_O.GB.gp1.

gp1
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:22

Important hint: At least one warning has occurred during the calculation:
1-> Check in the dialog 'Define details of strength':
- Gear1 Gear2 : Input for profile modification (as for calculation of the safety
against scuffing)

(Equivalent tip relief Ceq: 14.0: 14.0)

(Optimal tip relief Ceff: 13.2: 13.2)

CALCULATION OF A HELICAL GEAR PAIR

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

Calculation method DIN 3990:1987 Method B (YF Method C)

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

Power (kW) [P] 46.800

Speed (1/min) [n] 1500.0 590.2
Torque (Nm) [T] 297.9 757.3
Application factor [KA] 1.00
Required service life [H] 20000.00
Gear driving (+) / driven (-) + -

1/1021/1021/1021/1021/1021/1021/1021/102
1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to

ISO 21771:2007)
------- GEAR 1 -------- GEAR 2 --
Center distance (mm) [a] 100.000
Centre distance tolerance ISO 286:2010 Measure h6
Normal module (mm) [mn] 2.2500
Pressure angle at normal section (°) [alfn] 20.0000
Helix angle at reference circle (°) [beta] 12.0000
Number of teeth [z] 24 61
Facewidth (mm) [b] 45.00 45.00
Hand of gear left right
Accuracy grade [Q-DIN 3961:1978] 6 6
Inner diameter (mm) [di] 0.00 0.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

Material
Gear 1: 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Figure 9/10 (MQ), core strength >=30HRC
Gear 2: 18CrNiMo7-6, Case-carburized steel, case-hardened
ISO 6336-5 Figure 9/10 (MQ), core strength >=30HRC

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

Surface hardness HRC 61 HRC 61
Fatigue strength. tooth root stress (N/mm²)
[sigFlim] 500.00 500.00
Fatigue strength for Hertzian pressure (N/mm²)
[sigHlim] 1500.00 1500.00
Tensile strength (N/mm²) [Rm] 1200.00 1200.00
Yield point (N/mm²) [Rp] 850.00 850.00
Young's modulus (N/mm²) [E] 206000 206000
Poisson's ratio [ny] 0.300 0.300
Mean roughness, Ra, tooth flank (µm) [RAH] 0.60 0.60
Mean roughness height, Rz, flank (µm) [RZH] 4.80 4.80
Mean roughness height, Rz, root (µm) [RZF] 20.00 20.00

Tool or reference profile of gear 1 :

Reference profile 1.40 / 0.39 / 1.0 DIN 867:1986
Addendum coefficient [haP*] 1.000
Dedendum coefficient [hfP*] 1.400
Tip radius factor [rhoaP*] 0.000

2/1022/1022/1022/1022/1022/1022/1022/102
Root radius factor [rhofP*] 0.390
Tip form height coefficient [hFaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Ramp angle [alfKP] 0.000
not topping

Tool or reference profile of gear 2 :

Reference profile 1.40 / 0.39 / 1.0 DIN 867:1986
Addendum coefficient [haP*] 1.000
Dedendum coefficient [hfP*] 1.400
Tip radius factor [rhoaP*] 0.000
Root radius factor [rhofP*] 0.390
Tip form height coefficient [hFaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Ramp angle [alfKP] 0.000
not topping

Summary of reference profile gears:

Dedendum reference profile (module) [hfP*] 1.400 1.400
Tooth root radius Refer. profile (module)
[rofP*] 0.390 0.390
Addendum Reference profile (module) [haP*] 1.000 1.000
Protuberance height factor (module) [hprP*] 0.000 0.000
Protuberance angle (°) [alfprP] 0.000 0.000
Tip form height coefficient (module) [hFaP*] 0.000 0.000
Ramp angle (°) [alfKP] 0.000 0.000
Data for Grinding / Honing:
Depth of immersion (module) [hgrind*] 1.209 1.209
Radius at cutter head (module) [rgrind*] 0.100 0.100

Type of profile modification:

for high load capacity gearboxe
Tip relief (µm) [Ca] 14.0 14.0

Lubrication type oil bath lubrication

Type of oil Oil: ISO-VG 320
Lubricant base Mineral-oil base
Kinem. viscosity oil at 40 °C (mm²/s) [nu40] 320.00
Kinem. viscosity oil at 100 °C (mm²/s) [nu100] 22.00
FZG test A/8.3/90 (

3/1023/1023/1023/1023/1023/1023/1023/102
 ISO 14635-1:2006) [FZGtestA] 12
Specific density at 15 °C (kg/dm³) [roOil] 0.900
Oil temperature (°C) [TS] 95.000

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

Overall transmission ratio [itot] -2.542
Gear ratio [u] 2.542
Transverse module (mm) [mt] 2.300
Pressure angle at pitch circle (°) [alft] 20.410
Working transverse pressure angle (°) [alfwt] 23.618
[alfwt.e/i] 23.618 / 23.589
Working pressure angle at normal section (°) [alfwn] 23.136
Helix angle at operating pitch circle (°)
[betaw] 12.267
Base helix angle (°) [betab] 11.267
Reference centre distance (mm) [ad] 97.761
Sum of profile shift coefficients [Summexi] 1.0715
Profile shift coefficient [x] 0.4928 0.5787
Tooth thickness (Arc) (module) [sn*] 1.9295 1.9921

Tip alteration (mm) [k*mn] -0.172 -0.172

Reference diameter (mm) [d] 55.206 140.316
Base diameter (mm) [db] 51.740 131.507
Tip diameter (mm) [da] 61.580 147.077
(mm) [da.e/i] 61.580 / 61.570 147.077 / 147.067
Tip diameter allowances (mm) [Ada.e/i] 0.000 / -0.010 0.000 / -0.010
Tip chamfer / tip rounding (mm) [hK] 0.000 0.000
Tip form diameter (mm) [dFa] 61.580 147.077
(mm) [dFa.e/i] 61.580 / 61.570 147.077 / 147.067
Active tip diameter (mm) [dNa.e/i] 61.580 / 61.570 147.077 / 147.067
Operating pitch diameter (mm) [dw] 56.471 143.529
(mm) [dw.e/i] 56.471 / 56.458 143.529 / 143.498
Root diameter (mm) [df] 51.124 136.621
Generating Profile shift coefficient [xE.e/i] 0.4501 / 0.4257 0.5207 / 0.4902
Manufactured root diameter with xE (mm) [df.e/i] 50.932 / 50.822 136.359 / 136.222
Theoretical tip clearance (mm) [c] 0.900 0.900
Effective tip clearance (mm) [c.e/i] 1.104 / 1.008 1.056 / 0.974
Active root diameter (mm) [dNf] 53.672 139.565
(mm) [dNf.e/i] 53.678 / 53.643 139.571 / 139.528
Root form diameter (mm) [dFf] 52.868 137.944
(mm) [dFf.e/i] 52.757 / 52.696 137.720 / 137.604
Reserve (dNf-dFf)/2 (mm) [cF.e/i] 0.491 / 0.443 0.983 / 0.904

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Addendum (mm) [ha = mn * (haP*+x)] 3.187 3.380
(mm) [ha.e/i] 3.187 / 3.182 3.380 / 3.375
Dedendum (mm) [hf = mn * (hfP*-x)] 2.041 1.848
(mm) [hf.e/i] 2.137 / 2.192 1.978 / 2.047
Roll angle at dFa (°) [xsi_dFa.e/i] 36.977 / 36.957 28.694 / 28.684
Roll angle to dNa (°) [xsi_dNa.e/i] 36.977 / 36.957 28.694 / 28.684
Roll angle to dNf (°) [xsi_dNf.e/i] 15.825 / 15.678 20.370 / 20.314
Roll angle at dFf (°) [xsi_dFf.e/i] 11.413 / 11.064 17.819 / 17.648
Tooth height (mm) [H] 5.228 5.228
Virtual gear no. of teeth [zn] 25.510 64.838
Normal tooth thickness at tip cyl. (mm) [san] 1.439 1.725
(mm) [san.e/i] 1.367 / 1.317 1.631 / 1.574
Normal spacewidth at root cylinder (mm) [efn] 0.000 1.348
(mm) [efn.e/i] 0.000 / 0.000 1.367 / 1.378
Max. sliding velocity at tip (m/s) [vga] 1.178 0.914
Specific sliding at the tip [zetaa] 0.449 0.449
Specific sliding at the root [zetaf] -0.816 -0.816
Sliding factor on tip [Kga] 0.266 0.206
Sliding factor on root [Kgf] -0.206 -0.266
Pitch on reference circle (mm) [pt] 7.226
Base pitch (mm) [pbt] 6.773
Transverse pitch on contact-path (mm) [pet] 6.773
Lead height (mm) [pz] 815.952 2073.879
Axial pitch (mm) [px] 33.998
Length of path of contact (mm) [ga, e/i] 9.562 ( 9.617 / 9.542)
Length T1-A, T2-A (mm) [T1A, T2A] 7.134( 7.079/ 7.145)
32.929(32.929/32.918)
Length T1-B (mm) [T1B, T2B] 9.923( 9.923/ 9.914)
30.140(30.085/30.149)
Length T1-C (mm) [T1C, T2C] 11.312(11.297/11.312)
28.751(28.712/28.751)
Length T1-D (mm) [T1D, T2D] 13.907(13.852/13.918)
26.157(26.157/26.145)
Length T1-E (mm) [T1E, T2E] 16.696(16.696/16.687)
23.367(23.313/23.377)
Length T1-T2 (mm) [T1T2] 40.063 (40.009 / 40.063)
Diameter of single contact point B (mm)
[d-B] 55.416(55.416/55.410)
144.665(144.619/144.672)
Diameter of single contact point D (mm)
[d-D] 58.743(58.691/58.753)
141.530(141.530/141.522)

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Addendum contact ratio [eps] 0.795( 0.797/ 0.794) 0.617( 0.623/
0.615)
Minimal length of contact line (mm) [Lmin] 60.160

Transverse contact ratio [eps_a] 1.412

Transverse contact ratio with allowances [eps_a.e/m/i] 1.420 / 1.414 / 1.409
Overlap ratio [eps_b] 1.324
Total contact ratio [eps_g] 2.735
Total contact ratio with allowances [eps_g.e/m/i] 2.744 / 2.738 / 2.732

2. FACTORS OF GENERAL INFLUENCE

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

Nominal circum. force at pitch circle (N)
[Ft] 10793.6
Axial force (N) [Fa] 2294.3
Radial force (N) [Fr] 4016.3
Normal force (N) [Fnorm] 11742.9
Tangent.load at p.c.d.per mm (N/mm) (N/mm)
[w] 239.86
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N) [Ftw] 10552.0
Axial force (N) [Faw] 2294.3
Radial force (N) [Frw] 4614.0
Circumferential speed pitch d.. (m/sec) [v] 4.34

Running-in value (µm) [yp] 0.6

Running-in value (µm) [yf] 0.6
Correction coefficient [CM] 0.800
Gear body coefficient [CR] 1.000
Reference profile coefficient [CBS] 0.900
Material coefficient [E/Est] 1.000
Singular tooth stiffness (N/mm/µm) [c'] 13.934
Meshing stiffness (N/mm/µm) [cg] 18.238
Reduced mass (kg/mm) [mRed] 0.00998
Resonance speed (min-1) [nE1] 17012
Running-in value (µm) [ya] 0.3

Dynamic factor [KV] 1.022

User specified factor KHb:

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Face load factor - flank [KHb] 1.100
- Tooth root [KFb] 1.088
- Scuffing [KBb] 1.100

Transverse load factor - flank [KHa] 1.013

- Tooth root [KFa] 1.013
- Scuffing [KBa] 1.013

Helical load factor scuffing [Kbg] 1.258

Number of load cycles (in mio.) [NL] 1800.000 708.197

3. TOOTH ROOT STRENGTH

Calculation of Tooth form coefficients according method: C

(Calculate tooth form factor YF with manufacturing addendum mod. xE.e)
------- GEAR 1 -------- GEAR 2 --
Tooth form factor [YF] 2.20 2.06
Stress correction factor [YS] 1.75 1.87
Working angle (°) [alfFen] 31.03 25.48
Bending lever arm (mm) [hF] 4.63 4.59
Tooth thickness at root (mm) [sFn] 5.09 5.38
Tooth root radius (mm) [roF] 1.07 0.97
(hF* = 2.057/2.041 sFn* = 2.263/2.391 roF* = 0.473/0.430 dsFn = 51.74/137.21 alfsFn =
30.00/30.00)

Contact ratio factor [Yeps] 0.761

Helical load factor [Ybet] 0.900
Effective facewidth (mm) [beff] 45.00 45.00
Nominal shear stress at tooth root (N/mm²)
[sigF0] 280.61 280.36
Tooth root stress (N/mm²) [sigF] 316.00 315.72

Permissible bending stress at root of Test-gear

Support factor [YdrelT] 0.999 1.003
Surface factor [YRrelT] 0.957 0.957
Size coefficient (Tooth root) [YX] 1.000 1.000
Finite life factor [YNT] 1.000 1.000
[YdrelT*YRrelT*YX*YNT] 0.956 0.959
Alternating bending coefficient [YM] 1.000 1.000
Stress correction factor [Yst] 2.00

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Limit strength tooth root (N/mm²) [sigFG] 955.73 959.21
Permissible tooth root stress (N/mm²)
[sigFP=sigFG/SFmin] 682.67 685.15
Required safety [SFmin] 1.40 1.40
Safety for Tooth root stress [SF=sigFG/sigF] 3.02 3.04
Transmittable power (kW) [kWRating] 101.10 101.56

4. SAFETY AGAINST PITTING (TOOTH FLANK)

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

Zone factor [ZH] 2.260
Elasticity coefficient (N^.5/mm) [ZE] 189.812
Contact ratio factor [Zeps] 0.842
Helix angle factor [Zbet] 0.989
Effective facewidth (mm) [beff] 45.00
Nominal flank pressure (N/mm²) [sigH0] 878.50
Surface pressure at operating pitch circle (N/mm²)
[sigHw] 937.52
Single tooth contact factor [ZB,ZD] 1.00 1.00
Flank pressure (N/mm²) [sigH] 937.52 937.52

Lubrication factor [ZL] 1.047 1.047

Speed factor [ZV] 0.979 0.979
Roughness factor [ZR] 0.963 0.963
Material mating factor [ZW] 1.000 1.000
Finite life factor [ZNT] 1.000 1.000
[ZL*ZV*ZR*ZNT] 0.988 0.988
Small amount of pitting permissible (0=no, 1=yes) 0 0
Size coefficient (flank) [ZX] 1.000 1.000
Limit strength pitting (N/mm²) [sigHG] 1481.25 1481.25
Permissible surface pressure (N/mm²) [sigHP=sigHG/SHmin] 1481.25 1481.25

Safety for surface pressure at operating pitch circle

[SHw] 1.58 1.58
Required safety [SHmin] 1.00 1.00
Transmittable power (kW) [kWRating] 116.83 116.83
Safety for stress at single tooth contact
[SHBD=sigHG/sigH] 1.58 1.58
(Safety regarding nominal torque) [(SHBD)^2] 2.50 2.50

