nm
= 14.03624 degrees
Wc = Wc + c Wc
(B.24)
(B.7)
(B.8)
= W c cos(10.1072)
= 0.9845 W c
W cx = W c sin Wc
(B.9)
= W c sin(10.1072)
= 0.1755 W c
Calculate the bending stress factor,
h f = x WcC x f
(B.10)
= 39.7919 x f
where xf varies depending on the location on the
fillet.
wf = 2 yf
(B.11)
hf
s BS = 6 W c cos Wc
w 2f
= 6 W c cos 10.1072
(B.23)
AGMA 930--A05
= 5.9070 W c
(B.13)
hf
w 2f
hf
w 2f
f BS = 6 cos Wc [ BT ]
(B.14)
71
AGMA 930--A05
(A.50)
(B.10)
= 39.7919 34.8552
= 4.9367 mm
wf = 2 yf
(B.15)
w 2f
= 0.081328
(A.49)
y f = y fC r f sin f
hf
= 4.9366 2
(7.7910)
(B.11)
= 2 (3.8955)
= 7.7910 mm
The inclusion of the effect of friction has changed the
value for hf.
(B.14)
Table G.8
f
30
35
40
50
60
65
67
68
68.3
68.6
68.7
68.8
68.79
72
xf
34.8552
34.9186
34.9903
35.1569
35.3499
35.4544
35.4975
35.5193
35.5259
35.5324
35.5346
35.5368
35.5366
yf
3.8955
3.7960
3.7025
3.5359
3.4008
3.3464
3.3272
3.3182
3.3156
3.3130
3.3121
3.3113
3.3113
hf
4.9367
4.8733
4.8016
4.6350
4.4420
4.3375
4.2944
4.2726
4.2660
4.2595
4.2573
4.2551
4.2553
wf
7.7910
7.5920
7.4050
7.0718
6.8016
6.6928
6.6544
6.6364
6.6312
6.6260
6.6242
6.6226
6.6226
BT
0.081328
0.084549
0.087566
0.092681
0.096019
0.096833
0.096981
0.097012
0.097015
0.097019
0.097021
0.097018
0.097023
Decreasing
No
No
No
No
No
No
No
No
No
No
Yes
Max BT
hf
(B.13)
w 2f
(B.17)
= W c sin 10.1072
6.6226
(B.18)
0.15226
6.6226
4.2553
0.45124
(C.5)
= 1.734
For occasional peak overloading
K fy = 1 + q K fs 1
= 0.5731 W c 0.0265 W c
= 0.5466 W c
(C.5)
= 1 + 0.8 (1.7340 1)
(B.19)
Jt = Y
K ft
= 1.8295
Adjustment ratio, mcA
= 1.5872
Calculate the geometry factor following G.9.
(29)
= 0.5917
1.734
Wc
0.5466 W c
cos A
cos Wc
= 1 + 1 (1.7340 1)
s t = s BS s CS
(C.3)
K ft = 1 + q K fs 1
m cA =
= 0.0265 W c
w fc
h fc
w
K fs = H + r fc
fc
K fs = 0.17881 + 6.6226
1.3513
= 1.7340
= 0.5731 W c
Therefore
= 6W c cos(10.1072) 4.25532
6.6226
s CS = W c
AGMA 930--A05
cos Wc + c
(B.25)
= 0.5917
1.5872
= 0.3728 for occasional peak overloading
= 1.0269
(B.21)
= 1.8295 (1.0269)
= 1.8787
Step 8. Calculate the non--dimensional Y factor
A WsA
m
1.8787
=
3.175
Y=
= 0.5917
(B.22)
(30)
Tt =
S t K ts d c F e J t m
2000 K tw
(1)
Tt =
73
AGMA 930--A05
T = inv 1 inv +
= inv 1 inv 20 +
= 3.175
NG
= 24
(F.1)
= 76.2 mm
(F.2)
= (40)(3.175)
= 127.0 mm
Step 2. Reference center distance
C=
d G + d MG
2
(F.3)
C (cos )
cos T
(F.4)
= 9.9746 mm
2 N G C AN
NG + NMG
74
(F.8)
= 76.2953 mm
d AMG =
= 5.7277 mm
= 20
(F.7)
(2)(24)(101.727)
(24 + 40)
tMG = 4.2469 mm
(cos 20)
(cos 20)
d AG =
tG
(F.6)
= 101.6 mm
C AN = 101.727 mm
= 76.2 + 127.0
2
pc = m
= (3.175)
2 101.6
= 101.6 mm
= (24)(3.175)
d MG = N MG m
= 101.6
NMG = 40
dG = NG m
(F.5)
= 20 degrees
CT =
2C
= inv 1 0.0149
pc tG tMG
2 N MG C AN
NG + NMG
(F.9)
(2)(40)(101.727)
(24 + 40)
= 127.1588 mm
AGMA 930--A05
A = arccos C
(cos )
C AN
= arccos 101.6
(cos 20)
101.727
t BMG = p c t G + 2C
inv A (inv )
(F.16)
= 0.03417 radians
G.13.1.4.8 Find the angular location relative to
the adjusted tooth centerline
rCBMG
BMG
+ inv tan
OEMG
+ rCMG
(F.17)
r rMG = 0.7620 mm
= 0.00598 radians
(F.12)
= 133.3 (2)(0.7620)
= 0.3426 degrees
= 131.776 mm
(F.13)
= 0.016404 radians
= 0.93996 degrees
G.13.2.2 Find the limit point for OE
OEMG = OEMG A OEBMG
= 127.0 cos 20
= 119.3410 mm
G.13.1.4.5 Find the pressure angle at the center
of the tip round for the mating gear
d BMG
d rCMG
t BMG
d MG
= 4.3398
127.0
(F.11)
= 9.9746 5.7277
rCMG = arccos
2(0.762)
119.341
= 25.6882 degrees
= 20.19561 degrees
G.13.1.4.2
thickness
(F.10)
2 r rMG
(F.15)
d BMG
(F.14)
(F.18)
(F.20)
= 0.00598 radians
G.13.2.4 Point path selection
= 0.43792 radians
= 25.091 degrees
Therefore, n = 5.
