KISSsoft Release 03/2017 E
Team-SolidSQUAD
File
Name : 1750 with own inputs
Description: KISSsoft example
Changed by: Santosh Reddy on: 05.12.2019 at: 23:36:02
Important hint: At least one warning has occurred during the calculation:
1-> Grease lubrication:
The chosen calculation method requires oil lubrication!
The calculation is performed as for oil lubrication.
2-> The entered gear data does not meet the restrictions of the calculation method!
According to ISO14521 and DIN3996 the following restrictions are applied:
u: 5...100 (u= 92.00)
a: 50...500 mm (a= 26.0000 mm)
vg: 0.1..25 m/s (vg= 0.1576 m/s)
Notice:
The results have to be verified by tests.
3-> The preliminary formulae for the calculation of
the idling and sealing and bearing losses gives
too high values.
These values are set to 0.
WORM GEAR ANALYSIS
Drawing or article number:
Worm: 0.000.0
Gear: 0.000.0
Calculation method DIN 3996:2012
(Geometry: DIN 3975:2002)
Geometry calculation from axial module
------- WORM---------------- WHEEL ----
Worm driving
Working flank gear 1: Right flank
Power (kW) [P] 0.010 0.004
Speed (1/min) [n] 499.9 5.4
Torque (Nm) [TN] 0.199 6.500
Torque (Nm) [T] 0.249 8.125
Application factor [KA] 1.25
Required service life [H] 1000.00
Number of starts (1/h) [Ns] 0.00
1. TOOTH GEOMETRY AND MATERIAL
Shape of flank: ZA (ISO/DTR 10828.2:2011)
------- WORM---------------- WHEEL ----
1/8
Center distance (mm) [a] 26.000
Centre distance tolerance ISO 286:2010 Measure js7
Shaft angle (°) [Sigma] 90.0000
Transverse module (mm) [mt] 0.5000
Normal module (mm) [mn] 0.4983
Axial module (mm) [mx] 0.5000
Pressure angle at normal section (°) [alfn] 20.0000
Mean lead angle (°) [gamma] 4.7636
Hand of gear right right
Number of teeth [z] 1 92
Facewidth (mm) [b1] 12.20
Wheel rim width b2R (mm) [b2R] 4.20
Wheel width b2H (mm) [b2H] 4.20
Facewidth for calculation (mm) [b1, b2] 12.20 3.97
Accuracy grade (manufacturing) [Vqual] 6 7
Internal diameter gearbody (mm) [di] 0.00 0.00
Material
Worm: (Own input) CUSTOM 465 H950, Through hardened steel, nitrided
ALLOY STEEL THROUGH HARDENDED
Gear 2: CuSn12Ni2-C-GZ, Bronze, untreated
DIN 3996:2005
------- WORM---------------- WHEEL ----
Surface hardness HRC 50 HBW 95
Pulsating shear strength (N/mm²) [τFlim] 363.00 90.00
Fatigue strength for Hertzian pressure (N/mm²) [σHlim] 998.00 520.00
Material Coefficient YW [YW] 0.95
Material lubrication coefficient [WML_Min] 1.00
Tensile strength (N/mm²) [σB] 1750.00 300.00
Yield point (N/mm²) [σS] 1640.00 180.00
Young's modulus (N/mm²) [E] 206000 98100
Poisson's ratio [ν] 0.300 0.350
Roughness average value DS, flank (µm) [RAH] 0.50 2.00
Roughness average value DS, root (µm) [RAF] 0.50 2.00
Mean roughness height, Rz, flank (µm) [RZH] 3.00 8.00
Mean roughness height, Rz, root (µm) [RZF] 3.00 8.00
Gear reference profile 1:
Reference profile 1.20 / 0.20 / 1.0 DIN 867:1986
Dedendum coefficient [hfP*] 1.200
Root radius factor [rhofP*] 0.200 (rhofPmax*= 0.498)