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

Calculation did not run. (Lubricant: Load stage micropitting test is unknown

5. STRENGTH AGAINST SCUFFING

Calculation method according to

DIN 3990:1987

Lubrication coefficient (for lubrication type)

[XS] 1.000
Relative structure coefficient (Scuffing)
[XWrelT] 1.000
Thermal contact factor (N/mm/s^.5/K) [BM] 13.780 13.780
Relevant tip relief (µm) [Ca] 14.00 14.00
Optimal tip relief (µm) [Ceff] 13.15
Effective facewidth (mm) [beff] 45.000
Applicable circumferential force/facewidth (N/mm)
[wBt] 343.677
Pressure angle factor (eps1:
0.795, eps2: 0.617) [Xalfbet] 1.026

Flash temperature-criteria
Tooth mass temperature (°C) [theM-B] 109.03
theM-B = theoil + XS*0.47*theflamax [theflamax] 29.86
Scuffing temperature (°C) [theS] 403.59
Coordinate gamma (point of highest temp.) [Gamma] 0.229
[Gamma.A]= -0.369 [Gamma.E]= 0.476
Highest contact temp. (°C) [theB] 138.89
Flash factor (°K*N^-.75*s^.5*m^-.5*mm) [XM] 50.058
Geometry factor [XB] 0.115
Load sharing factor [XGam] 1.000
Dynamic viscosity (mPa*s) [etaM] 14.27
Coefficient of friction [mym] 0.097
Required safety [SBmin] 2.000
Safety factor for scuffing (flash-temp) [SB] 7.029

Integral temperature-criteria
Tooth mass temperature (°C) [theM-C] 105.07

9/1029/1029/1029/1029/1029/1029/1029/102
 theM-C = theoil + XS*0.70*theflaint [theflaint] 14.39
Integral scuffing temperature (°C) [theSint] 403.59
Flash factor (°K*N^-.75*s^.5*m^-.5*mm) [XM] 50.058
Contact ratio factor [Xeps] 0.278
Dynamic viscosity (mPa*s) [etaOil] 21.55
Averaged coefficient of friction [mym] 0.091
Geometry factor [XBE] 0.228
Meshing factor [XQ] 1.000
Tip relief factor [XCa] 1.081
Integral tooth flank temperature (°C) [theint] 126.65
Required safety [SSmin] 1.800
Safety factor for scuffing (intg.-temp.) [SSint] 3.187
Safety referring to transferred torque [SSL] 9.750

6. MEASUREMENTS FOR TOOTH THICKNESS

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

Tooth thickness deviation DIN 3967:1978 cd2 DIN 3967:1978
cd2
Tooth thickness allowance (normal section) (mm)
[As.e/i] -0.070 / -0.110 -0.095 /
-0.145

Number of teeth spanned [k] 4.000 9.000

Base tangent length (no backlash) (mm) [Wk] 24.812 59.398
Actual base tangent length ('span') (mm) [Wk.e/i] 24.746 / 24.709 59.308 /
59.261
Diameter of contact point (mm) [dMWk.m] 57.142 143.787

Theoretical diameter of ball/pin (mm) [DM] 4.305 4.002

Eff. Diameter of ball/pin (mm) [DMeff] 4.500 4.000
Theor. dim. centre to ball (mm) [MrK] 32.138 74.248
Actual dimension centre to ball (mm) [MrK.e/i] 32.071 / 32.032 74.137 /
74.079
Diameter of contact point (mm) [dMMr.m] 57.540 142.651
Diametral measurement over two balls without clearance (mm)
[MdK] 64.276 148.447
Actual dimension over balls (mm) [MdK.e/i] 64.142 / 64.064 148.227 /
148.110
Diametral measurement over rolls without clearance (mm)
[MdR] 64.276 148.495

10/10210/10210/10210/10210/10210/10210/10210/102
Actual dimension over rolls (mm) [MdR.e/i] 64.142 / 64.064 148.275 /
148.158
Dimensions over 3 rolls without clearance (mm)
[Md3R] 0.000 148.495
Actual dimensions over 3 rolls (mm) [Md3R.e/i] 0.000 / 0.000 148.275 /
148.158

Chordal tooth thickness (no backlash) (mm)

['sn] 4.337 4.481
Actual chordal tooth thickness (mm) ['sn.e/i] 4.267 / 4.227 4.386 / 4.336
Reference chordal height from da.m (mm) [ha] 3.266 3.412
Tooth thickness (Arc) (mm) [sn] 4.341 4.482
(mm) [sn.e/i] 4.271 / 4.231 4.387 / 4.337

Backlash free center distance (mm) [aControl.e/i] 99.802 / 99.693

Backlash free center distance, allowances (mm)
[jta] -0.198 / -0.307
Centre distance allowances (mm) [Aa.e/i] 0.000 / -0.022
Circumferential backlash from Aa (mm) [jt_Aa.e/i] 0.000 / -0.019
Radial clearance (mm) [jr] 0.307 / 0.176
Circumferential backlash (transverse section) (mm)
[jt] 0.267 / 0.153
Torsional angle for fixed gear 1 (°) 0.2178 /0.1252
Normal backlash (mm) [jn] 0.245 / 0.141

7. GEAR ACCURACY

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

According to
DIN 3961:1978:
Accuracy grade [Q-DIN3961] 6 6
Profile form deviation (µm) [ff] 8.00 8.00
Profile slope deviation (µm) [fHa] 6.00 6.00
Total profile deviation (µm) [Ff] 10.00 10.00
Helix form deviation (µm) [ffb] 8.00 8.00
Helix slope deviation (µm) [fHb] 10.00 10.00
Total helix deviation (µm) [Fb] 13.00 13.00
Normal base pitch deviation (µm) [fpe] 8.00 8.00
Single pitch deviation (µm) [fp] 8.00 8.00
Difference between adjacent pitches (µm) [fu] 10.00 10.00
Total cumulative pitch deviation (µm) [Fp] 27.00 32.00

11/10211/10211/10211/10211/10211/10211/10211/102
Cumulative circular pitch deviation over z/8 pitches (µm)
[Fpz/8] 17.00 20.00
Concentricity deviation (µm) [Fr] 19.00 22.00
Tooth Thickness Variation (µm) [Rs] 11.00 13.00
Total radial composite deviation (µm) [Fi"] 22.00 26.00
Radial tooth-to-tooth composite deviation (µm)
[fi"] 9.00 11.00
Total tangential composite deviation (µm)
[Fi'] 30.00 34.00
Tangential tooth-to-tooth composite deviation (µm)
[fi'] 13.00 13.00

According to
DIN 58405:1972 (Feinwerktechnik):
Tooth-to-tooth composite error (µm) [fi"] 9.00 10.00
Composite error (µm) [Fi"] 25.00 28.00
Axis alignment error (µm) [fp] 17.00 17.00
Flank direction error (µm) [fbeta] 9.45 9.45
Concentricity deviation (µm) [Trk, Fr] 24.00 28.00

Axis alignment tolerances (recommendation acc. ISO TR 10064:1992, Quality

6)
Maximum value for deviation error of axis (µm)
[fSigbet] 15.00 (Fb=15.00)
Maximum value for inclination error of axes (µm)
[fSigdel] 30.00

8. ADDITIONAL DATA

Maximal possible centre distance (eps_a=1.0)

[aMAX] 101.150
Torsional stiffness (MNm/rad) [cr] 0.5 3.5
Mean coeff. of friction (acc. Niemann) [mum] 0.073
Wear sliding coef. by Niemann [zetw] 0.634
Power loss from gear load (kW) [PVZ] 0.383
(Meshing efficiency (%) [etaz] 99.181)
Weight - calculated with da (kg) [Mass] 1.049 5.986
Total weight (kg) [Mass] 7.036
Moment of inertia (System referenced to wheel 1):
calculation without consideration of the exact tooth shape
single gears ((da+df)/2...di) (kg*m²) [TraeghMom] 0.0003457 0.01394

12/10212/10212/10212/10212/10212/10212/10212/102
System ((da+df)/2...di) (kg*m²) [TraeghMom] 0.002503

9. DETERMINATION OF TOOTHFORM

Profile and tooth trace modifications for gear 1

Symmetric (both flanks)
- Tip relief, linear Caa = 14.000µm LCa = 0.620*mn dCa = 60.113mm

Profile and tooth trace modifications for gear 2

Symmetric (both flanks)
- Tip relief, linear Caa = 14.000µm LCa = 0.620*mn dCa = 145.849mm

Data for the tooth form calculation :

Data not available.

REMARKS:
- Specifications with [.e/i] imply: Maximum [e] and Minimal value [i] with
consideration of all tolerances
Specifications with [.m] imply: Mean value within tolerance
- For the backlash tolerance, the center distance tolerances and the tooth thickness
deviation are taken into account. Shown is the maximal and the minimal backlash
corresponding
the largest resp. the smallest allowances
The calculation is done for the Operating pitch circle..
- Details of calculation method:
cg according to method B
KV according to method B
KHb, KFb according method C
KHa, KFa according to method B

End report lines: 500

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_O.GB.gp2.gp2
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:24

Important hint: At least one warning has occurred during the calculation:
1-> Check in the dialog 'Define details of strength':
- Gear1 Gear2 : Input for profile modification (as for calculation of the safety
against scuffing)

(Equivalent tip relief Ceq: 32.0: 32.0)

(Optimal tip relief Ceff: 30.5: 30.5)

CALCULATION OF A HELICAL GEAR PAIR

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

Calculation method DIN 3990:1987 Method B (YF Method C)

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

Power (kW) [P] 46.800

Speed (1/min) [n] 590.2 149.6
Torque (Nm) [T] 757.3 2987.0
Application factor [KA] 1.00
Required service life [H] 20000.00
Gear driving (+) / driven (-) + -

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1. TOOTH GEOMETRY AND MATERIAL

(geometry calculation according to

ISO 21771:2007)
------- GEAR 1 -------- GEAR 2 --
Center distance (mm) [a] 125.000
Centre distance tolerance ISO 286:2010 Measure h6
Normal module (mm) [mn] 2.7500
Pressure angle at normal section (°) [alfn] 20.0000
Helix angle at reference circle (°) [beta] 10.0000
Number of teeth [z] 18 71
Facewidth (mm) [b] 56.00 56.00
Hand of gear right left
Accuracy grade [Q-DIN 3961:1978] 6 6
Inner diameter (mm) [di] 0.00 0.00
Inner diameter of gear rim (mm) [dbi] 0.00 0.00

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

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

Surface hardness HRC 61 HRC 61
Fatigue strength. tooth root stress (N/mm²)
[sigFlim] 430.00 430.00
Fatigue strength for Hertzian pressure (N/mm²)
[sigHlim] 1500.00 1500.00
Tensile strength (N/mm²) [Rm] 1200.00 1200.00
Yield point (N/mm²) [Rp] 850.00 850.00
Young's modulus (N/mm²) [E] 206000 206000
Poisson's ratio [ny] 0.300 0.300
Mean roughness, Ra, tooth flank (µm) [RAH] 0.60 0.60
Mean roughness height, Rz, flank (µm) [RZH] 4.80 4.80
Mean roughness height, Rz, root (µm) [RZF] 20.00 20.00

Tool or reference profile of gear 1 :

Reference profile 1.40 / 0.39 / 1.0 DIN 867:1986
Addendum coefficient [haP*] 1.000

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Dedendum coefficient [hfP*] 1.400
Tip radius factor [rhoaP*] 0.000
Root radius factor [rhofP*] 0.390
Tip form height coefficient [hFaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Ramp angle [alfKP] 0.000
not topping

Tool or reference profile of gear 2 :

Reference profile 1.40 / 0.39 / 1.0 DIN 867:1986
Addendum coefficient [haP*] 1.000
Dedendum coefficient [hfP*] 1.400
Tip radius factor [rhoaP*] 0.000
Root radius factor [rhofP*] 0.390
Tip form height coefficient [hFaP*] 0.000
Protuberance height factor [hprP*] 0.000
Protuberance angle [alfprP] 0.000
Ramp angle [alfKP] 0.000
not topping

Summary of reference profile gears:

Dedendum reference profile (module) [hfP*] 1.400 1.400
Tooth root radius Refer. profile (module)
[rofP*] 0.390 0.390
Addendum Reference profile (module) [haP*] 1.000 1.000
Protuberance height factor (module) [hprP*] 0.000 0.000
Protuberance angle (°) [alfprP] 0.000 0.000
Tip form height coefficient (module) [hFaP*] 0.000 0.000
Ramp angle (°) [alfKP] 0.000 0.000
Data for Grinding / Honing:
Depth of immersion (module) [hgrind*] 1.209 1.209
Radius at cutter head (module) [rgrind*] 0.100 0.100

Type of profile modification:

for high load capacity gearboxe
Tip relief (µm) [Ca] 32.0 32.0

Lubrication type oil bath lubrication

Type of oil Oil: ISO-VG 320
Lubricant base Mineral-oil base
Kinem. viscosity oil at 40 °C (mm²/s) [nu40] 320.00

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Kinem. viscosity oil at 100 °C (mm²/s) [nu100] 22.00
FZG test A/8.3/90 (
ISO 14635-1:2006) [FZGtestA] 12
Specific density at 15 °C (kg/dm³) [roOil] 0.900
Oil temperature (°C) [TS] 95.000

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

Overall transmission ratio [itot] -3.944
Gear ratio [u] 3.944
Transverse module (mm) [mt] 2.792
Pressure angle at pitch circle (°) [alft] 20.284
Working transverse pressure angle (°) [alfwt] 21.179
[alfwt.e/i] 21.179 / 21.149
Working pressure angle at normal section (°) [alfwn] 20.882
Helix angle at operating pitch circle (°)
[betaw] 10.058
Base helix angle (°) [betab] 9.391
Reference centre distance (mm) [ad] 124.263
Sum of profile shift coefficients [Summexi] 0.2738
Profile shift coefficient [x] 0.3988 -0.1251
Tooth thickness (Arc) (module) [sn*] 1.8611 1.4798

Tip alteration (mm) [k*mn] -0.016 -0.016

Reference diameter (mm) [d] 50.264 198.262
Base diameter (mm) [db] 47.147 185.968
Tip diameter (mm) [da] 57.925 203.042
(mm) [da.e/i] 57.925 / 57.915 203.042 / 203.032
Tip diameter allowances (mm) [Ada.e/i] 0.000 / -0.010 0.000 / -0.010
Tip chamfer / tip rounding (mm) [hK] 0.000 0.000
Tip form diameter (mm) [dFa] 57.925 203.042
(mm) [dFa.e/i] 57.925 / 57.915 203.042 / 203.032
Active tip diameter (mm) [dNa.e/i] 57.925 / 57.915 203.042 / 203.032
Operating pitch diameter (mm) [dw] 50.562 199.438
(mm) [dw.e/i] 50.562 / 50.552 199.438 / 199.398
Root diameter (mm) [df] 44.757 189.874
Generating Profile shift coefficient [xE.e/i] 0.3639 / 0.3439 -0.1725 /
-0.1975
Manufactured root diameter with xE (mm) [df.e/i] 44.565 / 44.455 189.613 / 189.476
Theoretical tip clearance (mm) [c] 1.100 1.100
Effective tip clearance (mm) [c.e/i] 1.305 / 1.206 1.256 / 1.171
Active root diameter (mm) [dNf] 47.965 194.410
(mm) [dNf.e/i] 47.969 / 47.939 194.415 / 194.369

