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KISSsoft Release 03/2013 KISSsoft-Demo-Version KISSsoft AG CH-8634 Hombrechtikon

File Name : BevelGear 5 (Gleason)Description: KISSsoft exampleChanged by: JPM am: 13.10.2013 um: 09:18:12

This KISSsoft demoversion may not be used for professional application !Important hint: At least one warning has occurred during the calculation:1-> Gear 1:The sat and sac material data may not match the values stated in AGMA 2001 or 2101.

2-> Gear 2:The sat and sac material data may not match the values stated in AGMA 2001 or 2101.

3-> Materials in KISSsoft database are according to the recommendations of AGMA2001 (cylindrical gears).Indications for sat and sac acc. AGMA2003 (bevel gears) differ partly.

You can modify the values by adjusting the material data using 'Own input'.

BEVEL-GEAR-CALCULATION (BEVEL-GEAR-PAIR)

Drawing or article number:Gear 1: 0.000.0Gear 2: 0.000.0

Calculation method Bevel gear AGMA 2003-C10Geometry calculation according ISO 23509:2006, method 1 Constant slot width, fig 2 (Gleason)Manufacture process: lappedSpiral toothingFace milling (single indexing method)Cutter radius (in) [rc0] 7.50

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

Power (hp) [P] 292.02Speed (1/min) [n] 1000.0 222.2Rotation direction, wheel 1, viewed on cone tip: leftTorque (ft*lbf) [T] 1533.7 6901.6Gear driving (+) / driven (-) + -Overload factor [Ko] 1.00Required service life [H] 1000.00

1. TOOTH GEOMETRY AND MATERIAL

------- GEAR 1 -------- GEAR 2 -------Hypoid offset (in) [a] 0.000Shaft angle () [Sigma] 90.000Mean normal module (in) [mmn] 0.3150Pressure angle at normal section () [alfn] 20.000Mean spiral angle () [betm] 35.0000Hand of gear left right

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Number of teeth [z] 8 36Facewidth (in) [b] 2.76 2.76Assumed and measured contact pattern width (in) [be] 2.76 2.76Accuracy grade [Q-ISO17485] 7 7

Internal diameter gearbody (in) [di] 0.000 0.000Pitch apex to front of gear blank (in) [yi] 5.681 1.805Pitch apex to back of gear blank (in) [yo] 8.440 2.798H misalignment (P misalignment) (mil) [DeltaH] 0.000G misalignment (mil) [DeltaG] 0.000V misalignment (E misalignment) (mil) [DeltaV] 0.000

MaterialGear 1: 17NiCrMo6-4, Case-carburized steel, case-hardened ISO 6336-5 Figure 9/10 (MQ), core strength >=25HRC Jominy J=12mm=25HRC Jominy J=12mm

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Addendum reference profile (in module) [haP*] 0.960 0.960Protuberance height coefficient (in module) [hprP*] 0.000 0.000Protuberance angle () [alfprP] 0.000 0.000Tip form height coefficient (in module) [hFaP*] 0.000 0.000Ramp angle () [alfKP] 0.000 0.000

Type of profile modification: none (only running-in)Tip relief (mil) [Ca] 0.1 0.1

No modification at tip circle

Lubrication type oil bath lubricationType of oil Oil: ISO-VG 150Lubricant base Mineral-oil baseKinem. viscosity oil at 40 C (cSt) [nu40] 150.00Kinem. viscosity oil at 100 C (cSt) [nu100] 13.00FZG test A/8.3/90 ( ISO 14635-1:2006) [FZGtestA] 12Specific density at 15 C (lb/ft) [roOil] 55.686Oil temperature (F) [TS] 212.000

------- GEAR 1 -------- GEAR 2 -------Overall transmission ratio [itot] -4.500Gear ratio [u] 4.500Outer spiral angle () [bete] 40.469 40.469Mean spiral angle () [betm] 35.000 35.000Inner spiral angle () [beti] 30.400 30.400Pinion offset angle in axial plane () [zetm] 0.000Pinion offset angle in pitch plane () [zetmp] 0.000Offset in pitch plane (in) [ap] 0.000Outer normal module (in) [men] 0.3494Outer transverse module (in) [met] 0.4593 0.4593Mean normal module (in) [mmn] 0.3150Mean transverse module (in) [mmt] 0.3846 0.3846Inner normal module (in) [min] 0.2673Inner transverse module (in) [mit] 0.3099 0.3099

Sum of profile shift coefficients [xhm1+xhm2] 0.0000Profile shift coefficient [xhm] 0.2307 -0.2307Undercut boundary [xhmmin] 0.2307 -15.6455Tooth thickness modification coefficient [xsmn] 0.0000 -0.0000

Outer pitch diameter (in) [de] 3.675 16.535Outer tip diameter (in) [dae] 4.625 16.665Outer root diameter (in) [dfe] 2.956 16.294Mean pitch diameter (in) [dm] 3.077 13.845Mean tip diameter (in) [dam] 3.809 13.945Mean root diameter (in) [dfm] 2.492 13.652Inner pitch diameter (in) [di] 2.479 11.155Inner tip diameter (in) [dai] 2.992 11.225Inner root diameter (in) [dfi] 2.028 11.011Addendum (in) [hae] 0.487 0.298 (in) [ham] 0.375 0.230 (in) [hai] 0.263 0.161Dedendum (in) [hfe] 0.368 0.557 (in) [hfm] 0.299 0.445

