User Manual for Web-based

Calculation Software eAssistant

Release May 2022

© 2022 GWJ Technology GmbH

Celler Strasse 67-69  38114 Braunschweig  Germany  Tel.: +49 531 129 399-0

www.eAssistant.eu
Contents

1 A Helpful Guideline to the Manual 3

2 Registration 4
2.1 How to Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Login for Registered Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Lost Your Password? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 General Functions 8
3.1 Project Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Creating a New Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 Copying and Pasting a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.3 Renaming a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.4 Deleting a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.5 Project Folder `Default' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.6 Calculation Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.1 Copying and Pasting a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.2 Renaming a le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.3 Cutting a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.4 Deleting a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 The Button `File' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.1 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.2 Quit the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.3 Quit the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 The Button `Extras' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.1 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Button `Help' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7 File Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7.1 Time Account . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.8 Logging Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.9 General eAssistant Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.10 Opening a Calculation from the eAssistant Server . . . . . . . . . . . . . . . . . . . . . . . . 33
3.11 Opening a Calculation From Your Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.12 Saving a Calculation to the eAssistant Server . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.13 Saving a Calculation to Your Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.14 The Button `Calculate' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.15 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.16 Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.16.1 DXF Output for Exact Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.16.2 3D CAD Plugins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.16.3 Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.16.4 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.17 The Button `Report' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.18 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.19 The button `Help' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.20 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3.21 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.22 How to Change the Unit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.23 Automatic Dimensioning Functions (Calculator Symbol) . . . . . . . . . . . . . . . . . . . . . 44
3.24 User-Dened Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.25 The Button `Question Mark' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.26 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.27 Template Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 Shafts with Strength According to DIN 743 49

4.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 The Geometry Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2.1 Shaft Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2.2 Coordinate System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2.3 Relative and Absolute Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2.4 Creating a Shaft Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2.5 Creating a Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2.6 Creating a Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2.7 Force Elements: Cylindrical Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2.8 Force Elements: Bevel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2.9 Force Elements: Coupling/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.10 Force Element: Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2.11 Extra Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2.12 Notch Eect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 General Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.3.1 How to Select an Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.3.2 How to Shift an Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3.3 How to Copy and Add an Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3.4 How to Cut Out an Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.5 How to Delete an Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.6 Menu Item `Delete All' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.4 2D and 3D View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.5 Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.6 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.7 Quick Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.8 Calculation Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.8.1 Bearing Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.8.2 Deection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.8.3 Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.8.4 Critical Speed (Bending) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8.5 Critical Speed (Torsion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.9 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.10 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.11 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.12 The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.12.1 eAssistant 3D CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.13 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.14 Calculation Examples: Shaft According to DIN 743 . . . . . . . . . . . . . . . . . . . . . . . 82
4.14.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.14.2 First Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.14.3 Start Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.14.4 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.14.5 Save Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.14.6 Second Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.14.7 Start Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.14.8 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.14.9 Save Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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5 Rolling Bearings According to DIN ISO 281 104

5.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2 General Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2.1 Number of Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2.2 How to Delete a Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3 Selection of Manufacturer and Bearing Type . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3.1 Bearing Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3.2 Fatigue Limit Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3.3 Bearing Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.4 Specication of Bearing Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.4.1 Calculation with Load Collectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.4.2 Lubricant Contamination Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.5 Nominal Rating Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.6 Modied Rating Life Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.6.1 Lubricant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.6.2 Dene Your Own Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.7 Bearing Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.7.1 Bearing Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.7.2 Dene Your Own Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.10 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.11 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.12 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.13 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.14 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.15 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.16 Calculation Examples: Rolling Bearing According to DIN ISO 281 . . . . . . . . . . . . . . . 124
5.16.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.16.2 First Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.16.3 The Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.16.4 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.16.5 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.16.6 Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.16.7 Second Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.16.8 The Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.16.9 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.16.10 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.16.11 Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6 Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 138
6.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.2 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2.1 Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2.2 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.2.3 Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.2.4 Direction of Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.2.5 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.2.6 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.2.7 Prole Shift Coecient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.2.8 Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.9 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.10 Modication of Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.11 Root Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.12 Allowances of Root . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.13 Innen and Outer Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.2.14 Web Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.2.15 Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.2.16 Addendum Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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6.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

6.3.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.3.2 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.3.3 Tip Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.3.4 Addendum Coecient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.3.5 Semi Topping Flank and Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.3.6 Protuberance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.3.7 Machining Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.4 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 157
6.4.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.4.2 Backlash Allowance and Tolerance Sequence . . . . . . . . . . . . . . . . . . . . . . . 159
6.4.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.4.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
6.4.5 Measurement of Tooth Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
6.5 Representation of Gear Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
6.5.1 Representation of Cylindrical Gear Pair . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.5.2 Representation of Tooth Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.5.3 Rotating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.5.4 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.5.5 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.5.6 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.6 Input of Gear Tooth Prole and Gear Flank Modications . . . . . . . . . . . . . . . . . . . . 168
6.6.1 Gear Tooth Prole Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
6.6.2 Gear Flank Modications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.7 Some Notes for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6.8 Input of Geometry Data for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.8.1 Direction of Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.8.2 Internal Helical Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.8.3 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.8.4 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.9 Manufacturing Process for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.10 Meshing Interferences for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.10.1 Generation meshing interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.10.2 Feed Meshing Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.11 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.12 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.13 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.14 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.15 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6.16 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.17 The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.17.1 DXF Output for the Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . 185
6.17.2 STEP/IGES Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
6.17.3 GDE Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
6.17.4 eAssistant CAD-PlugIn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.17.5 Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.17.6 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.18 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