Addendum coefficient [haP*] 1.000
Tip radius factor [rhoaP*] 0.000
Protuberance height coefficient [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping
Gear reference profile 2:
Reference profile 1.20 / 0.20 / 1.0 DIN 867:1986
Dedendum coefficient [hfP*] 1.200
Root radius factor [rhofP*] 0.200 (rhofPmax*= 0.498)
Addendum coefficient [haP*] 1.000
Tip radius factor [rhoaP*] 0.000
2/8
Protuberance height coefficient [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Tip form height coefficient [hFaP*] 0.000
Ramp angle [alfKP] 0.000
not topping
Summary of reference profile gears:
Dedendum reference profile [hfP*] 1.200 1.200
Tooth root radius Refer. profile [rofP*] 0.200 0.200
Addendum Reference profile [haP*] 1.000 1.000
Protuberance height coefficient [hprP*] 0.000 0.000
Protuberance angle (°) [alfprP] 0.000 0.000
Tip form height coefficient [hFaP*] 0.000 0.000
Ramp angle (°) [alfKP] 0.000 0.000
Type of profile modification: none (only running-in)
Tip relief (µm) [Ca] 0.0 0.0
Lubrication type Grease lubrication
Type of grease Grease: MICROLUBE GB 00
Lubricant base Mineral-oil base
Kinem. viscosity base oil at 40 °C (mm²/s) [nu40] 700.00
Kinem. viscosity base oil at 100 °C (mm²/s) [nu100] 35.00
FZG-Test A/8.3/90 step [FZGtestA] 12
Specific density at 15 °C (kg/dm³) [roOil] 0.930
Grease temperature (°C) [TS] 31.114
Ambient temperature (°C) [TU] 20.000
------- WORM---------------- WHEEL ----
Generating angle (°) [alfa0] 20.064
Pressure angle at normal section (°) [alfn] 20.000
Indications for the manufacture of the worm wheel according to ISO 14521:
(Only valid for worm wheels which are manufactured with a hob similar to the worm.)
Mean lead angle of the worm (°) [gamma] 4.7636
Transverse module (mm) [mt] 0.5000
Reference diameter (mm) [d] 46.000
Reference operating diameter (mm) [dm] 46.000
Throat radius (mm) [rk] 2.500
Throat center distance (mm) [a_rk] 26.000
Facewidth chamfer angle (°) [theta] 0.0000
Chamfering center distance (mm) [a_theta] 26.000
External diameter (mm) [de] 47.500
Tip diameter (mm) [da] 47.000
Profile shift coefficient [x-worm] 0.0000
Pitch on reference circle (mm) [p2] 1.571
Indications for the manufacture of the worm wheel as a cylindrical gear
(This specification is only a suggestion. It is necessary to do a calculation of the exact geometry using the crossed-helical
calculation!)
Pressure angle at Transverse section (°) [alft] ( 77.147) 20.064
Pressure angle at axial section (°) [alfx] ( 20.064) 77.147
Helix angle at reference circle (°) [beta] ( 85.236) 4.764
Lead angle at reference diameter (°) [gamma] ( 4.764) 85.236
Transverse module (mm) [mt] ( 6.000) 0.500
Axial module (mm) [mx] ( 0.500) 6.000
3/8
Helix angle at operating pitch circle (°) [betas] ( 85.236) 4.764
Operating pitch diameter (mm) [dw] ( 6.000) 46.000
Profile shift coefficient [x-DIN3960] ( 0.0000) 0.0000
Overall transmission ratio [itot] -92.000
Gear ratio [u] 92.000