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(in) [hfi] 0.231 0.333Tooth height (in) [he] 0.855 0.855 (in) [hm] 0.674 0.674 (in) [hi] 0.494 0.494Working depth (in) [whe] 0.785 (in) [whm] 0.605 (in) [whi] 0.424Tip clearance (in) [ce] 0.070 0.070 (in) [cm] 0.070 0.070 (in) [ci] 0.070 0.070Outer cone distance (in) [Re] 8.469 8.469Mean cone distance (in) [Rm] 7.091 7.091Inner cone distance (in) [Ri] 5.713 5.713Pitch angle () [delta] 12.529 77.471Face angle () [dela] 17.176 80.317Addendum angle () [thea=dela-delta] 4.647 2.845Root angle () [delf] 9.683 72.824Dedendum angle () [thef=delta-delf] 2.845 4.647Distance along axis to crossing point (in) [txo] 8.162 1.546 (in) [txi] 5.520 1.082Distance apex to crossing point (in) [tz] 0.000 0.000 (in) [tzF] -0.680 -0.124 (in) [tzR] 0.315 0.137Distance in axial direction to the cone tip (in) [ye] 8.268 1.837 (in) [yae] 8.162 1.546 (in) [yai] 5.520 1.082

Theoretical tip clearance (in) [c] 0.070 0.070Effective tip clearance (in) [c.e/i] 0.070 / 0.070 0.070 / 0.070

Characteristic values for sizing [Re2/b2] 3.073 [b2/mmn] 8.748

2. FACTORS OF GENERAL INFLUENCE

Effective facewidth (in) [F,b] 2.76Nominal transverse load at operating pitch circle (lbf) [Ftw] 11963.7Nominal circum. force at pitch circle (lbf) [Ft] 11963.7Axial force (lbf) [Fa] 9330.7 3371.9Radial force (lbf) [Fr] 3371.9 9330.7Normal force (lbf) [Fnorm] 15542.3Circumferential speed at dm (m/sec) [vm] 4.09Circumferential speed at de (m/sec) [ve] 4.89Load distribution modifier [Kmb] 1.000Load distribution factor [Km,KHb] 1.027Transmission accuracy grade number [Qv] 10Dynamic factor [Kv] 1.133Number of load cycles (in mio.) [NL] 60.000 13.333

3. TOOTH ROOT STRENGTH

------- GEAR 1 -------- GEAR 2 -------Size factor [KS, Yx] 0.5847 0.5847 (in) , (mm) (in) , (mm)Bending lever arm (in) [hN] 0.012, 0.30 0.009, 0.23Tooth thickness at critical section [2*sN] 0.601, 15.27 0.732, 18.61

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Radius at curvature of fillet curve [rfm] 0.087, 2.22 0.069, 1.76Load angle () [alfh] 21.35 19.38Tooth form factor Y [Y] 0.503 1.018Stress correction factor [Kf] 2.006 2.559Cutter radius (in) [rc0] 7.500Tooth lengthwise correction factor [Kx,Ybet] 1.000Bending strength geometry factor J [J] 0.166 0.248 (lb/in), (N/mm) (lb/in), (N/mm)Bending stress number [st] 32464, 223.83 21723, 149.77Stress cycle factor [KL,YNT] 0.986 1.012 (for general applications) (lb/in), (N/mm) (lb/in), (N/mm)Allowable bending stress number [sat] 62366, 430.00 62366, 430.00Temperature factor [KT] 1.00 1.00Reliability factor [KR,YZ] 1.00Reverse loading factor [-] 1.000 1.000Effective allow. b.s.n. [sateff] 61474, 423.85 63142, 435.35Bending strength power rating (hp) [Pat] 552.96( 412.34 kW) 848.81( 632.95 kW) Note: Pat calculated with Ko=1, KR=1, SFmin=1Safety factor (foot) [sateff/st] 1.89 2.91Required safety factor [SFmin] 1.00 1.00Transmittable power [Pat/SFmin] 552.96( 412.34 kW) 848.81( 632.95 kW)

AGMA2003, Annex C(M):hfe1 = 0.368 in hfe2 = 0.557 in rhoao1= 0.066 in rhoao2= 0.066 ins1 = 0.539 in s2 = 0.435 in thef1= 2.85 thef2= 4.65 Y1 = 0.50 Yf1 = 2.01 YK1 = 0.25 epsNJ= 1.00 Yi = 1.02rmyo1= 1.656 in rmpt1= 1.576 in b1' = 2.115 in b1 = 2.756 inY2 = 1.02 Yf2 = 2.56 YK2 = 0.40 epsNJ= 1.00 Yi = 1.02rmyo2= 33.218 in rmpt2= 31.911 in b2' = 2.012 in b2 = 2.756 in