7 Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 190
7.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.2 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7.2.1 Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7.2.2 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.2.3 Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.2.4 Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.2.5 Helix Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.2.6 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.2.7 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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7.2.8 Prole Shift on the Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

7.2.9 Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.10 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.11 Modication of Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.12 Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.2.13 Root Diameter and Allowances of Root . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.2.14 Gear Rack Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7.2.15 Addendum Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7.2.16 Inner Diameter for the Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.2.17 Web Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.2.18 Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7.3.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7.3.2 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7.3.3 Tip Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.3.4 Semi Topping Flank and Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.3.5 Protuberance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.3.6 Machining Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7.4 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 211
7.4.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
7.4.2 Backlash Allowance and Tolerance Sequence . . . . . . . . . . . . . . . . . . . . . . . 213
7.4.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7.4.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
7.4.5 Measurement of Tooth Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
7.4.6 Tolerance Field for Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7.4.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
7.4.8 Backlash Normal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
7.4.9 Backlash Pitch Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.4.10 Radial Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.5 Representation of Gear Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7.5.1 Rotating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.5.2 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.5.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.5.4 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.5.5 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.6 Calculation of Gear Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
7.6.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
7.6.2 Inputs for Load Capacity According to DIN 3990 Method B . . . . . . . . . . . . . . 226
7.6.3 Extended General Input Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
7.6.4 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank . . . . . . 239
7.6.5 Extended Input Options for Scung Load Capacity . . . . . . . . . . . . . . . . . . . 242
7.6.6 Input Options for Load Capacity According to ISO 6336 Method B . . . . . . . . . . . 247
7.6.7 Scung Load Capacity According to ISO/TR 13989 . . . . . . . . . . . . . . . . . . 250
7.6.8 Input Options for Load Capacity According to ANSI/AGMA 2101-D04 . . . . . . . . . 254
7.7 Input of Gear Tooth Prole and Gear Flank Modications . . . . . . . . . . . . . . . . . . . . 257
7.7.1 Gear Tooth Prole Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.7.2 Gear Flank Modications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.8 Meshing Interferences for External Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.8.1 Meshing Interferences Due to Low Contact Ratio . . . . . . . . . . . . . . . . . . . . 265
7.9 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.10 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.11 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.12 Dokumentation: Protokoll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
7.13 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.14 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.15 The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.15.1 DXF Output for the Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . 269
7.15.2 GDE Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.15.3 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

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7.15.4 Manufaturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

7.15.5 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.16 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

8 Cylindrical Gears According to DIN 3990 and Other Standards 274

8.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
8.2 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.2.1 Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.2.2 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.2.3 Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.2.4 Standard Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.2.5 Working Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.2.6 Direction of Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.2.7 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.2.8 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
8.2.9 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
8.2.10 Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.2.11 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.2.12 Modication of Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.2.13 Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.2.14 Root Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.2.15 Allowances of Root . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.2.16 Inner and Outer Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
8.2.17 Web Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
8.2.18 Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
8.2.19 Addendum Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
8.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.3.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.3.2 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
8.3.3 Tip Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.3.4 Addendum Coecient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.3.5 Semi Topping Flank and Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
8.3.6 Protuberance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
8.3.7 Machining Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
8.4 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 295
8.4.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.4.2 Backlash Allowance and Tolerance Sequence . . . . . . . . . . . . . . . . . . . . . . . 297
8.4.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.4.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
8.4.5 Measurement of Tooth Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
8.4.6 Tolerance Field for Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
8.4.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.4.8 Backlash Normal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.4.9 Backlash Pitch Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
8.4.10 Radial Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
8.5 Representation of Gear Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
8.5.1 Representation of Cylindrical Gear Pair . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8.5.2 Representation of Tooth Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8.5.3 Rotating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
8.5.4 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
8.5.5 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
8.5.6 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
8.5.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
8.6 Calculation of Gear Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
8.6.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
8.6.2 Input Options for Load Capacity According to DIN 3990 Method B . . . . . . . . . . 311
8.6.3 Extended General Input Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
8.6.4 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank . . . . . . 324
8.6.5 Extended Input Options for Scung Load Capacity . . . . . . . . . . . . . . . . . . . 327