Base helix angle (°) [betab] 4.476
Reference centre distance (mm) [ad] 26.000
Diametral factor q [q] 12.000
Sum of profile shift coefficients [Summexi] 0.0000
Profile shift coefficient [x-worm] 0.0000 0.0000
Profile shift (x*m) (mm) [x*mx] 0.0000 0.0000
(The profile shift is related to the axial module of the worm subject to ISO TR 14521:2010/DIN 3975:2002. )
Tip alteration (mm) [k*mn] 0.000 0.000
Theoretical tip clearance (mm) [c] 0.100 0.100
Effective tip clearance (mm) [c.e/i] 0.165/ 0.114 0.140/ 0.102
Reference operating diameter (mm) [dm] 6.000 46.000
Reference diameter (mm) [d] 46.000
Base diameter (mm) [db] 43.208
Tip diameter (mm) [da] 7.000 47.000
Tip form diameter (mm) [dFa] 7.000 47.000
(mm) [dFa.e/i] 7.000/ 6.990 47.000/ 46.990
Tip diameter allowances (mm) [Ada.e/i] 0.000/ -0.010 0.000/ -0.010
Root diameter (mm) [df] 4.800 44.800
Generating Profile shift coefficient [xE.e/i] -0.0499/ -0.0998
Manufactured root diameter with xE (mm) [df.e/i] 4.775/ 4.750 44.750/ 44.700
Lead height (mm) [pz] 1.571
Axial pitch (mm) [px] 1.571
Transverse contact ratio (approximate value following Thomas-Charchut) [eps_a] 1.921
2. FACTORS OF GENERAL INFLUENCE
------- WORM---------------- WHEEL ----
Nominal circum. force at pitch circle (N) [Ft] 66.4 282.6
Axial force (N) [Fa] -282.6 -66.4
Radial force (N) [Fr] 106.0 -106.0
Normal force (N) [Fn] 308.3
Circumferential speed reference circle (m/s) [v] 0.157 0.013
Sliding velocity an mean circle (m/s) [vgm] 0.158
Number of load cycles (in mio.) [NL] 29.996 0.326
Data of reference gearbox:
Equivalent Young's modulus (N/mm²) [EredT] 150622.00
Surface roughness of worm (µm) [RaT] 0.500
Center distance (mm) [aT] 100.000
Transmission ratio [uT] 20.500
Reference operating diameter (mm) [dm1T] 36.000 164.000
Characteristic value for mean Hertzian pressure [pmT*] 0.962
Characteristic value for mean lubricant gap thickness [hT*] 0.070
Characteristic value for mean sliding path [sT*] 30.800
Physical characteristic values:
Characteristic value for mean lubrication Space width [h*] 0.0439
4/8
Characteristic value for mean Hertzian pressure [pm*] 1.2904
Characteristic value for mean sliding path [s*] 87.3000
Efficiency according method C:
Bearing power loss, Sealing power loss, Idle power loss: not considered
Base friction number [muOT] 0.1000
Size factor [YS] 1.240
Geometry factor [YG] 1.263
Roughness factor [YR] 1.000
Material Coefficient YW [YW] 0.950
Mean tooth friction number [muzm] 0.1488
Tooth friction angle (°) [roz] 8.462
Meshing efficiency (%) [etaz] 35.459
Mesh loss power (kW) [PVZ] 0.006
Total loss power (kW) [PV] 0.006
Total efficiency (calculated with KA) (%) [etaGes] 35.459
Gear mass temperature:
Lubrication type Grease lubrication
Worm submerges into lubricant
Cooling area of wheel-pair (cm²) [AR] 1.932
Heat-transfer coefficient wheels (W/m²/K) [alfL] 9438.920
Gear mass temperature (°C) [theM] 34.6
Oil sump temperature (°C) [theS] 0.0
3. WEAR STRENGTH ACCORDING METHOD B,C