4. SAFETY AGAINST PITTING (TOOTH FLANK)

------- GEAR 1 -------- GEAR 2 ------- (lb^.5/in), (N^.5/mm)Elastic coefficient [Cp,ZE] 2285.3, 189.81Size factor [Cs,Zx] 0.782 0.782Crowning factor [Cxx,Zxx] 1.500Geometry factor I [I] 0.1131 (lb/in), (N/mm)Contact stress number [sc,sigH] 249769, 1722.10Stress cycle factor [CL,ZNT] 1.185 1.297 (for general applications)Hardness ratio factor [CH,ZW] 1.00 1.00Temperature factor [KT] 1.00 1.00Reliability factor [CR,ZZ] 1.00 (lb/in), (N/mm) (lb/in), (N/mm)Allowable contact stress number [sac] 217557, 1500.00 217557, 1500.00Effective allow. c.s.n. (lb/in) [saceff] 257740, 1777.05 282166, 1945.47Pitting resistance power rating (hp) [Pac] 310.95( 231.87 kW) 372.68( 277.91 kW) Note: Pac calculated with Ko=1, KR=1, SHmin=1Safety factor (flanc) [saceff/sc] 1.03 1.13Required safety factor [SHmin] 1.00 1.00Transmittable power [Pac/SHmin^2] 310.95( 231.87 kW) 372.68( 277.91 kW)

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AGMA2003, Annex C(M):Re = 8.469 in hae1 = 0.487 in hae2 = 0.298 in de1 = 3.675 in de2 = 16.535 indel1 = 12.53 del2 = 77.47 dela1= 17.18 dela2= 80.32 p2 = 1.311 in gan1 = 0.793 in gan2 = 0.660 in gc = 1.452 inrhoy0= 0.966 in mmt = 0.385 in met = 0.459 inZi = 0.040 in epsNI= 0.99

SERVICE FACTORS:Service factor for tooth root [KSF] 1.89 2.91Service factor for pitting [CSF] 1.06 1.28Service factor for gear set [SF] 1.06 Note: Service factors are calculated with Ko=1, KR=1

Transmittable power including required service factors KSFmin, CSFmin (hp) 310.95( 231.87 kW)KSFmin = 1.00, CSFmin = 1.00

4c. Safety of the hardened layer (EHT) according to DNV41.2:2012

Required hardening depth EHT (in) [t550] 0.03/ 0.03 0.03/ 0.03Required hardness at t550 (HV) [HV.t] 550 550Condition for hardness on the surface (HV) [HV.0] > 676 (HRC 60) > 676 (HRC 60)Safety of the hardened layer [SEHT] 0.78 0.78Required safety [SHssmin] 1.00 1.00Result 3 3(-1:Not checked 0:EHT too small 1:EHT too great or HV.0 too low 2:EHT too great (> 0.25*mn) 3,4:Proved)

6. ALLOWANCES FOR TOOTH THICKNESS

------- GEAR 1 -------- GEAR 2 -------Tooth thickness deviation Own Input Own InputTooth thickness allowance (normal section) (in) [As.e/i] -0.006 / -0.009 -0.006 / -0.009

The following data apply on the middle of the facewidth:Tooth thickness (chordal) in pitch diameter (in) [smnc] 0.546 0.442 (in) [smnc.e/i] 0.540 / 0.538 0.436 / 0.433Reference chordal height from dam (in) [hamc] 0.391 0.230

Circumferential backlash (in) [jmt] 0.020 / 0.015 (in) [jet] 0.024 / 0.018Normal backlash (in) [jmn] 0.016 / 0.012 (in) [jen] 0.018 / 0.013

7. GEAR ACCURACY

------- GEAR 1 -------- GEAR 2 --According to ISO 17485:2006:Accuracy grade [Q-ISO17485] 7 7(Diameter (in) [dT] 3.39 13.78)Single pitch deviation (mil) [fpT] 0.87 0.94Total cumulative pitch deviation (mil) [FpT] 2.64 3.35Concentricity deviation (mil) [FrT] 2.09 2.68

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Tangential tooth-to-tooth composite deviation (mil) [fisTmax/fisTmin] 1.57/ 0.00 1.57/ 0.00(fisTmax, fisTmin: ISO 17485:2006, Table B1, q=2)Total tangential composite deviation (mil) [FisT] 4.21 4.92

9. DETERMINATION OF TOOTHFORM

Data for the tooth form calculation :Data not available.

10. ADDITIONAL DATA

Input data for calculating the gear measurements according to ISO 23509:2006Data of type 1 (according to table 3, ISO 23509:2006):xhm1= 0.2307 khap= 0.9595 khfp= 1.1809 xsmn= 0.0000Data of type 2 (according to table 3, ISO 23509:2006):cham= 0.3798 kd= 1.9190 kc= 0.1154 kt= 0.0000

Calculation according to NiemannMean coeff. of friction (acc. Niemann) [mum] 0.078Wear sliding coef. by Niemann [zetw] 0.770Power loss from gear load (hp) [PVZ] 4.754Meshing efficiency (%) [etaz] 98.372Weight - calculated with da (lb) [Mass] 8.804 26.156

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