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Root form diameter (mm) [dFf] 47.480 192.215
(mm) [dFf.e/i] 47.417 / 47.384 192.026 / 191.927
Reserve (dNf-dFf)/2 (mm) [cF.e/i] 0.292 / 0.261 1.244 / 1.172
Addendum (mm) [ha = mn * (haP*+x)] 3.831 2.390
(mm) [ha.e/i] 3.831 / 3.826 2.390 / 2.385
Dedendum (mm) [hf = mn * (hfP*-x)] 2.753 4.194
(mm) [hf.e/i] 2.849 / 2.904 4.324 / 4.393
Roll angle at dFa (°) [xsi_dFa.e/i] 40.897 / 40.876 25.110 / 25.102
Roll angle to dNa (°) [xsi_dNa.e/i] 40.897 / 40.876 25.110 / 25.102
Roll angle to dNf (°) [xsi_dNf.e/i] 10.749 / 10.551 17.464 / 17.416
Roll angle at dFf (°) [xsi_dFf.e/i] 6.146 / 5.761 14.743 / 14.621
Tooth height (mm) [H] 6.584 6.584
Virtual gear no. of teeth [zn] 18.778 74.067
Normal tooth thickness at tip cyl. (mm) [san] 1.425 2.238
(mm) [san.e/i] 1.351 / 1.298 2.145 / 2.090
Normal spacewidth at root cylinder (mm) [efn] 0.000 2.000
(mm) [efn.e/i] 0.000 / 0.000 2.036 / 2.055
Max. sliding velocity at tip (m/s) [vga] 0.596 0.366
Specific sliding at the tip [zetaa] 0.573 0.573
Specific sliding at the root [zetaf] -1.343 -1.342
Sliding factor on tip [Kga] 0.381 0.234
Sliding factor on root [Kgf] -0.234 -0.381
Pitch on reference circle (mm) [pt] 8.773
Base pitch (mm) [pbt] 8.229
Transverse pitch on contact-path (mm) [pet] 8.229
Lead height (mm) [pz] 895.540 3532.407
Axial pitch (mm) [px] 49.752
Length of path of contact (mm) [ga, e/i] 12.416 (12.485 / 12.395)
Length T1-A, T2-A (mm) [T1A, T2A] 4.410( 4.341/ 4.423)
40.750(40.750/40.738)
Length T1-B (mm) [T1B, T2B] 8.598( 8.598/ 8.589)
36.562(36.493/36.571)
Length T1-C (mm) [T1C, T2C] 9.134( 9.120/ 9.134)
36.027(35.971/36.027)
Length T1-D (mm) [T1D, T2D] 12.639(12.570/12.651)
32.521(32.521/32.509)
Length T1-E (mm) [T1E, T2E] 16.826(16.826/16.818)
28.334(28.265/28.342)
Length T1-T2 (mm) [T1T2] 45.160 (45.091 / 45.160)
Diameter of single contact point B (mm)
[d-B] 50.185(50.185/50.179)
199.828(199.777/199.834)

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Diameter of single contact point D (mm)
[d-D] 53.496(53.430/53.507)
197.014(197.014/197.006)
Addendum contact ratio [eps] 0.935( 0.937/ 0.934) 0.574( 0.581/
0.572)
Minimal length of contact line (mm) [Lmin] 82.423

Transverse contact ratio [eps_a] 1.509

Transverse contact ratio with allowances [eps_a.e/m/i] 1.517 / 1.512 / 1.506
Overlap ratio [eps_b] 1.126
Total contact ratio [eps_g] 2.634
Total contact ratio with allowances [eps_g.e/m/i] 2.643 / 2.637 / 2.632

2. FACTORS OF GENERAL INFLUENCE

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

Nominal circum. force at pitch circle (N)
[Ft] 30131.5
Axial force (N) [Fa] 5313.0
Radial force (N) [Fr] 11136.2
Normal force (N) [Fnorm] 32559.9
Tangent.load at p.c.d.per mm (N/mm) (N/mm)
[w] 538.06
Only as information: Forces at operating pitch circle:
Nominal circumferential force (N) [Ftw] 29953.8
Axial force (N) [Faw] 5313.0
Radial force (N) [Frw] 11605.6
Circumferential speed pitch d.. (m/sec) [v] 1.55

Running-in value (µm) [yp] 0.6

Running-in value (µm) [yf] 0.6
Correction coefficient [CM] 0.800
Gear body coefficient [CR] 1.000
Reference profile coefficient [CBS] 0.900
Material coefficient [E/Est] 1.000
Singular tooth stiffness (N/mm/µm) [c'] 12.775
Meshing stiffness (N/mm/µm) [cg] 17.650
Reduced mass (kg/mm) [mRed] 0.00896
Resonance speed (min-1) [nE1] 23545
Running-in value (µm) [ya] 0.3

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Dynamic factor [KV] 1.003

User specified factor KHb:

Face load factor - flank [KHb] 1.100
- Tooth root [KFb] 1.088
- Scuffing [KBb] 1.100

Transverse load factor - flank [KHa] 1.000

- Tooth root [KFa] 1.000
- Scuffing [KBa] 1.000

Helical load factor scuffing [Kbg] 1.245

Number of load cycles (in mio.) [NL] 708.197 179.543

3. TOOTH ROOT STRENGTH

Calculation of Tooth form coefficients according method: C

(Calculate tooth form factor YF with manufacturing addendum mod. xE.e)
------- GEAR 1 -------- GEAR 2 --
Tooth form factor [YF] 2.48 2.39
Stress correction factor [YS] 1.65 1.65
Working angle (°) [alfFen] 33.79 22.76
Bending lever arm (mm) [hF] 5.93 5.70
Tooth thickness at root (mm) [sFn] 5.91 6.21
Tooth root radius (mm) [roF] 1.40 1.57
(hF* = 2.157/2.072 sFn* = 2.150/2.258 roF* = 0.508/0.572 dsFn = 45.54/190.84 alfsFn =
30.00/30.00)

Contact ratio factor [Yeps] 0.734

Helical load factor [Ybet] 0.917
Effective facewidth (mm) [beff] 56.00 56.00
Nominal shear stress at tooth root (N/mm²)
[sigF0] 536.08 518.63
Tooth root stress (N/mm²) [sigF] 584.80 565.77

Permissible bending stress at root of Test-gear

Support factor [YdrelT] 0.996 0.995
Surface factor [YRrelT] 0.957 0.957
Size coefficient (Tooth root) [YX] 1.000 1.000
Finite life factor [YNT] 1.000 1.000

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 [YdrelT*YRrelT*YX*YNT] 0.953 0.952
Alternating bending coefficient [YM] 1.000 1.000
Stress correction factor [Yst] 2.00
Limit strength tooth root (N/mm²) [sigFG] 819.72 818.51
Permissible tooth root stress (N/mm²)
[sigFP=sigFG/SFmin] 585.52 584.65
Required safety [SFmin] 1.40 1.40
Safety for Tooth root stress [SF=sigFG/sigF] 1.40 1.45
Transmittable power (kW) [kWRating] 46.86 48.36

4. SAFETY AGAINST PITTING (TOOTH FLANK)

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

Zone factor [ZH] 2.406
Elasticity coefficient (N^.5/mm) [ZE] 189.812
Contact ratio factor [Zeps] 0.814
Helix angle factor [Zbet] 0.992
Effective facewidth (mm) [beff] 56.00
Nominal flank pressure (N/mm²) [sigH0] 1351.46
Surface pressure at operating pitch circle (N/mm²)
[sigHw] 1419.56
Single tooth contact factor [ZB,ZD] 1.00 1.00
Flank pressure (N/mm²) [sigH] 1419.56 1419.56

Lubrication factor [ZL] 1.047 1.047

Speed factor [ZV] 0.960 0.960
Roughness factor [ZR] 0.969 0.969
Material mating factor [ZW] 1.000 1.000
Finite life factor [ZNT] 1.000 1.000
[ZL*ZV*ZR*ZNT] 0.974 0.974
Small amount of pitting permissible (0=no, 1=yes) 0 0
Size coefficient (flank) [ZX] 1.000 1.000
Limit strength pitting (N/mm²) [sigHG] 1461.64 1461.64
Permissible surface pressure (N/mm²) [sigHP=sigHG/SHmin] 1461.64 1461.64

Safety for surface pressure at operating pitch circle

[SHw] 1.03 1.03
Required safety [SHmin] 1.00 1.00
Transmittable power (kW) [kWRating] 49.62 49.62
Safety for stress at single tooth contact

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 [SHBD=sigHG/sigH] 1.03 1.03
(Safety regarding nominal torque) [(SHBD)^2] 1.06 1.06

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

Calculation did not run. (Lubricant: Load stage micropitting test is unknown

5. STRENGTH AGAINST SCUFFING

Calculation method according to

DIN 3990:1987

Lubrication coefficient (for lubrication type)

[XS] 1.000
Relative structure coefficient (Scuffing)
[XWrelT] 1.000
Thermal contact factor (N/mm/s^.5/K) [BM] 13.780 13.780
Relevant tip relief (µm) [Ca] 32.00 32.00
Optimal tip relief (µm) [Ceff] 30.48
Effective facewidth (mm) [beff] 56.000
Applicable circumferential force/facewidth (N/mm)
[wBt] 739.116
Pressure angle factor (eps1:
0.935, eps2: 0.574) [Xalfbet] 0.992

Flash temperature-criteria
Tooth mass temperature (°C) [theM-B] 132.42
theM-B = theoil + XS*0.47*theflamax [theflamax] 79.61
Scuffing temperature (°C) [theS] 403.59
Coordinate gamma (point of highest temp.) [Gamma] 0.384
[Gamma.A]= -0.517 [Gamma.E]= 0.842
Highest contact temp. (°C) [theB] 212.02
Flash factor (°K*N^-.75*s^.5*m^-.5*mm) [XM] 50.058
Geometry factor [XB] 0.172
Load sharing factor [XGam] 1.000
Dynamic viscosity (mPa*s) [etaM] 8.06
Coefficient of friction [mym] 0.176
Required safety [SBmin] 2.000
Safety factor for scuffing (flash-temp) [SB] 2.637

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Integral temperature-criteria
Tooth mass temperature (°C) [theM-C] 112.61
theM-C = theoil + XS*0.70*theflaint [theflaint] 25.16
Integral scuffing temperature (°C) [theSint] 403.59
Flash factor (°K*N^-.75*s^.5*m^-.5*mm) [XM] 50.058
Contact ratio factor [Xeps] 0.251
Dynamic viscosity (mPa*s) [etaOil] 21.55
Averaged coefficient of friction [mym] 0.151
Geometry factor [XBE] 0.345
Meshing factor [XQ] 1.000
Tip relief factor [XCa] 1.361
Integral tooth flank temperature (°C) [theint] 150.36
Required safety [SSmin] 1.800
Safety factor for scuffing (intg.-temp.) [SSint] 2.684
Safety referring to transferred torque [SSL] 5.574

6. MEASUREMENTS FOR TOOTH THICKNESS

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

Tooth thickness deviation DIN 3967:1978 cd2 DIN 3967:1978
cd2
Tooth thickness allowance (normal section) (mm)
[As.e/i] -0.070 / -0.110 -0.095 /
-0.145

Number of teeth spanned [k] 3.000 9.000

Base tangent length (no backlash) (mm) [Wk] 21.770 71.628
Actual base tangent length ('span') (mm) [Wk.e/i] 21.705 / 21.667 71.538 /
71.491
Diameter of contact point (mm) [dMWk.m] 51.774 198.902

Theoretical diameter of ball/pin (mm) [DM] 5.353 4.604

Eff. Diameter of ball/pin (mm) [DMeff] 5.500 5.000
Theor. dim. centre to ball (mm) [MrK] 30.382 102.627
Actual dimension centre to ball (mm) [MrK.e/i] 30.318 / 30.281 102.505 /
102.440
Diameter of contact point (mm) [dMMr.m] 52.496 198.186
Diametral measurement over two balls without clearance (mm)
[MdK] 60.764 205.205
Actual dimension over balls (mm) [MdK.e/i] 60.635 / 60.562 204.960 /

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204.831
Diametral measurement over rolls without clearance (mm)
[MdR] 60.764 205.254
Actual dimension over rolls (mm) [MdR.e/i] 60.635 / 60.562 205.009 /
204.880
Dimensions over 3 rolls without clearance (mm)
[Md3R] 0.000 205.254
Actual dimensions over 3 rolls (mm) [Md3R.e/i] 0.000 / 0.000 205.009 /
204.880

Chordal tooth thickness (no backlash) (mm)

['sn] 5.110 4.069
Actual chordal tooth thickness (mm) ['sn.e/i] 5.040 / 5.000 3.974 / 3.924
Reference chordal height from da.m (mm) [ha] 3.955 2.408
Tooth thickness (Arc) (mm) [sn] 5.118 4.069
(mm) [sn.e/i] 5.048 / 5.008 3.974 / 3.924

Backlash free center distance (mm) [aControl.e/i] 124.781 /124.661

Backlash free center distance, allowances (mm)
[jta] -0.219 / -0.339
Centre distance allowances (mm) [Aa.e/i] 0.000 / -0.025
Circumferential backlash from Aa (mm) [jt_Aa.e/i] 0.000 / -0.019
Radial clearance (mm) [jr] 0.339 / 0.194
Circumferential backlash (transverse section) (mm)
[jt] 0.260 / 0.149
Torsional angle for fixed gear 1 (°) 0.1505 /0.0862
Normal backlash (mm) [jn] 0.241 / 0.138

7. GEAR ACCURACY

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

According to
DIN 3961:1978:
Accuracy grade [Q-DIN3961] 6 6
Profile form deviation (µm) [ff] 8.00 8.00
Profile slope deviation (µm) [fHa] 6.00 6.00
Total profile deviation (µm) [Ff] 10.00 10.00
Helix form deviation (µm) [ffb] 8.00 8.00
Helix slope deviation (µm) [fHb] 10.00 10.00
Total helix deviation (µm) [Fb] 13.00 13.00
Normal base pitch deviation (µm) [fpe] 8.00 8.00