Mean lubricant gap thickness (µm) [hminm] 0.1555
(hminm calculated with etaOM= 0.9857 Ns/m2 theM=34.6°)
Pressure factor [WH] 1.0000
Factor for lubricant structure [WS] 1.0000
Factor for start [WNS] 1.0000
Characteristic value [Kw] 0.1555
Wear intensity [JOT] 9.5283e-009
Wear intensity [Jw] 9.5283e-009
Wear path (m) [sWm] 1881
Wear removal (mm) [delWn] 0.018
Permissible tooth thickness reduction (coefficient in module) [DeltaS] 0.300
Permissible mass decrease (kg)
Normal tooth thickness at tip circle (mm) [san] 0.400
(mm) [san.e/i] 0.385/ 0.363
Permissible wear on flank (mm) [delWlimn] 0.149
Limited by: Permissible tooth thickness decrease
Safety against wear [SW] 8.340
Required safety [SWmin] 1.100
As information:
Achievable service life (with SW = 1.100) (h) [Lh] 7581.67
4. PITTING RESISTANCE ACCORDING METHOD B,C
------- WORM---------------- WHEEL ----
Equivalent Young's modulus (N/mm²) [Ered] 149673.38
Mean contact stress (N/mm²) [sigHm] 380.45
Life coefficient [Zh] 1.600
Speed factor [ZV] 1.097
5/8
Size factor [ZS] 1.013
Lubrication factor [Zoil] 0.890
Ratio factor [Zu] 1.000
Boundary value of average contact stress (N/mm²) [sigHG] 822.243
Safety factor for contact stress [SH] 2.161
Required safety [SHmin] 1.000
As information:
Achievable service life (with SHmin = 1.000) (h) [Lh] 151848.74
5. DEFLECTION SAFETY
Bearing distance l1 (mm) [l1] 42.500
Distance l11 (mm) [l11] 21.250
Deflection (mm) [delm] 0.030
Boundary value bending (mm) [dellim] 0.028
Safety for deflection [Sdel] 0.931
Required safety [Sdelmin] 1.000
6. TOOTH ROOT STRENGTH ACCORDING METHOD C
------- WORM---------------- WHEEL ----
Calculation taking into account the decrease of the tooth thickness due to wear
(with minimum (delWn, delWlimn))
Tooth thickness at root (mm) [sft2] 1.280
Tooth form factor [YF2] 1.133
Contact ratio factor [Yeps] 0.500
Lead coefficient [Ygam] 1.003
Rim thickness (mm) [sk2] 22.400
Rim thickness coefficient [YK2] 1.000
Nominal shear stress at tooth root (N/mm²) [tauF2] 95.64
No Quality reduction by small plastic deformation is accepted.
Life coefficient [YNL] 1.000
Boundary value of shear stress at tooth root (N/mm²) [tauFG] 90.00
Safety for tooth root stress [SF] 0.941
Required safety [SFmin] 1.100
7. TEMPERATURE SAFETY ACCORDING METHOD C
8. ALLOWANCES FOR TOOTH THICKNESS
Tooth thickness deviation
Worm: DIN 58405 6f
Gear: DIN 58405 7f
------- WORM---------------- WHEEL ----
Tooth thickness allowance (normal section) (mm) [As.e/i] -0.009/ -0.018 -0.018/ -0.036
Backlash free center distance (mm) [aControl] 25.963/ 25.925
Backlash free center distance, allowances (mm) [jta] -0.037/ -0.075
Number of teeth spanned [k] 11.000
Base tangent length (mm) [Wk] 16.094
6/8
Actual base tangent length ('span') (mm) [Wk.e/i] 16.077/ 16.060
Diameter of measuring circle (mm) [dMWk.m] 46.082
Base tangent length (span): Can only be measured, if the worm-wheel is manufactured like a cylindrical gear!