= arccos 119.341
131.776
75
AGMA 930--A05
General form
At point ORMG
r1MG = ORMG = 0.00598 radians (F.21)
= 0.3426 degrees
At point OEMG
r5MG = OEMG = 4.55263 degrees
(F.22)
( n j ) + rnMG( j 1 )
rjMG = r1MG
(n 1 )
(F.28)
(F.23)
For j = 2
0.3426(5 2) + 4.55263(2 1)
(5 1)
= 0.8811 degrees
(F.27)
For points j = 2 to 4
r2MG =
(F.26)
(F.29)
(F.25)
(F.30)
= 360
40
= 9.0 degrees
G.13.2.6 Calculation of path points projected on
the fixed gear
For j = 1
x rCMGj = (100.9841) 0.5(131.776)
rjG = rjMG + MG
2
(F.31)
N MG
NG
(F.24)
For j = 1
and
(F.24)
= 6.92865 degrees
For other values of j, see table G.9.
= 4.3236 mm
rjG
xPPj
yPPj
xCMGj
yCMGj
xrCMGj
yrCMGj
rPPj
xrj
yj
zpfCj
Does
interference
exist
--0.3426
6.9287
37.8690
4.6019
100.9841
12.2717
35.5772
4.3236
2.3086
34.8209
4.2315
1.2516
No
0.8811
8.9684
37.6812
5.9468
100.4833
15.8582
35.6351
4.1992
2.6909
35.0557
3.7043
1.3007
No
2.1049
11.0082
37.4457
7.2843
99.8552
19.4247
35.7759
4.0928
3.6019
35.4226
3.4176
1.3016
No
3.3288
13.0480
37.1627
8.6125
99.1006
22.9666
35.9980
4.0114
4.7462
35.8110
3.2727
1.3160
No
4.5526
15.0877
36.8326
9.9297
98.2203
26.4793
36.2992
3.9625
5.9911
36.2314
3.2035
1.3830
Yes
76
x rj = x PPj
y rj = y PPj
x PPj x rCMGj
rPPj + r rMG
rPPj
x PPj x rCMGj
(F.33)
y PPj y rCMGj
(F.34)
For j = 1
rPPj
+ y PPj y rCMGj
(F.32)
rPPj + r rMG
rPPj
rPPJ =
AGMA 930--A05
= 4.2315 mm
For other values of j, see table G.9.
G.13.3 Test for path point interference
As indicated in the problem statement, it is assumed
in this example that the 24 tooth gear has a full round
fillet region instead of a trochoid shaped region.
The coordinate (xfc, yfc) for the fillet radius center has
previously been calculated (see A.40 and A.41) as
(36.0256, 4.5711).
To test for path point interference, we use the
following:
z fCj =
= 2.3086 mm
x rj x fC + y rj y fC
(F.35)
For j = 1
z fC1 =
= 1.2516
77
AGMA 912--A04
Bibliography
The following documents are either referenced in the text of AGMA 930--A05, Calculated Bending Load
Capacity of Powder Metallurgy (P/M) External Spur Gears, or indicated for additional information.
1.
MPIF Standard 35, Material Standards for
P/M Structural Parts, 1997 edition.
2.
Sanderow, H.I., Spirko, J.R. and Friedhoff,
T.B., Fatigue Properties of P/M Materials: Relationship of RBF and AF Results to Material--Processing
Parameters, Advances in Powder Metallurgy and
Particulate Materials, 1997, Vol. 2, MPIF, Princeton,
NJ, 1997, pgs. 13--117.
6.
AGMA 2000--A88, Gear Classification and
Inspection Handbook -- Tolerances And Measuring
Methods For Unassembled Spur And Helical Gears
(Including Metric Equivalents)
3.
ANSI/AGMA 2001--D04, Fundamental Rating Factors And Calculation Methods For Involute
Spur And Helical Gear Teeth
4.
AGMA 908--B89, Geometry Factors for Determining the Pitting Resistance and Bending
Strength of Spur, Helical and Herringbone Gear
Teeth.
5.
AGMA 918--A93, A Summary of Numerical
Examples Demonstrating the Procedures for Cal-
78
7.
ANSI/AGMA 1012--F90, Gear Nomenclature, Definitions of Terms with Symbols
8.
AGMA 900--G00, Style Manual for the Preparation of Standards, Information Sheets and
Editorial Manuals
9.
ANSI B92.1--1970, Involute Splines and
Inspection, table 109.
10.
98FTM2, Mesh Friction in Gearing, C.M.
Denny, October 1998.
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