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Single pitch deviation (µm) [fp] 8.00 8.00
Difference between adjacent pitches (µm) [fu] 10.00 10.00
Total cumulative pitch deviation (µm) [Fp] 27.00 32.00
Cumulative circular pitch deviation over z/8 pitches (µm)
[Fpz/8] 17.00 20.00
Concentricity deviation (µm) [Fr] 19.00 22.00
Tooth Thickness Variation (µm) [Rs] 11.00 13.00
Total radial composite deviation (µm) [Fi"] 22.00 26.00
Radial tooth-to-tooth composite deviation (µm)
[fi"] 9.00 11.00
Total tangential composite deviation (µm)
[Fi'] 30.00 34.00
Tangential tooth-to-tooth composite deviation (µm)
[fi'] 13.00 13.00

According to
DIN 58405:1972 (Feinwerktechnik):
Tooth-to-tooth composite error (µm) [fi"] 9.00 10.00
Composite error (µm) [Fi"] 25.00 28.00
Axis alignment error (µm) [fp] 21.25 21.25
Flank direction error (µm) [fbeta] 11.76 11.76
Concentricity deviation (µm) [Trk, Fr] 24.00 30.00

Axis alignment tolerances (recommendation acc. ISO TR 10064:1992, Quality

6)
Maximum value for deviation error of axis (µm)
[fSigbet] 15.00 (Fb=15.00)
Maximum value for inclination error of axes (µm)
[fSigdel] 30.00

8. ADDITIONAL DATA

Maximal possible centre distance (eps_a=1.0)

[aMAX] 126.573
Torsional stiffness (MNm/rad) [cr] 0.5 8.5
Mean coeff. of friction (acc. Niemann) [mum] 0.113
Wear sliding coef. by Niemann [zetw] 0.865
Power loss from gear load (kW) [PVZ] 0.816
(Meshing efficiency (%) [etaz] 98.257)
Weight - calculated with da (kg) [Mass] 1.156 14.198
Total weight (kg) [Mass] 15.353

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Moment of inertia (System referenced to wheel 1):
calculation without consideration of the exact tooth shape
single gears ((da+df)/2...di) (kg*m²) [TraeghMom] 0.0002962 0.06391
System ((da+df)/2...di) (kg*m²) [TraeghMom] 0.004404

9. DETERMINATION OF TOOTHFORM

Profile and tooth trace modifications for gear 1

Symmetric (both flanks)
- Tip relief, linear Caa = 32.000µm LCa = 0.761*mn dCa = 55.597mm

Profile and tooth trace modifications for gear 2

Symmetric (both flanks)
- Tip relief, linear Caa = 32.000µm LCa = 0.761*mn dCa = 201.398mm

Data for the tooth form calculation :

Data not available.

REMARKS:
- Specifications with [.e/i] imply: Maximum [e] and Minimal value [i] with
consideration of all tolerances
Specifications with [.m] imply: Mean value within tolerance
- For the backlash tolerance, the center distance tolerances and the tooth thickness
deviation are taken into account. Shown is the maximal and the minimal backlash
corresponding
the largest resp. the smallest allowances
The calculation is done for the Operating pitch circle..
- Details of calculation method:
cg according to method B
KV according to method B
KHb, KFb according method C
KHa, KFa according to method B

End report lines: 500

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_O.GB.s1.b1
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:25

Important hint: At least one warning has occurred during the calculation:
1-> Angular contact ball bearing, taper roller bearing and high precision angular contact
ball bearing :
If you want to calculate the reciprocal influence of a bearing pair in face-to-face or
back-to-back arrangement,
you have to choose the option under 'Basic data', 'Additional data'!

ROLLER BEARING ANALYSIS

Calculation method: ISO 281:2007 und Herstellerangaben

- With constant a23-factor (1.0)
General data:
Speed (1/min) 1500.000
Axial force (N) -2294.252
Required service life (h) 20000.000

Roller bearing No. 1:

Bearing type SKF 32310 J2/Q
Type Taper roller bearing (single row)
Radial and axial load
Radial force (N) [Fr] 3861.288

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Axial force (N) [Fa] -2294.252

Inner diameter (mm) [d] 50.000

External diameter (mm) [D] 110.000
Width (mm) [T] 42.250
Dynamic load number (kN) [C] 172.000
Static load number (kN) [C0] 212.000
Speed limit (oil) (1/min) [n.max] 6300
Dynamic equivalent load (N) [P] 5444.744
Static equivalent load (N) [P0] 3995.471
Torque of friction (Nmm) [M] 1630.195

Service life (h) [Lh] 1107288.733

Static safety factor [S0] 53.060

Roller bearing No. 2:

Bearing type SKF 32310 J2/Q
Type Taper roller bearing (single row)
Radial and axial load
Radial force (N) [Fr] 7718.049
Axial force (N) [Fa] 0.000

Inner diameter (mm) [d] 50.000

External diameter (mm) [D] 110.000
Width (mm) [T] 42.250
Dynamic load number (kN) [C] 172.000
Static load number (kN) [C0] 212.000
Speed limit (oil) (1/min) [n.max] 6300
Dynamic equivalent load (N) [P] 7718.049
Static equivalent load (N) [P0] 7718.049
Torque of friction (Nmm) [M] 936.445

Service life (h) [Lh] 346067.229

Static safety factor [S0] 27.468

Torque of friction M is calculated according to the indications in the SKF catalog 2004..

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End report lines: 69

29/10229/10229/10229/10229/10229/10229/10229/102
_O.GB.s1.s1
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:25

Analysis of shafts, axle and beams

Input data

Coordinate system shaft: see picture W-002

Label s1
Drawing
Initial position (mm) 0.000
Length (mm) 414.000
Speed (1/min) 1500.00
Sense of rotation: clockwise

Material 42 CrMo 4 (1)

Young's modulus (N/mm²) 206000.000
Poisson's ratio nu 0.300
Specific weight (kg/m³) 7830.000
Warmth elongation coefficient (10^-6/K) 11.500
Temperature (°C) 20.000
Weight of shaft (kg) 5.759
Mass moment of inertia (kg*mm²) 1721.421
Momentum of mass GD2 (Nm²) 0.068

Weight towards ( 0.000, 0.000,-1.000)

Consider deformations due to shearing
Shear correction coefficient 1.100
Contact angle of roller bearings is considered
Reference temperature (°C) 20.000

30/10230/10230/10230/10230/10230/10230/10230/102
Figure: Load applications

SHAFT DEFINITION (s1)

Outer contour

31/10231/10231/10231/10231/10231/10231/10231/102
Cylinder (Cylinder) y= 0.00...39.00
(mm)
d=50.00 (mm), l=39.00 (mm), Rz= 4.8

Radius right (Radius right)

r=2.00 (mm), Rz= 8.0

Chamfer left (Chamfer left)

l=1.50 (mm), alpha=45.00 (°)

Cylinder (Cylinder) y= 39.00...49.00

(mm)
d=62.00 (mm), l=10.00 (mm), Rz= 8.0

Chamfer left (Chamfer left)

l=1.00 (mm), alpha=45.00 (°)

Chamfer right (Chamfer right)

l=1.00 (mm), alpha=45.00 (°)

Cylinder (Cylinder) y= 49.00...163.00

(mm)
d=50.00 (mm), l=114.00 (mm), Rz= 8.0

Radius left (Radius left)

r=1.00 (mm), Rz= 8.0

Cylinder (Cylinder) y= 163.00...249.00

(mm)
d=45.00 (mm), l=86.00 (mm), Rz= 8.0

Radius right (Radius right)

r=2.00 (mm), Rz= 8.0

Radius left (Radius left)

r=0.50 (mm), Rz= 8.0

Cylinder (Cylinder) y= 249.00...259.00

(mm)
d=62.00 (mm), l=10.00 (mm), Rz= 4.8

32/10232/10232/10232/10232/10232/10232/10232/102
 Chamfer left (Chamfer left)
l=1.00 (mm), alpha=45.00 (°)

Chamfer right (Chamfer right)

l=1.00 (mm), alpha=45.00 (°)

Cylinder (Cylinder) y= 259.00...309.00

(mm)
d=50.00 (mm), l=50.00 (mm), Rz= 4.8

Radius left (Radius left)

r=2.00 (mm), Rz= 8.0

Cylinder (Cylinder) y= 309.00...334.00

(mm)
d=49.95 (mm), l=25.00 (mm), Rz= 8.0

Chamfer right (Chamfer right)

l=1.50 (mm), alpha=45.00 (°)

Cylinder (Cylinder) y= 334.00...414.00

(mm)
d=38.00 (mm), l=80.00 (mm), Rz= 4.8

Key way (Key) y= 338.00...411.00

(mm)
l=73.00 (mm), Rz= 8.0

Radius left (Radius left)

r=2.00 (mm), Rz= 8.0

Chamfer right (Chamfer right)

l=1.50 (mm), alpha=45.00 (°)

Inner contour

Forces
Coupling (cin(in)) y= 373.00 (mm)
Eff. Diameter (mm) 57.0000

33/10233/10233/10233/10233/10233/10233/10233/102
Radial force coefficient (-) 0.0000
Direction of radial force (°) 0.0000
Axial force coefficient (-) 0.0000
Length of load application (mm) 80.0000
Power (kW) 46.8000 driven (Input)
Torque (Nm) 297.9381
Mass (kg) 0.0000

Centric force (oh) y= 374.00 (mm)

Length of load application (mm) 0.0000
Torque (Nm) -0.0000

Cylindrical gear (p1(gp1)) y= 193.00 (mm)

Operating pitch diameter (mm) 56.4706
Helix angle (°) 12.2666 left
Working pressure angle at normal section(°) 23.1359
Position of contact point (°) 180.0000
Length of load application (mm) 45.0000
Power (kW) 46.8000 driving (Output)
Torque (Nm) -297.9381
Axial force (N) -2294.2520
Shearing force X (N) 4613.9614
Shearing force Z (N) -10551.9725
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 64.7789

Bearing
Taper roller bearing (single row) SKF 32310 J2/Q (bl) y= 18.00 (mm)
Set fixed bearing left
d = 50.000 (mm), D = 110.000 (mm), B = 42.250 (mm), r = 2.500 (mm)
C = 172.000 (kN), C0 = 212.000 (kN), Cu = 24.000 (kN)
The bearing pressure angle will be considered in the calculation
Position (center of pressure) (mm) 23.8750

Taper roller bearing (single row) SKF 32310 J2/Q (br) y= 280.00 (mm)
Set fixed bearing right
d = 50.000 (mm), D = 110.000 (mm), B = 42.250 (mm), r = 2.500 (mm)
C = 172.000 (kN), C0 = 212.000 (kN), Cu = 24.000 (kN)
The bearing pressure angle will be considered in the calculation
Position (center of pressure) (mm) 274.1250

34/10234/10234/10234/10234/10234/10234/10234/102
________________________________________________________________________

maximum deflection 127.00 µm (s1, 414.00 (mm))

Center of mass
s1 190.3 mm

Deformation due to torsion

s1 [phi.t] 0.10 °

Probability of failure [n] 10.00 %

Axial clearance [uA] 10.00 µm
Roller bearings, classical calculation (contact angle considered)

Shaft 's1' Roller bearing 'bl'

Position (Y-coordinate) [y] 18.00 mm
Equivalent load [P] 9.30 kN
Equivalent load [P0] 6.04 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 185633.36 h
Operating viscosity [nu] 48.88 mm²/s
Reference viscosity [nu1] 0.00 mm²/s
static safety factor [S0] 35.11
Bearing reaction force [Fx] -1.755 kN
Bearing reaction force [Fy] 4.564 kN
Bearing reaction force [Fz] 3.440 kN
Bearing reaction force [Fr] 3.861 kN (117.03°)
Bearing reaction moment [Mx] 20.21 Nm
Bearing reaction moment [My] 0.00 Nm
Bearing reaction moment [Mz] 10.31 Nm
Bearing reaction moment [Mr] 22.69 Nm (27.03°)
Torque of friction [Mloss] 1.998 Nm
Displacement of bearing [ux] -0.002 mm
Displacement of bearing [uy] -0.010 mm
Displacement of bearing [uz] 0.003 mm
Displacement of bearing [ur] 0.004 mm (115.89°)
Misalignment of bearing [rx] -0.585 mrad (-2.01')
Misalignment of bearing [ry] 0.000 mrad (0')

35/10235/10235/10235/10235/10235/10235/10235/102
Misalignment of bearing [rz] -0.284 mrad (-0.98')
Misalignment of bearing [rr] 0.650 mrad (2.23')

Shaft 's1' Roller bearing 'br'

Position (Y-coordinate) [y] 280.00 mm
Equivalent load [P] 7.72 kN
Equivalent load [P0] 7.72 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 346067.23 h
Operating viscosity [nu] 48.88 mm²/s
Reference viscosity [nu1] 0.00 mm²/s
static safety factor [S0] 27.47
Bearing reaction force [Fx] -2.859 kN
Bearing reaction force [Fy] -2.270 kN
Bearing reaction force [Fz] 7.169 kN
Bearing reaction force [Fr] 7.718 kN (111.75°)
Bearing reaction moment [Mx] -42.12 Nm
Bearing reaction moment [My] 0.00 Nm
Bearing reaction moment [Mz] -16.80 Nm
Bearing reaction moment [Mr] 45.34 Nm (-158.25°)
Torque of friction [Mloss] 1.671 Nm
Displacement of bearing [ux] -0.002 mm
Displacement of bearing [uy] -0.013 mm
Displacement of bearing [uz] 0.005 mm
Displacement of bearing [ur] 0.005 mm (114.78°)
Misalignment of bearing [rx] 0.825 mrad (2.84')
Misalignment of bearing [ry] 0.678 mrad (2.33')
Misalignment of bearing [rz] 0.381 mrad (1.31')
Misalignment of bearing [rr] 0.908 mrad (3.12')

36/10236/10236/10236/10236/10236/10236/10236/102
Figure: Displacement (bending etc.) (Arbitrary plane -65.20910542 °)

37/10237/10237/10237/10237/10237/10237/10237/102
GEH(von Mises): sigV = ((sigB+sigZ,D)^2 + 3*(tauT+tauS)^2)^1/2

Figure: Equivalent stress

38/10238/10238/10238/10238/10238/10238/10238/102
39/10239/10239/10239/10239/10239/10239/10239/102
Strength calculation as specified in
DIN 743:2000
Summary

Label s1
Drawing

Material 42 CrMo 4 (1)

Material type Through hardened steel
Material treatment alloyed, through hardened
Surface treatment No

Calculation of endurance limit and the static strength

Calculation for load case 2 (sig.av/sig.mv = const)

Cross section Position (Y-Coord) (mm)

A-A 39.00 Shoulder
B-B 163.00 Shoulder
C-C 249.00 Shoulder
D-D 334.00 Shoulder
Results:
Cross section Kfb Kfsig K2d SD SS
A-A 2.06 0.87 0.87 31.30 299.92
B-B 2.72 0.87 0.88 2.33 10.40
C-C 2.05 0.87 0.88 6.47 15.73
D-D 1.93 0.87 0.89 10.36 11.31

Nominal safety: 1.20 1.20

Abbreviations:
Kfb: Notch factor bending
Kfsig: Surface factor
K2d: Size coefficient bending
SD: Safety endurance limit
SS: Safety against yield point

40/10240/10240/10240/10240/10240/10240/10240/102
The requirements of the safety proof of the shaft are:

satisfied [x] not satisfied [ ]

Design engineer:................... Date:........... Signature:......