Theoretical diameter of ball/pin (mm) [dm] 0.833 0.838
Effective diameter of ball/pin (mm) [DMeff] 0.895 0.895
Radial single-ball measurement backlash free (mm) [MrK] 23.673
Radial single-ball measurement (mm) [MrK.e/i] 23.649/ 23.626
Diameter of measuring circle (mm) [dMMr.m] 6.122 46.064
Diametral measurement over two balls without clearance (mm) [MdK] 47.345
Diametral two ball measure (mm) [MdK.e/i] 47.299/ 47.252
Theoretical dim. over 3 wires (mm) [Md3R] 7.361
Measurement over 3 pins (mm) [Md3R.e/i] 7.336/ 7.311
Normal tooth thickness (chord) in the reference circle (mm) [sc] 0.783 0.783
(mm) [sc.e/i] 0.774/ 0.765 0.765/ 0.746
Tooth thickness in the transverse section (chord) in the reference circle (mm) ['st] 0.785
(mm) ['st.e/i] 0.767/ 0.749
Tooth thickness in the transverse section (Arc) (mm) [st] 0.785
(mm) [st.e/i] 0.767/ 0.749
Tooth thickness on axial cut (mm) [smx] 0.785
(mm) [smx.e/i] 0.776/ 0.767
Tooth space in axial cut (mm) [emx] 0.785
(mm) [emx.e/i] 0.794/ 0.804
Reference chordal height from da.m (mm) [ham1, ha2] 0.498 0.501
Centre distance allowances (mm) [Aa.e/i] 0.011/ -0.011
Circumferential backlash (transverse section) (mm) [jt] 0.062/ 0.020
Normal backlash (mm) [jn] 0.058/ 0.018
9. GEAR ACCURACY
------- WORM---------------- WHEEL ----
According to DIN 3974:1995:
Accuracy grade [Vqual] 6 7
Single pitch deviation (µm) [fpx, fp2] 6.50 9.00
Adjacent pitch difference (µm) [fux, fu2] 7.50 12.00
Total deviation of the slope (µm) [Fpz] 6.50
Total cumulative pitch deviation (µm) [Fp2] 25.00
Profile slope deviation (µm) [fHa] 5.00 7.00
Profile form deviation (µm) [ffa] 5.50 8.00
Total profile deviation (µm) [Fa] 7.50 11.00
Runout (µm) [Fr] 11.00 18.00
Single flank composite, total (µm) [Fi'] 18.00 30.00
Single flank composite, tooth-to-tooth (µm) [fi'] 10.00 14.00
10. ADDITIONAL DATA
Weight - calculated with da (kg) [Mass] 0.003 0.058
Start under load:
Tooth friction number (acc. Niemann) [muzm_S] 0.140
Torque (Nm) [T1_S] 0.192 6.500
7/8
11. SERVICE LIFE, DAMAGE
Could not be calculated.
Required safety for tooth root [SFmin] 1.10
Required safety for tooth flank [SHmin] 1.00
Service life (calculated with required safeties):
System service life (h) [Hatt] 0.000
Tooth root service life (h) [HFatt] 1e+006 0
Tooth flank service life (h) [HHatt] 1e+006 1.519e+005
Note: The entry 1e+006 h means that the Service life > 1,000,000 h.
Damage calculated on the basis of the required service life [H] ( 1000.0 h)
F1% F2% H1% H2%
0.00 9999.99 0.00 0.66
Damage calculated on basis of system service life [Hatt] ( 0.0 h)
F1% F2% H1% H2%
0.00 100.00 0.00 0.00
Calculation of the factors required to define reliability R(t) according to B. Bertsche with Weibull distribution:
R(t) = 100 * Exp(-((t*fac - t0)/(T - t0))^b) %; t (h)
Gear fac b t0 T R(H)%
1 Tooth root 29996 1.7 9.654e+029 1.484e+030 100.00
1 Tooth flank 29996 1.3 9.014e+029 4.295e+030 100.00
2 Tooth root 326 1.7 0 0 0.00
2 Tooth flank 326 1.3 4.463e+007 2.126e+008 100.00
Reliability of the configuration for required service life (%) 0.00 (Bertsche)
REMARKS:
- Specifications with [.e/i] imply: Maximum [e] and Minimal value [i] with
consideration of all tolerances
- The specification of circumferential backlash (as well as the backlash-free distance
for the tooth thickness check) is not yet fully checked,
and serves only as a guide.
- The details of the chordal tooth thickness are imprecise and merely an indication
(The calculation is done according to ISO TR 14521:2010/DIN 3975:2002, without taking into account the exact shape of flank.).
- In ISO14521 and DIN3996, the necessary data for each material are not always complete.
In such a case you get the message: "Not calculated (material data missing)'
End of Report lines: 417
8/8