41/10241/10241/10241/10241/10241/10241/10241/102
Figure: Strength

Calculation details:

General statements

42/10242/10242/10242/10242/10242/10242/10242/102
Label s1
Drawing
Length (mm) [l] 414.00
Speed (1/min) [n] 1500.00

Material 42 CrMo 4 (1)

Material type Through hardened steel
Material treatment alloyed, through hardened
Surface treatment No

Tension/Compression Bending Torsion Shearing

Load factor static calculation 1.700 1.700 1.700 1.700
Load factor endurance limit 1.000 1.000 1.000 1.000

Reference diameter material (mm) [dB] 16.00

sigB according DIN 743 (at dB) (N/mm²) [sigB] 1100.00
sigS according DIN 743 (at dB) (N/mm²) [sigS] 900.00
[sigzdW] (bei dB) (N/mm²) 440.00
[sigbW] (bei dB) (N/mm²) 550.00
[tautW] (bei dB) (N/mm²) 330.00
Thickness of raw material (mm) [dWerkst] 65.00
Material data calculated according DIN743/3 with K1(d)
Material strength calculated from size of raw material
Geometric size coefficient K1d calculated from raw material diameter
[sigBeff] (N/mm²) 925.89
[sigSeff] (N/mm²) 757.54
[sigbF] (N/mm²) 909.05
[tautF] (N/mm²) 524.84

[sigzdW] (N/mm²) 370.35

[sigbW] (N/mm²) 462.94
[tautW] (N/mm²) 277.77

Endurance limit for single stage use

Calculation for load case 2 (sig.av/sig.mv = const)

Cross section 'A-A' Shoulder

Comment Y= 134.00mm
Position (Y-Coordinate) (mm) [y] 39.00
External diameter (mm) [da] 50.000

43/10243/10243/10243/10243/10243/10243/10243/102
Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 62.000 2.000 0.000
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -2282.1 0.0 0.0 0.0
Amplitude 2282.1 58.3 0.0 3856.2
Maximum value -7759.3 99.1 0.0 6555.6
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 1963.5 12272 24544 1963.5

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -1.162 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 1.162 4.751 0.000 2.619
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -3.952 8.076 0.000 4.452

Technological size influence [K1(sigB)] 0.842

[K1(sigS)] 0.842

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 2.369 2.152 1.578
References stress slope [G'] 1.279 1.279 0.575
support coefficient n [n] 1.046 1.046 1.031
Notch effect coefficient [beta] 2.266 2.058 1.531
Geometrical size influence [K2(d)] 1.000 0.873 0.873
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 2.418 2.509 1.835

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 1.162
Equivalent mean stress (N/mm²) [taumV] 0.671
Fatigue limit of part (N/mm²) [sigWK] 153.144 184.541 151.355
Influence coeff. mean stress sensitivity.
[PsisigK] 0.090 0.111 0.089
Permissible amplitude (N/mm²) [sigADK] 168.319 189.678 151.355
Margin of safety endurance limit [S] 31.298

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Required safety [Smin] 1.200
Result (%) [S/Smin] 2608.1

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.200 1.200
Increase coefficient [gammaF] 1.100 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 833.297 999.956 524.841
Margin of safety yield stress [S] 299.919
Required safety [Smin] 1.200
Result (%) [S/Smin] 24993.2

Cross section 'B-B' Shoulder

Comment Y= 196.00...249.00mm
Position (Y-Coordinate) (mm) [y] 163.00
External diameter (mm) [da] 45.000
Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 50.000 0.500 0.000
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -2282.1 0.0 0.0 0.0
Amplitude 2282.1 535.3 0.0 3839.2
Maximum value -7759.3 910.1 0.0 6526.6
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 1590.4 8946 17892 1590.4

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -1.435 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 1.435 59.839 0.000 3.219
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -4.879 101.727 0.000 5.472

Technological size influence [K1(sigB)] 0.842

[K1(sigS)] 0.842

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 3.207 2.961 1.930

45/10245/10245/10245/10245/10245/10245/10245/102
References stress slope [G'] 5.020 5.020 2.300
support coefficient n [n] 1.090 1.090 1.061
Notch effect coefficient [beta] 2.941 2.715 1.818
Geometrical size influence [K2(d)] 1.000 0.880 0.880
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 3.094 3.236 2.148

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 1.435
Equivalent mean stress (N/mm²) [taumV] 0.828
Fatigue limit of part (N/mm²) [sigWK] 119.720 143.042 129.336
Influence coeff. mean stress sensitivity.
[PsisigK] 0.069 0.084 0.075
Permissible amplitude (N/mm²) [sigADK] 128.609 143.329 129.336
Margin of safety endurance limit [S] 2.333
Required safety [Smin] 1.200
Result (%) [S/Smin] 194.4

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.200 1.200
Increase coefficient [gammaF] 1.150 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 871.174 999.956 524.841
Margin of safety yield stress [S] 10.402
Required safety [Smin] 1.200
Result (%) [S/Smin] 866.9

Cross section 'C-C' Shoulder

Comment Y= 192.00mm
Position (Y-Coordinate) (mm) [y] 249.00
External diameter (mm) [da] 45.000
Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 62.000 2.000 0.000
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

46/10246/10246/10246/10246/10246/10246/10246/102
Stress: (N) (Nm)
Mean value -1135.0 0.0 149.0 0.0
Amplitude 1135.0 192.6 149.0 7698.5
Maximum value -3859.0 327.4 506.5 13087.4
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 1590.4 8946 17892 1590.4

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.714 0.000 8.326 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.714 21.529 8.326 6.454
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -2.426 36.599 28.308 10.972

Technological size influence [K1(sigB)] 0.842

[K1(sigS)] 0.842

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 2.394 2.148 1.593
References stress slope [G'] 1.262 1.262 0.575
support coefficient n [n] 1.045 1.045 1.031
Notch effect coefficient [beta] 2.290 2.055 1.546
Geometrical size influence [K2(d)] 1.000 0.880 0.880
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 2.442 2.486 1.838

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 14.438
Equivalent mean stress (N/mm²) [taumV] 8.336
Fatigue limit of part (N/mm²) [sigWK] 151.641 186.209 151.114
Influence coeff. mean stress sensitivity.
[PsisigK] 0.089 0.112 0.089
Permissible amplitude (N/mm²) [sigADK] 39.339 173.250 138.769
Margin of safety endurance limit [S] 6.471
Required safety [Smin] 1.200
Result (%) [S/Smin] 539.3

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.200 1.200

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Increase coefficient [gammaF] 1.100 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 833.297 999.956 524.841
Margin of safety yield stress [S] 15.725
Required safety [Smin] 1.200
Result (%) [S/Smin] 1310.4

Cross section 'D-D' Shoulder

Comment Fit at bearing 2
Position (Y-Coordinate) (mm) [y] 334.00
External diameter (mm) [da] 38.000
Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 49.950 2.000 0.000
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -0.0 0.0 147.1 0.0
Amplitude 0.0 0.3 147.1 7.0
Maximum value -0.0 0.5 500.2 12.0
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 1134.1 5387 10774 1134.1

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.000 0.000 13.654 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.000 0.052 13.654 0.008
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -0.000 0.088 46.423 0.014

Technological size influence [K1(sigB)] 0.842

[K1(sigS)] 0.842

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 2.233 2.021 1.522
References stress slope [G'] 1.279 1.279 0.575
support coefficient n [n] 1.046 1.046 1.031
Notch effect coefficient [beta] 2.136 1.933 1.477
Geometrical size influence [K2(d)] 1.000 0.892 0.892
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924

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Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 2.288 2.320 1.739

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 23.649
Equivalent mean stress (N/mm²) [taumV] 13.654
Fatigue limit of part (N/mm²) [sigWK] 161.865 199.537 159.748
Influence coeff. mean stress sensitivity.
[PsisigK] 0.096 0.121 0.094
Permissible amplitude (N/mm²) [sigADK] 0.035 2.183 145.967
Margin of safety endurance limit [S] 10.363
Required safety [Smin] 1.200
Result (%) [S/Smin] 863.6

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.200 1.200
Increase coefficient [gammaF] 1.100 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 833.297 999.956 524.841
Margin of safety yield stress [S] 11.306
Required safety [Smin] 1.200
Result (%) [S/Smin] 942.1

Remarks:
- The shearing force is not considered in the analysis according to DIN 743..
- Cross section with square groove:
The reference diameter for the notch number is not defined.
Therefore the shaft diameter is taken as reference diameter..
- Cross section with interference fit:
The notching factor for the light fit case is no longer defined in DIN 743.
The values are imported from the FKM-Guideline..

End report lines: 616

49/10249/10249/10249/10249/10249/10249/10249/102
_O.GB.s2.b2
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:26

Important hint: At least one warning has occurred during the calculation:
1-> Angular contact ball bearing, taper roller bearing and high precision angular contact
ball bearing :
If you want to calculate the reciprocal influence of a bearing pair in face-to-face or
back-to-back arrangement,
you have to choose the option under 'Basic data', 'Additional data'!

ROLLER BEARING ANALYSIS

Calculation method: ISO 281:2007 und Herstellerangaben

- With constant a23-factor (1.0)
General data:
Speed (1/min) 590.164
Axial force (N) -3018.745
Required service life (h) 20000.000

Roller bearing No. 1:

Bearing type SKF 32312 J2/Q
Type Taper roller bearing (single row)
Radial and axial load
Radial force (N) [Fr] 23828.015

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Axial force (N) [Fa] -3018.745

Inner diameter (mm) [d] 60.000

External diameter (mm) [D] 130.000
Width (mm) [T] 48.500
Dynamic load number (kN) [C] 229.000
Static load number (kN) [C0] 290.000
Speed limit (oil) (1/min) [n.max] 5300
Dynamic equivalent load (N) [P] 23828.015
Static equivalent load (N) [P0] 23828.015
Torque of friction (Nmm) [M] 1844.266

Service life (h) [Lh] 53296.842

Static safety factor [S0] 12.171

Roller bearing No. 2:

Bearing type SKF 32312 J2/Q
Type Taper roller bearing (single row)
Radial and axial load
Radial force (N) [Fr] 17810.597
Axial force (N) [Fa] 0.000

Inner diameter (mm) [d] 60.000

External diameter (mm) [D] 130.000
Width (mm) [T] 48.500
Dynamic load number (kN) [C] 229.000
Static load number (kN) [C0] 290.000
Speed limit (oil) (1/min) [n.max] 5300
Dynamic equivalent load (N) [P] 17810.597
Static equivalent load (N) [P0] 17810.597
Torque of friction (Nmm) [M] 1153.037

Service life (h) [Lh] 140626.146

Static safety factor [S0] 16.282

Torque of friction M is calculated according to the indications in the SKF catalog 2004..

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End report lines: 69

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_O.GB.s2.s2
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : FINAL_PIN_SHT
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:27

Analysis of shafts, axle and beams

Input data

Coordinate system shaft: see picture W-002

Label s2
Drawing
Initial position (mm) 0.000
Length (mm) 286.000
Speed (1/min) 590.16
Sense of rotation: counter clockwise

Material 18CrNiMo7-6
Young's modulus (N/mm²) 206000.000
Poisson's ratio nu 0.300
Specific weight (kg/m³) 7830.000
Warmth elongation coefficient (10^-6/K) 11.500
Temperature (°C) 20.000
Weight of shaft (kg) 9.591
Mass moment of inertia (kg*mm²) 7157.321
Momentum of mass GD2 (Nm²) 0.281

Weight towards ( 0.000, 0.000,-1.000)

Consider deformations due to shearing
Shear correction coefficient 1.100
Contact angle of roller bearings is considered
Reference temperature (°C) 20.000

53/10253/10253/10253/10253/10253/10253/10253/102
Figure: Load applications

SHAFT DEFINITION (s2)

Outer contour

54/10254/10254/10254/10254/10254/10254/10254/102
Cylinder (Cylinder) y= 0.00...44.50
(mm)
d=60.00 (mm), l=44.50 (mm), Rz= 4.8

Radius right (Radius right)

r=2.50 (mm), Rz= 4.8

Chamfer left (Chamfer left)

l=1.00 (mm), alpha=45.00 (°)

Cylinder (Cylinder) y= 44.50...58.50

(mm)
d=70.00 (mm), l=14.00 (mm), Rz= 8.0

Radius right (Radius right)

r=2.50 (mm), Rz= 8.0

Cylinder (Cylinder) y= 58.50...159.50

(mm)
d=86.50 (mm), l=101.00 (mm), Rz= 8.0

Radius left (Radius left)

r=1.00 (mm), Rz= 8.0

Radius right (Radius right)

r=1.00 (mm), Rz= 8.0

Cylinder (Cylinder) y= 159.50...218.50

(mm)
d=75.00 (mm), l=59.00 (mm), Rz= 4.8

Radius left (Radius left)

r=3.00 (mm), Rz= 4.8

Key way (Key) y= 169.50...217.50

(mm)
l=48.00 (mm), Rz= 4.8

Cylinder (Cylinder) y= 218.50...241.50

(mm)
d=60.10 (mm), l=23.00 (mm), Rz= 8.0

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 Radius left (Radius left)
r=1.50 (mm), Rz= 8.0

Cylinder (Cylinder) y= 241.50...286.00

(mm)
d=60.00 (mm), l=44.50 (mm), Rz= 4.8

Radius left (Radius left)

r=1.50 (mm), Rz= 4.8

Chamfer right (Chamfer right)

l=1.00 (mm), alpha=45.00 (°)

Inner contour

Forces
Cylindrical gear (g1(gp1)) y= 190.50 (mm)
Operating pitch diameter (mm) 143.5294
Helix angle (°) 12.2666 right
Working pressure angle at normal section(°) 23.1359
Position of contact point (°) -0.0000
Length of load application (mm) 45.0000
Power (kW) 46.8000 driven (Input)
Torque (Nm) -757.2592
Axial force (N) 2294.2520
Shearing force X (N) -4613.9614
Shearing force Z (N) 10551.9725
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 164.6463

Cylindrical gear (p2(gp2)) y= 107.00 (mm)

Operating pitch diameter (mm) 50.5618
Helix angle (°) 10.0581 right
Working pressure angle at normal section(°) 20.8817
Position of contact point (°) 180.0000
Length of load application (mm) 56.0000
Power (kW) 46.8000 driving (Output)
Torque (Nm) 757.2592

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 Axial force (N) -5312.9973
Shearing force X (N) 11605.6399
Shearing force Z (N) 29953.8086
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 134.3174

Bearing
Taper roller bearing (single row) SKF 32312 J2/Q (bl) y= 20.00 (mm)
Set fixed bearing left
d = 60.000 (mm), D = 130.000 (mm), B = 48.500 (mm), r = 3.000 (mm)
C = 229.000 (kN), C0 = 290.000 (kN), Cu = 34.000 (kN)
The bearing pressure angle will be considered in the calculation
Position (center of pressure) (mm) 26.7500

Taper roller bearing (single row) SKF 32312 J2/Q (br) y= 265.00 (mm)
Set fixed bearing right
d = 60.000 (mm), D = 130.000 (mm), B = 48.500 (mm), r = 3.000 (mm)
C = 229.000 (kN), C0 = 290.000 (kN), Cu = 34.000 (kN)
The bearing pressure angle will be considered in the calculation
Position (center of pressure) (mm) 258.2500

________________________________________________________________________

maximum deflection 26.72 µm (s2, 147.25 (mm))

Center of mass
s2 136.9 mm

Deformation due to torsion

s2 [phi.t] -0.01 °

Probability of failure [n] 10.00 %

Axial clearance [uA] 10.00 µm
Roller bearings, classical calculation (contact angle considered)

Shaft 's2' Roller bearing 'bl'

Position (Y-coordinate) [y] 20.00 mm

57/10257/10257/10257/10257/10257/10257/10257/102
Equivalent load [P] 23.83 kN
Equivalent load [P0] 23.83 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 53296.84 h
Operating viscosity [nu] 48.88 mm²/s
Reference viscosity [nu1] 0.00 mm²/s
static safety factor [S0] 12.17
Bearing reaction force [Fx] -7.524 kN
Bearing reaction force [Fy] 8.257 kN
Bearing reaction force [Fz] -22.609 kN
Bearing reaction force [Fr] 23.828 kN (-108.41°)
Bearing reaction moment [Mx] -152.61 Nm
Bearing reaction moment [My] 0.00 Nm
Bearing reaction moment [Mz] 50.78 Nm
Bearing reaction moment [Mr] 160.84 Nm (161.59°)
Torque of friction [Mloss] 2.373 Nm
Displacement of bearing [ux] -0.000 mm
Displacement of bearing [uy] -0.010 mm
Displacement of bearing [uz] -0.002 mm
Displacement of bearing [ur] 0.002 mm (-101.73°)
Misalignment of bearing [rx] 0.290 mrad (1')
Misalignment of bearing [ry] 0.000 mrad (0')
Misalignment of bearing [rz] -0.060 mrad (-0.21')
Misalignment of bearing [rr] 0.296 mrad (1.02')

Shaft 's2' Roller bearing 'br'

Position (Y-coordinate) [y] 265.00 mm
Equivalent load [P] 17.81 kN
Equivalent load [P0] 17.81 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 140626.15 h
Operating viscosity [nu] 48.88 mm²/s
Reference viscosity [nu1] 0.00 mm²/s
static safety factor [S0] 16.28
Bearing reaction force [Fx] 0.532 kN
Bearing reaction force [Fy] -5.238 kN
Bearing reaction force [Fz] -17.803 kN
Bearing reaction force [Fr] 17.811 kN (-88.29°)
Bearing reaction moment [Mx] 120.17 Nm
Bearing reaction moment [My] 0.00 Nm
Bearing reaction moment [Mz] 3.59 Nm

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Bearing reaction moment [Mr] 120.22 Nm (1.71°)
Torque of friction [Mloss] 2.061 Nm
Displacement of bearing [ux] -0.000 mm
Displacement of bearing [uy] -0.012 mm
Displacement of bearing [uz] -0.002 mm
Displacement of bearing [ur] 0.002 mm (-96.82°)
Misalignment of bearing [rx] -0.331 mrad (-1.14')
Misalignment of bearing [ry] -0.187 mrad (-0.64')
Misalignment of bearing [rz] 0.040 mrad (0.14')
Misalignment of bearing [rr] 0.333 mrad (1.15')

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Figure: Displacement (bending etc.) (Arbitrary plane 80.2715607 °)

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GEH(von Mises): sigV = ((sigB+sigZ,D)^2 + 3*(tauT+tauS)^2)^1/2

Figure: Equivalent stress

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62/10262/10262/10262/10262/10262/10262/10262/102
Strength calculation as specified in
DIN 743:2000
Summary

Label s2
Drawing

Material 18CrNiMo7-6
Material type Case-carburized steel
Material treatment case-hardened
Surface treatment No

Calculation of endurance limit and the static strength

Calculation for load case 2 (sig.av/sig.mv = const)

Cross section Position (Y-Coord) (mm)

A-A 44.50 Shoulder
B-B 58.50 Shoulder
C-C 159.50 Shoulder
D-D 220.00 Smooth shaft
E-E 240.50 Smooth shaft
Results:
Cross section Kfb Kfsig K2d SD SS
A-A 1.71 0.90 0.86 10.39 28.40
B-B 1.85 0.87 0.85 8.47 23.64
C-C 1.74 0.90 0.85 5.47 12.33
D-D 1.00 0.87 0.86 10.76 14.43
E-E 1.00 0.87 0.86 22.58 33.74

Nominal safety: 1.20 1.20

Abbreviations:
Kfb: Notch factor bending
Kfsig: Surface factor
K2d: Size coefficient bending
SD: Safety endurance limit
SS: Safety against yield point

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The requirements of the safety proof of the shaft are:

satisfied [x] not satisfied [ ]

Design engineer:................... Date:........... Signature:......

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Figure: Strength

Calculation details:

General statements

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Label s2
Drawing
Length (mm) [l] 286.00
Speed (1/min) [n] 590.16

Material 18CrNiMo7-6
Material type Case-carburized steel
Material treatment case-hardened
Surface treatment No

Tension/Compression Bending Torsion Shearing

Load factor static calculation 1.700 1.700 1.700 1.700
Load factor endurance limit 1.000 1.000 1.000 1.000

Reference diameter material (mm) [dB] 16.00

sigB according DIN 743 (at dB) (N/mm²) [sigB] 1150.00
sigS according DIN 743 (at dB) (N/mm²) [sigS] 830.00
[sigzdW] (bei dB) (N/mm²) 460.00
[sigbW] (bei dB) (N/mm²) 575.00
[tautW] (bei dB) (N/mm²) 345.00
Thickness of raw material (mm) [dWerkst] 90.00
Material data calculated according DIN743/3 with K1(d)
Material strength calculated from size of raw material
Geometric size coefficient K1d calculated from raw material diameter
[sigBeff] (N/mm²) 925.71
[sigSeff] (N/mm²) 668.12
[sigbF] (N/mm²) 734.94
[tautF] (N/mm²) 424.32

[sigzdW] (N/mm²) 370.29

[sigbW] (N/mm²) 462.86
[tautW] (N/mm²) 277.71

Endurance limit for single stage use

Calculation for load case 2 (sig.av/sig.mv = const)

Cross section 'A-A' Shoulder

Comment Y= 92.00...122.00mm
Position (Y-Coordinate) (mm) [y] 44.50
External diameter (mm) [da] 60.000

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Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 70.000 2.500 0.000
Mean roughness (µm) [Rz] 4.800

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -4128.6 0.0 0.0 0.0
Amplitude 4128.6 423.2 0.0 23836.8
Maximum value -14037.2 719.4 0.0 40522.6
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 2827.4 21206 42412 2827.4

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -1.460 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 1.460 19.955 0.000 11.241
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -4.965 33.923 0.000 19.109

Technological size influence [K1(sigB)] 0.805

[K1(sigS)] 0.805

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 2.238 2.055 1.515
References stress slope [G'] 1.040 1.040 0.460
support coefficient n [n] 1.203 1.203 1.135
Notch effect coefficient [beta] 1.860 1.707 1.334
Geometrical size influence [K2(d)] 1.000 0.861 0.861
Influence coefficient surface roughness
[KF] 0.900 0.900 0.943
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.970 2.093 1.610

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 1.460
Equivalent mean stress (N/mm²) [taumV] 0.843
Fatigue limit of part (N/mm²) [sigWK] 187.915 221.097 172.469
Influence coeff. mean stress sensitivity.
[PsisigK] 0.113 0.136 0.103
Permissible amplitude (N/mm²) [sigADK] 211.845 223.314 172.469
Margin of safety endurance limit [S] 10.390

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Required safety [Smin] 1.200
Result (%) [S/Smin] 865.8

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.100
Increase coefficient [gammaF] 1.100 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 734.936 808.430 424.315
Margin of safety yield stress [S] 28.404
Required safety [Smin] 1.200
Result (%) [S/Smin] 2367.0

Cross section 'B-B' Shoulder

Comment Y= 88.00mm
Position (Y-Coordinate) (mm) [y] 58.50
External diameter (mm) [da] 70.000
Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 86.500 2.500 0.000
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -4128.6 0.0 0.0 0.0
Amplitude 4128.6 756.9 0.0 23839.1
Maximum value -14037.2 1286.7 0.0 40526.6
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 3848.5 33674 67348 3848.5

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -1.073 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 1.073 22.477 0.000 8.259
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -3.647 38.211 0.000 14.041

Technological size influence [K1(sigB)] 0.805

[K1(sigS)] 0.805

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 2.451 2.224 1.613

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References stress slope [G'] 1.019 1.019 0.460
support coefficient n [n] 1.201 1.201 1.135
Notch effect coefficient [beta] 2.040 1.851 1.421
Geometrical size influence [K2(d)] 1.000 0.851 0.851
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 2.193 2.327 1.752

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 1.073
Equivalent mean stress (N/mm²) [taumV] 0.619
Fatigue limit of part (N/mm²) [sigWK] 168.885 198.870 158.527
Influence coeff. mean stress sensitivity.
[PsisigK] 0.100 0.120 0.094
Permissible amplitude (N/mm²) [sigADK] 187.728 200.018 158.527
Margin of safety endurance limit [S] 8.468
Required safety [Smin] 1.200
Result (%) [S/Smin] 705.7

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.100
Increase coefficient [gammaF] 1.100 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 734.936 808.430 424.315
Margin of safety yield stress [S] 23.639
Required safety [Smin] 1.200
Result (%) [S/Smin] 1969.9

Cross section 'C-C' Shoulder

Comment Y= 88.00mm
Position (Y-Coordinate) (mm) [y] 159.50
External diameter (mm) [da] 75.000
Inner diameter (mm) [di] 0.000
Notch effect Shoulder
[D, r, t] (mm) 86.500 3.000 0.000
Mean roughness (µm) [Rz] 4.800

Tension/Compression Bending Torsion Shearing

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Stress: (N) (Nm)
Mean value -1472.1 0.0 378.6 0.0
Amplitude 1472.1 1455.4 378.6 8353.4
Maximum value -5005.1 2474.2 1287.3 14200.8
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 4417.9 41417 82835 4417.9

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.333 0.000 4.571 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.333 35.139 4.571 2.521
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -1.133 59.737 15.541 4.286

Technological size influence [K1(sigB)] 0.805

[K1(sigS)] 0.805

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 2.240 2.060 1.514
References stress slope [G'] 0.868 0.868 0.383
support coefficient n [n] 1.186 1.186 1.124
Notch effect coefficient [beta] 1.889 1.737 1.348
Geometrical size influence [K2(d)] 1.000 0.846 0.846
Influence coefficient surface roughness
[KF] 0.900 0.900 0.943
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 2.000 2.164 1.653

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 7.924
Equivalent mean stress (N/mm²) [taumV] 4.575
Fatigue limit of part (N/mm²) [sigWK] 185.159 213.915 167.975
Influence coeff. mean stress sensitivity.
[PsisigK] 0.111 0.131 0.100
Permissible amplitude (N/mm²) [sigADK] 29.708 207.804 152.723
Margin of safety endurance limit [S] 5.471
Required safety [Smin] 1.200
Result (%) [S/Smin] 455.9

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.100

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Increase coefficient [gammaF] 1.100 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 734.936 808.430 424.315
Margin of safety yield stress [S] 12.331
Required safety [Smin] 1.200
Result (%) [S/Smin] 1027.6

Cross section 'D-D' Smooth shaft

Comment
Position (Y-Coordinate) (mm) [y] 220.00
External diameter (mm) [da] 60.100
Inner diameter (mm) [di] 0.000
Notch effect Smooth shaft
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -2619.2 0.0 0.0 0.0
Amplitude 2619.2 681.7 0.0 17825.1
Maximum value -8905.3 1158.9 0.0 30302.7
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 2836.9 21312 42624 2836.9

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.923 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.923 31.988 0.000 8.378
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -3.139 54.380 0.000 14.242

Technological size influence [K1(sigB)] 0.805

[K1(sigS)] 0.805

Tension/Compression Bending Torsion

Notch effect coefficient [beta(dB)] 0.000 0.000 0.000
[dB] (mm) = 0.0
Geometrical size influence [K3(d)] 0.000 0.000 0.000
Geometrical size influence [K3(dB)] 0.000 0.000 0.000
Notch effect coefficient [beta] 1.000 1.000 1.000
Geometrical size influence [K2(d)] 1.000 0.861 0.861
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924

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Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.152 1.314 1.244

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 0.923
Equivalent mean stress (N/mm²) [taumV] 0.533
Fatigue limit of part (N/mm²) [sigWK] 321.330 352.328 223.309
Influence coeff. mean stress sensitivity.
[PsisigK] 0.210 0.235 0.137
Permissible amplitude (N/mm²) [sigADK] 334.062 354.734 223.309
Margin of safety endurance limit [S] 10.760
Required safety [Smin] 1.200
Result (%) [S/Smin] 896.7

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.100
Increase coefficient [gammaF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [sigFK] 668.124 734.936 424.315
Margin of safety yield stress [S] 14.431
Required safety [Smin] 1.200
Result (%) [S/Smin] 1202.6

Cross section 'E-E' Smooth shaft

Comment Y= 27.00mm
Position (Y-Coordinate) (mm) [y] 240.50
External diameter (mm) [da] 60.100
Inner diameter (mm) [di] 0.000
Notch effect Smooth shaft
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -2619.2 0.0 0.0 0.0
Amplitude 2619.2 316.4 0.0 17821.6
Maximum value -8905.3 537.8 0.0 30296.7
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 2836.9 21312 42624 2836.9

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Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.923 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.923 14.844 0.000 8.376
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -3.139 25.235 0.000 14.240

Technological size influence [K1(sigB)] 0.805

[K1(sigS)] 0.805

Tension/Compression Bending Torsion

Notch effect coefficient [beta(dB)] 0.000 0.000 0.000
[dB] (mm) = 0.0
Geometrical size influence [K3(d)] 0.000 0.000 0.000
Geometrical size influence [K3(dB)] 0.000 0.000 0.000
Notch effect coefficient [beta] 1.000 1.000 1.000
Geometrical size influence [K2(d)] 1.000 0.861 0.861
Influence coefficient surface roughness
[KF] 0.868 0.868 0.924
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.152 1.314 1.244

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 0.923
Equivalent mean stress (N/mm²) [taumV] 0.533
Fatigue limit of part (N/mm²) [sigWK] 321.330 352.328 223.309
Influence coeff. mean stress sensitivity.
[PsisigK] 0.210 0.235 0.137
Permissible amplitude (N/mm²) [sigADK] 334.062 357.555 223.309
Margin of safety endurance limit [S] 22.584
Required safety [Smin] 1.200
Result (%) [S/Smin] 1882.0

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.100
Increase coefficient [gammaF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [sigFK] 668.124 734.936 424.315
Margin of safety yield stress [S] 33.740
Required safety [Smin] 1.200
Result (%) [S/Smin] 2811.7

73/10273/10273/10273/10273/10273/10273/10273/102
Remarks:
- The shearing force is not considered in the analysis according to DIN 743..
- Cross section with square groove:
The reference diameter for the notch number is not defined.
Therefore the shaft diameter is taken as reference diameter..
- Cross section with interference fit:
The notching factor for the light fit case is no longer defined in DIN 743.
The values are imported from the FKM-Guideline..

End report lines: 659

74/10274/10274/10274/10274/10274/10274/10274/102
_O.GB.s3.b3
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:28

Warning : Calculation not consistent.

Results are probably not valid !

Important hint: At least one warning has occurred during the calculation:
1-> The axial force can only be taken by one bearing!

ROLLER BEARING ANALYSIS

Calculation method: ISO 281:2007 und Herstellerangaben

- With constant a23-factor (1.0)
General data:
Speed (1/min) 149.619
Axial force (N) 254312.997
Required service life (h) 20000.000

Roller bearing No. 1:

Bearing type NSK 29428E
Type Axial spherical roller bearings
Only axial load
Radial force (N) [Fr] 0.000

75/10275/10275/10275/10275/10275/10275/10275/102
Axial force (N) [Fa] 251816.390

Inner diameter (mm) [d] 140.000

External diameter (mm) [D] 280.000
Width (mm) [B] 85.000
Dynamic load number (kN) [C] 1370.000
Static load number (kN) [C0] 4200.000
Speed limit (oil) (1/min) [n.max] 1200
Dynamic equivalent load (N) [P] 0.000
Static equivalent load (N) [P0] 0.000

Service life (h) [Lh] 0.000

Static safety factor [S0] 0.000

Roller bearing No. 2:

Bearing type SKF *22222E
Type Spherical roller bearings
Radial and axial load
Radial force (N) [Fr] 20236.687
Axial force (N) [Fa] -0.000

Inner diameter (mm) [d] 110.000

External diameter (mm) [D] 200.000
Width (mm) [B] 53.000
Dynamic load number (kN) [C] 560.000
Static load number (kN) [C0] 640.000
Speed limit (oil) (1/min) [n.max] 4000
Dynamic equivalent load (N) [P] 0.000
Static equivalent load (N) [P0] 0.000

Service life (h) [Lh] 0.000

Static safety factor [S0] 0.000

Roller bearing No. 3:

Bearing type SKF *22220E

76/10276/10276/10276/10276/10276/10276/10276/102
Type Spherical roller bearings
Radial and axial load
Radial force (N) [Fr] 12491.670
Axial force (N) [Fa] 2496.607

Inner diameter (mm) [d] 100.000

External diameter (mm) [D] 180.000
Width (mm) [B] 46.000
Dynamic load number (kN) [C] 425.000
Static load number (kN) [C0] 490.000
Speed limit (oil) (1/min) [n.max] 4500
Dynamic equivalent load (N) [P] 0.000
Static equivalent load (N) [P0] 0.000

Service life (h) [Lh] 0.000

Static safety factor [S0] 0.000

End report lines: 88

77/10277/10277/10277/10277/10277/10277/10277/102
_O.GB.s3.s3
KISSsoft - Release 03-2012
NAW New Allenberry Works, IN-Kolkata

File
Name : Unnamed
Changed by : Design_plnt1 on: 26.04.2013 at: 14:55:28

Important hint: At least one warning has occurred during the calculation:
1-> For shaft with internal diameter the notch factors are limited.
Non of the known calculation methods produces reliable data. It is proposed to
use the data for the full shaft and to judge the results conservatively

2-> Notching factor for

- Light fit
- Interference fit with reduction of pressure
are no longer defined in DIN743 .
The values correspond to the FKM-Guideline.

3-> Notching factor for

- Light fit
- Interference fit with reduction of pressure
are no longer defined in DIN743 .
The values correspond to the FKM-Guideline.

Analysis of shafts, axle and beams

Input data

Coordinate system shaft: see picture W-002

Label s3
Drawing

78/10278/10278/10278/10278/10278/10278/10278/102
Initial position (mm) 0.000
Length (mm) 548.000
Speed (1/min) 149.62
Sense of rotation: clockwise

Material C45 (1)

Young's modulus (N/mm²) 206000.000
Poisson's ratio nu 0.300
Specific weight (kg/m³) 7830.000
Warmth elongation coefficient (10^-6/K) 11.500
Temperature (°C) 20.000
Weight of shaft (kg) 36.931
Mass moment of inertia (kg*m²) 0.102
Momentum of mass GD2 (Nm²) 4.015

Weight towards ( 0.000, 0.000,-1.000)

Consider deformations due to shearing
Shear correction coefficient 1.100
Contact angle of roller bearings is considered
Reference temperature (°C) 20.000

79/10279/10279/10279/10279/10279/10279/10279/102
Figure: Load applications

SHAFT DEFINITION (s3)

Outer contour

80/10280/10280/10280/10280/10280/10280/10280/102
Cylinder (Cylinder) y= 0.00...65.00
(mm)
d=140.00 (mm), l=65.00 (mm), Rz= 8.0

Radius right (Radius right)

r=5.00 (mm), Rz= 8.0

Taper (Conus) y= 65.00...71.00

(mm)
dl=140.00 (mm), dr=205.00 (mm), l=6.00 (mm), Rz= 8.0

Cylinder (Cylinder) y= 71.00...91.00

(mm)
d=205.00 (mm), l=20.00 (mm), Rz= 4.8

Cylinder (Cylinder) y= 91.00...144.00

(mm)
d=140.00 (mm), l=53.00 (mm), Rz= 8.0

Radius left (Radius left)

r=2.50 (mm), Rz= 4.8

Cylinder (Cylinder) y= 144.00...194.00

(mm)
d=139.00 (mm), l=50.00 (mm), Rz= 8.0

Cylinder (Cylinder) y= 194.00...247.00

(mm)
d=110.00 (mm), l=53.00 (mm), Rz= 8.0

Radius left (Radius left)

r=1.50 (mm), Rz= 8.0

Cylinder (Cylinder) y= 247.00...356.00

(mm)
d=100.10 (mm), l=109.00 (mm), Rz= 8.0

Radius left (Radius left)

r=1.00 (mm), Rz= 4.8

Key way (Key way) y= 267.00...355.00

(mm)

81/10281/10281/10281/10281/10281/10281/10281/102
 l=88.00 (mm), Rz= 8.0

Cylinder (Cylinder) y= 356.00...504.00

(mm)
d=100.00 (mm), l=148.00 (mm), Rz= 8.0

Circumferential groove (Circumferential groove) y= 492.00...496.00

(mm)
t=3.15 (mm), r=2.00 (mm), Rz= 8.0

Chamfer right (Chamfer right)

l=1.00 (mm), alpha=45.00 (°)

Cylinder (Cylinder) y= 504.00...548.00

(mm)
d=90.00 (mm), l=44.00 (mm), Rz= 8.0

Chamfer right (Chamfer right)

l=2.00 (mm), alpha=45.00 (°)

Inner contour

Cylinder inside (Cylindrical bore) y= 0.00...160.00

(mm)
d=80.00 (mm), l=160.00 (mm)

Cylinder inside (Cylindrical bore) y= 160.00...175.00

(mm)
d=93.00 (mm), l=15.00 (mm)

Cylinder inside (Cylindrical bore) y= 175.00...487.00

(mm)
d=45.00 (mm), l=312.00 (mm)

Cylinder inside (Cylindrical bore) y= 487.00...548.00

(mm)
d=36.00 (mm), l=61.00 (mm)

Forces

82/10282/10282/10282/10282/10282/10282/10282/102
Centric force (aTh) y= 32.50 (mm)
Length of load application (mm) 0.0000
Torque (Nm) -0.0000
Axial force (N) 249000.0000
Shearing force X (N) 0.0000
Shearing force Z (N) 0.0000
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 0.0000

Coupling (cout(out)) y= 32.50 (mm)

Eff. Diameter (mm) 210.0000
Radial force coefficient (-) 0.0000
Direction of radial force (°) 0.0000
Axial force coefficient (-) 0.0000
Length of load application (mm) 65.0000
Power (kW) 46.8000 driving (Output)
Torque (Nm) -2986.9669
Mass (kg) 0.0000

Cylindrical gear (g2(gp2)) y= 311.00 (mm)

Operating pitch diameter (mm) 199.4382
Helix angle (°) 10.0581 left
Working pressure angle at normal section(°) 20.8817
Position of contact point (°) -0.0000
Length of load application (mm) 56.0000
Power (kW) 46.8000 driven (Input)
Torque (Nm) 2986.9669
Axial force (N) 5312.9973
Shearing force X (N) -11605.6399
Shearing force Z (N) -29953.8086
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 529.8073

Bearing
Axial spherical roller bearings NSK 29428E (bTh) y= 134.00 (mm)
Set axial bearing right
d = 140.000 (mm), D = 280.000 (mm), B = 85.000 (mm), r = 0.000 (mm)
C = 1370.000 (kN), C0 = 4200.000 (kN), Cu = 0.000 (kN)

83/10283/10283/10283/10283/10283/10283/10283/102
Spherical roller bearings SKF *22222E (bl) y= 221.00 (mm)
Set fixed bearing left
d = 110.000 (mm), D = 200.000 (mm), B = 53.000 (mm), r = 2.100 (mm)
C = 560.000 (kN), C0 = 640.000 (kN), Cu = 63.000 (kN)
Bearing clearance DIN 620:1988 C0 (97.50 µm)

Spherical roller bearings SKF *22220E (br) y= 471.00 (mm)

Set fixed bearing right
d = 100.000 (mm), D = 180.000 (mm), B = 46.000 (mm), r = 2.100 (mm)
C = 425.000 (kN), C0 = 490.000 (kN), Cu = 49.000 (kN)
Bearing clearance DIN 620:1988 C0 (80.00 µm)

________________________________________________________________________

maximum deflection 57.79 µm (s3, 325.00 (mm))

Center of mass
s3 232.7 mm

Deformation due to torsion

s3 [phi.t] 0.03 °

Probability of failure [n] 10.00 %

Axial clearance [uA] 10.00 µm
Roller bearings, classical calculation (contact angle considered)

Shaft 's3' Roller bearing 'bTh'

Position (Y-coordinate) [y] 134.00 mm
Equivalent load [P] 251.82 kN
Equivalent load [P0] 251.82 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 31548.87 h
Operating viscosity [nu] 0.00 mm²/s
Reference viscosity [nu1] 0.00 mm²/s
static safety factor [S0] 16.68
Bearing reaction force [Fx] 0.000 kN
Bearing reaction force [Fy] -251.816 kN
Bearing reaction force [Fz] 0.000 kN
Bearing reaction force [Fr] 0.000 kN

84/10284/10284/10284/10284/10284/10284/10284/102
Displacement of bearing [ux] -0.005 mm
Displacement of bearing [uy] 0.010 mm
Displacement of bearing [uz] -0.041 mm
Displacement of bearing [ur] 0.042 mm (-97.38°)
Misalignment of bearing [rx] -0.065 mrad (-0.22')
Misalignment of bearing [ry] 0.092 mrad (0.31')
Misalignment of bearing [rz] 0.085 mrad (0.29')
Misalignment of bearing [rr] 0.107 mrad (0.37')

Shaft 's3' Roller bearing 'bl'

Position (Y-coordinate) [y] 221.00 mm
Equivalent load [P] 20.24 kN
Equivalent load [P0] 20.24 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 7139875.29 h
Operating viscosity [nu] 48.88 mm²/s
Reference viscosity [nu1] 0.00 mm²/s
static safety factor [S0] 31.63
Bearing reaction force [Fx] 5.308 kN
Bearing reaction force [Fy] 0.000 kN
Bearing reaction force [Fz] 19.528 kN
Bearing reaction force [Fr] 20.237 kN (74.79°)
Torque of friction [Mloss] 1.293 Nm
Displacement of bearing [ux] -0.013 mm
Displacement of bearing [uy] 0.010 mm
Displacement of bearing [uz] -0.047 mm
Displacement of bearing [ur] 0.049 mm (-105.21°)
Misalignment of bearing [rx] -0.066 mrad (-0.23')
Misalignment of bearing [ry] 0.233 mrad (0.8')
Misalignment of bearing [rz] 0.085 mrad (0.29')
Misalignment of bearing [rr] 0.108 mrad (0.37')

Shaft 's3' Roller bearing 'br'

Position (Y-coordinate) [y] 471.00 mm
Equivalent load [P] 19.48 kN
Equivalent load [P0] 19.48 kN
Life modification factor for reliability[a1] 1.000
Service life [Lnh] 3231226.08 h
Operating viscosity [nu] 48.88 mm²/s
Reference viscosity [nu1] 0.00 mm²/s

85/10285/10285/10285/10285/10285/10285/10285/102
static safety factor [S0] 25.15
Bearing reaction force [Fx] 6.297 kN
Bearing reaction force [Fy] -2.497 kN
Bearing reaction force [Fz] 10.788 kN
Bearing reaction force [Fr] 12.492 kN (59.73°)
Torque of friction [Mloss] 1.113 Nm
Displacement of bearing [ux] -0.020 mm
Displacement of bearing [uy] 0.010 mm
Displacement of bearing [uz] -0.035 mm
Displacement of bearing [ur] 0.040 mm (-120.27°)
Misalignment of bearing [rx] 0.147 mrad (0.51')
Misalignment of bearing [ry] 0.559 mrad (1.92')
Misalignment of bearing [rz] -0.017 mrad (-0.06')
Misalignment of bearing [rr] 0.149 mrad (0.51')

86/10286/10286/10286/10286/10286/10286/10286/102
Figure: Displacement (bending etc.) (Arbitrary plane 68.3175284 °)

87/10287/10287/10287/10287/10287/10287/10287/102
GEH(von Mises): sigV = ((sigB+sigZ,D)^2 + 3*(tauT+tauS)^2)^1/2

Figure: Equivalent stress

88/10288/10288/10288/10288/10288/10288/10288/102
89/10289/10289/10289/10289/10289/10289/10289/102
Strength calculation as specified in
DIN 743:2000
Summary

Label s3
Drawing

Material C45 (1)

Material type Through hardened steel
Material treatment unalloyed, through hardened
Surface treatment No

Calculation of endurance limit and the static strength

Calculation for load case 2 (sig.av/sig.mv = const)

Cross section Position (Y-Coord) (mm)

A-A 65.00 Smooth shaft
B-B 176.00 Interference fit
C-C 91.00 Shoulder
D-D 195.00 Interference fit
E-E 357.00 Smooth shaft
F-F 494.00 Circumferential groove
Results:
Cross section Kfb Kfsig K2d SD SS
A-A 1.00 0.92 0.80 17.04 7.77
B-B 1.97 1.00 0.81 21.46 20.60
C-C 2.54 0.94 0.80 4.98 8.71
D-D 1.95 1.00 0.82 10.62 10.04
E-E 1.00 0.92 0.83 12.60 15.39
F-F 2.57 0.92 0.83 10000.00 10000.00

Nominal safety: 1.20 1.20

Abbreviations:
Kfb: Notch factor bending
Kfsig: Surface factor
K2d: Size coefficient bending
SD: Safety endurance limit

90/10290/10290/10290/10290/10290/10290/10290/102
SS: Safety against yield point

The requirements of the safety proof of the shaft are:

satisfied [x] not satisfied [ ]

Design engineer:................... Date:........... Signature:......

91/10291/10291/10291/10291/10291/10291/10291/102
Figure: Strength

Calculation details:

General statements

92/10292/10292/10292/10292/10292/10292/10292/102
Label s3
Drawing
Length (mm) [l] 548.00
Speed (1/min) [n] 149.62

Material C45 (1)

Material type Through hardened steel
Material treatment unalloyed, through hardened
Surface treatment No

Tension/Compression Bending Torsion Shearing

Load factor static calculation 1.700 1.700 1.700 1.700
Load factor endurance limit 1.000 1.000 1.000 1.000

Reference diameter material (mm) [dB] 16.00

sigB according DIN 743 (at dB) (N/mm²) [sigB] 700.00
sigS according DIN 743 (at dB) (N/mm²) [sigS] 490.00
[sigzdW] (bei dB) (N/mm²) 280.00
[sigbW] (bei dB) (N/mm²) 350.00
[tautW] (bei dB) (N/mm²) 210.00
Thickness of raw material (mm) [dWerkst] 210.00
Material data calculated according DIN743/3 with K1(d)
Material strength calculated from size of raw material
Geometric size coefficient K1d calculated from raw material diameter
[sigBeff] (N/mm²) 496.51
[sigSeff] (N/mm²) 347.55
[sigbF] (N/mm²) 382.31
[tautF] (N/mm²) 200.66

[sigzdW] (N/mm²) 198.60

[sigbW] (N/mm²) 248.25
[tautW] (N/mm²) 148.95

Endurance limit for single stage use

Calculation for load case 2 (sig.av/sig.mv = const)

Cross section 'A-A' Smooth shaft

Comment
Position (Y-Coordinate) (mm) [y] 65.00
External diameter (mm) [da] 140.000

93/10293/10293/10293/10293/10293/10293/10293/102
Inner diameter (mm) [di] 80.000
Notch effect Smooth shaft
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -124500.0 0.0 1493.5 0.0
Amplitude 124500.0 1.7 1493.5 45.3
Maximum value -423300.0 2.8 5077.8 77.0
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 10367.3 240668 481337 10367.3

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -12.009 0.000 3.103 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 12.009 0.007 3.103 0.008
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -40.830 0.012 10.549 0.014

Technological size influence [K1(sigB)] 0.709

[K1(sigS)] 0.709

Tension/Compression Bending Torsion

Notch effect coefficient [beta(dB)] 0.000 0.000 0.000
[dB] (mm) = 0.0
Geometrical size influence [K3(d)] 0.000 0.000 0.000
Geometrical size influence [K3(dB)] 0.000 0.000 0.000
Notch effect coefficient [beta] 1.000 1.000 1.000
Geometrical size influence [K2(d)] 1.000 0.805 0.805
Influence coefficient surface roughness
[KF] 0.922 0.922 0.955
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.085 1.328 1.290

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 13.157
Equivalent mean stress (N/mm²) [taumV] 7.596
Fatigue limit of part (N/mm²) [sigWK] 183.021 186.940 115.459
Influence coeff. mean stress sensitivity.
[PsisigK] 0.226 0.232 0.132
Permissible amplitude (N/mm²) [sigADK] 183.476 -0.521 115.459
Margin of safety endurance limit [S] 17.041

94/10294/10294/10294/10294/10294/10294/10294/102
Required safety [Smin] 1.200
Result (%) [S/Smin] 1420.1

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.000
Increase coefficient [gammaF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [sigFK] 347.554 382.310 200.660
Margin of safety yield stress [S] 7.771
Required safety [Smin] 1.200
Result (%) [S/Smin] 647.6

Cross section 'B-B' Interference fit

Comment
Position (Y-Coordinate) (mm) [y] 176.00
External diameter (mm) [da] 139.000
Inner diameter (mm) [di] 45.000
Notch effect Interference fit
Characteristics: Slight interference fit
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value 1408.2 0.0 1493.5 0.0
Amplitude 1408.2 15.3 1493.5 168.4
Maximum value 4787.9 26.0 5077.8 286.3
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 13584.2 260764 521528 13584.2

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) 0.104 0.000 2.864 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.104 0.059 2.864 0.021
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) 0.352 0.100 9.736 0.036

Technological size influence [K1(sigB)] 0.709

[K1(sigS)] 0.709

Tension/Compression Bending Torsion

Notch effect coefficient [beta(dB)] 1.973 1.973 1.438

95/10295/10295/10295/10295/10295/10295/10295/102
[dB] (mm) = 139.0
Geometrical size influence [K3(d)] 0.942 0.942 0.969
Geometrical size influence [K3(dB)] 0.942 0.942 0.969
Notch effect coefficient [beta] 1.973 1.973 1.438
Geometrical size influence [K2(d)] 1.000 0.805 0.805
Influence coefficient surface roughness
[KF] 1.000 1.000 1.000
Roughness factor is included into the notch effect coefficient
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.973 2.450 1.786

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 4.961
Equivalent mean stress (N/mm²) [taumV] 2.864
Fatigue limit of part (N/mm²) [sigWK] 100.677 101.317 83.410
Influence coeff. mean stress sensitivity.
[PsisigK] 0.113 0.114 0.092
Permissible amplitude (N/mm²) [sigADK] 7.114 4.472 76.403
Margin of safety endurance limit [S] 21.456
Required safety [Smin] 1.200
Result (%) [S/Smin] 1788.0

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.000
Increase coefficient [gammaF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [sigFK] 347.554 382.310 200.660
Margin of safety yield stress [S] 20.602
Required safety [Smin] 1.200
Result (%) [S/Smin] 1716.8

Cross section 'C-C' Shoulder

Comment Fit at bearing 1
Position (Y-Coordinate) (mm) [y] 91.00
External diameter (mm) [da] 140.000
Inner diameter (mm) [di] 80.000
Notch effect Shoulder
[D, r, t] (mm) 205.000 2.500 0.000
Mean roughness (µm) [Rz] 4.800

96/10296/10296/10296/10296/10296/10296/10296/102
 Tension/Compression Bending Torsion Shearing
Stress: (N) (Nm)
Mean value -124500.0 0.0 1493.5 0.0
Amplitude 124500.0 3.6 1493.5 82.1
Maximum value -423300.0 6.1 5077.8 139.5
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 10367.3 240668 481337 10367.3

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -12.009 0.000 3.103 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 12.009 0.015 3.103 0.015
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -40.830 0.025 10.549 0.026

Technological size influence [K1(sigB)] 0.709

[K1(sigS)] 0.709

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 3.345 2.925 2.003
References stress slope [G'] 0.976 0.976 0.460
support coefficient n [n] 1.150 1.150 1.103
Notch effect coefficient [beta] 2.909 2.543 1.816
Geometrical size influence [K2(d)] 1.000 0.805 0.805
Influence coefficient surface roughness
[KF] 0.941 0.941 0.966
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 2.972 3.223 2.292

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 13.157
Equivalent mean stress (N/mm²) [taumV] 7.596
Fatigue limit of part (N/mm²) [sigWK] 66.834 77.021 64.979
Influence coeff. mean stress sensitivity.
[PsisigK] 0.072 0.084 0.070
Permissible amplitude (N/mm²) [sigADK] 71.445 0.554 64.979
Margin of safety endurance limit [S] 4.981
Required safety [Smin] 1.200
Result (%) [S/Smin] 415.1

Present margin of safety

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for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.000
Increase coefficient [gammaF] 1.150 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 399.687 420.541 200.660
Margin of safety yield stress [S] 8.708
Required safety [Smin] 1.200
Result (%) [S/Smin] 725.7

Cross section 'D-D' Interference fit

Comment
Position (Y-Coordinate) (mm) [y] 195.00
External diameter (mm) [da] 110.000
Inner diameter (mm) [di] 45.000
Notch effect Interference fit
Characteristics: Slight interference fit
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value 1408.2 0.0 1493.5 0.0
Amplitude 1408.2 18.7 1493.5 188.0
Maximum value 4787.9 31.8 5077.8 319.6
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 7912.9 127011 254022 7912.9

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) 0.178 0.000 5.879 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.178 0.147 5.879 0.043
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) 0.605 0.250 19.990 0.073

Technological size influence [K1(sigB)] 0.709

[K1(sigS)] 0.709

Tension/Compression Bending Torsion

Notch effect coefficient [beta(dB)] 1.949 1.949 1.427
[dB] (mm) = 110.0
Geometrical size influence [K3(d)] 0.948 0.948 0.972
Geometrical size influence [K3(dB)] 0.948 0.948 0.972
Notch effect coefficient [beta] 1.949 1.949 1.427

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Geometrical size influence [K2(d)] 1.000 0.821 0.821
Influence coefficient surface roughness
[KF] 1.000 1.000 1.000
Roughness factor is included into the notch effect coefficient
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.949 2.375 1.739

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 10.185
Equivalent mean stress (N/mm²) [taumV] 5.880
Fatigue limit of part (N/mm²) [sigWK] 101.889 104.526 85.658
Influence coeff. mean stress sensitivity.
[PsisigK] 0.114 0.118 0.094
Permissible amplitude (N/mm²) [sigADK] 5.969 5.450 78.268
Margin of safety endurance limit [S] 10.616
Required safety [Smin] 1.200
Result (%) [S/Smin] 884.6

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.000
Increase coefficient [gammaF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [sigFK] 347.554 382.310 200.660
Margin of safety yield stress [S] 10.035
Required safety [Smin] 1.200
Result (%) [S/Smin] 836.3

Cross section 'E-E' Smooth shaft

Comment
Position (Y-Coordinate) (mm) [y] 357.00
External diameter (mm) [da] 100.000
Inner diameter (mm) [di] 45.000
Notch effect Smooth shaft
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -1248.3 0.0 0.0 0.0
Amplitude 1248.3 1416.8 0.0 12414.2

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Maximum value -4244.2 2408.6 0.0 21104.2
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 6263.6 94149 188298 6263.6

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.199 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.199 15.049 0.000 3.632
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -0.678 25.583 0.000 6.174

Technological size influence [K1(sigB)] 0.709

[K1(sigS)] 0.709

Tension/Compression Bending Torsion

Notch effect coefficient [beta(dB)] 0.000 0.000 0.000
[dB] (mm) = 0.0
Geometrical size influence [K3(d)] 0.000 0.000 0.000
Geometrical size influence [K3(dB)] 0.000 0.000 0.000
Notch effect coefficient [beta] 1.000 1.000 1.000
Geometrical size influence [K2(d)] 1.000 0.827 0.827
Influence coefficient surface roughness
[KF] 0.922 0.922 0.955
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.085 1.294 1.256

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 0.199
Equivalent mean stress (N/mm²) [taumV] 0.115
Fatigue limit of part (N/mm²) [sigWK] 183.021 191.816 118.561
Influence coeff. mean stress sensitivity.
[PsisigK] 0.226 0.239 0.136
Permissible amplitude (N/mm²) [sigADK] 173.777 192.426 118.561
Margin of safety endurance limit [S] 12.602
Required safety [Smin] 1.200
Result (%) [S/Smin] 1050.2

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.000
Increase coefficient [gammaF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [sigFK] 347.554 382.310 200.660

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Margin of safety yield stress [S] 15.392
Required safety [Smin] 1.200
Result (%) [S/Smin] 1282.7

Cross section 'F-F' Circumferential groove

Comment Fit at bearing 2
Position (Y-Coordinate) (mm) [y] 494.00
External diameter (mm) [da] 100.000
Inner diameter (mm) [di] 36.000
Notch effect Circumferential groove
[d, r, t] (mm) 93.700 2.000 3.150
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Stress: (N) (Nm)
Mean value -0.0 0.0 0.0 0.0
Amplitude 0.0 0.6 0.0 23.9
Maximum value -0.0 1.0 0.0 40.6
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 5877.7 79004 158009 5877.7

Stresses: (N/mm²)
[sigzdm, sigbm, taum, tauqm] (N/mm²) -0.000 0.000 0.000 0.000
[sigzda, sigba, taua, tauqa] (N/mm²) 0.000 0.008 0.000 0.007
[sigzdmax,sigbmax,taumax,tauqmax] (N/mm²) -0.000 0.013 0.000 0.012

Technological size influence [K1(sigB)] 0.709

[K1(sigS)] 0.709

Tension/Compression Bending Torsion

Stress concentration factor [alfa] 3.218 2.982 2.041
References stress slope [G'] 1.142 1.142 0.500
support coefficient n [n] 1.162 1.162 1.107
Notch effect coefficient [beta] 2.768 2.565 1.843
Geometrical size influence [K2(d)] 1.000 0.827 0.827
Influence coefficient surface roughness
[KF] 0.922 0.922 0.955
Influence coefficient surface strengthening
[KV] 1.000 1.000 1.000

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Total influence coefficient [K] 2.853 3.186 2.276

Present margin of safety for endurance limit:

Equivalent mean stress (N/mm²) [sigmV] 0.000
Equivalent mean stress (N/mm²) [taumV] 0.000
Fatigue limit of part (N/mm²) [sigWK] 69.602 77.908 65.454
Influence coeff. mean stress sensitivity.
[PsisigK] 0.075 0.085 0.071
Permissible amplitude (N/mm²) [sigADK] 69.602 77.908 65.454
Margin of safety endurance limit [S] 10000.000
Required safety [Smin] 1.200
Result (%) [S/Smin] 10000.0

Present margin of safety

for proof against exceed of yield point:
Static support number [K2F] 1.000 1.100 1.000
Increase coefficient [gammaF] 1.150 1.100 1.000
Yield stress of part (N/mm²) [sigFK] 399.687 420.541 200.660
Margin of safety yield stress [S] 10000.000
Required safety [Smin] 1.200
Result (%) [S/Smin] 10000.0

Remarks:
- The shearing force is not considered in the analysis according to DIN 743..
- Cross section with square groove:
The reference diameter for the notch number is not defined.
Therefore the shaft diameter is taken as reference diameter..
- Cross section with interference fit:
The notching factor for the light fit case is no longer defined in DIN 743.
The values are imported from the FKM-Guideline..

End report lines: 763

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