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8.6.6 Input Options for Load Capacity According to ISO 6336 Method B . . . . . . . . . . . 332
8.6.7 Scung Load Capacity According to ISO/TR 13989 . . . . . . . . . . . . . . . . . . 335
8.6.8 Input Options for Load Capacity According to ANSI/AGMA 2101-D04 . . . . . . . . . 339
8.6.9 Input Options for Load Capacity According to VDI 2736 for Plastic Gears . . . . . . . 342
8.7 Input of Gear Tooth Prole and Gear Flank Modications . . . . . . . . . . . . . . . . . . . . 344
8.7.1 Gear Tooth Prole Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.7.2 Gear Flank Modications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
8.8 Meshing Interferences for External Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
8.8.1 Meshing Interferences Due to Low Contact Ratio . . . . . . . . . . . . . . . . . . . . 353
8.8.2 Meshing Interferences Due to No Involute Area . . . . . . . . . . . . . . . . . . . . . 353
8.9 Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
8.10 Input of Geometry Data for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
8.10.1 Direction of Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
8.10.2 Internal Helical Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
8.10.3 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
8.10.4 Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
8.10.5 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.11 Manufacturing Process for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.12 Meshing Interferences for Internal Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.12.1 Tooth Root Meshing Interference on the Pinion . . . . . . . . . . . . . . . . . . . . . 358
8.12.2 Tooth Root Meshing Interference on the Internal Gear . . . . . . . . . . . . . . . . . 358
8.12.3 Generation Meshing Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.12.4 Tooth Crest Meshing Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.12.5 Feed Meshing Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.12.6 Radial Assembly Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.13 Examples for Internal Gears in eAssistant Software . . . . . . . . . . . . . . . . . . . . . . . . 360
8.13.1 Extremely Small Number of Teeth (Pinion) . . . . . . . . . . . . . . . . . . . . . . . 360
8.13.2 Standard Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
8.13.3 Small Dierence of Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
8.14 Dimensioning for Gear Pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
8.15 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
8.16 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
8.17 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
8.18 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
8.19 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
8.20 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
8.21 The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
8.21.1 DXF Output for the Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . 367
8.21.2 STEP/IGES Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
8.21.3 GDE Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
8.21.4 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.21.5 Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.21.6 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
8.22 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
8.23 How to Calculate the Accurate Tooth Form of Involute Splines . . . . . . . . . . . . . . . . . 373
8.23.1 Select Basic Data for Involute Spline . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.23.2 Modify Basic Rack Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.23.3 Enter Data for Involute Spline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
8.23.4 Dene Tooth Thickness Allowances . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
8.23.5 Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

9 Planetary Gear Trains According to DIN 3990 and Other Standards 378
9.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
9.2 Conguration of a Simple Planetary Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . 379
9.3 Basic Conguration of a Planetary Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . 380
9.3.1 Direction of Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
9.3.2 Reference Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
9.3.3 Standard Centre Distance and Working Centre Distance . . . . . . . . . . . . . . . . 381
9.3.4 Number of Planets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

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9.3.5 Minimum Distance Between the Planet Gears . . . . . . . . . . . . . . . . . . . . . . 382

9.3.6 Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
9.3.7 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
9.3.8 Motion State - Gearbox Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
9.3.9 Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
9.3.10 Transmission Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
9.4 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
9.4.1 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
9.4.2 Prole Shift and Balanced Specic Sliding . . . . . . . . . . . . . . . . . . . . . . . . 383
9.4.3 Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
9.4.4 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
9.4.5 Modication of Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
9.4.6 Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
9.4.7 Root Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
9.4.8 Inner and Outer Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
9.4.9 Web Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
9.4.10 Chamfer and Addendum Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
9.5 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
9.5.1 Selection of Sun Gear-Planet Gear and Planet Gear-Annulus Gear . . . . . . . . . . . 389
9.5.2 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
9.5.3 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
9.5.4 Tip Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
9.5.5 Addendum Coecient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
9.5.6 Semi Topping Flank and Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
9.5.7 Protuberance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
9.5.8 Machining Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
9.6 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 395
9.6.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
9.6.2 Backlash Allowance and Tolerance Sequence . . . . . . . . . . . . . . . . . . . . . . . 396
9.6.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
9.6.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
9.6.5 Measurement of Tooth Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
9.6.6 Tolerance Field for Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
9.6.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
9.6.8 Backlash Normal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
9.6.9 Backlash Pitch Diameter and Radial Backlash . . . . . . . . . . . . . . . . . . . . . . 399
9.7 Representation of Gear Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
9.7.1 Representation of Planetary Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . 401
9.7.2 Representation of Mesh of Sun Gear-Planet Gear and Planet Gear-Annulus Gear . . . . 401
9.7.3 Rotating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.7.4 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.7.5 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.7.6 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9.7.7 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9.7.8 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9.8 Input of Power Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.8.1 Power and Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.8.2 Input Power and Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.8.3 Pitch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.8.4 Coupling Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.8.5 Relative Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
9.9 Calculation of Gear Load Capacity of Planetary Gear Trains . . . . . . . . . . . . . . . . . . . 407
9.9.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
9.9.2 Input for Load Capacity According to DIN 3990 Method B . . . . . . . . . . . . . . . 409
9.9.3 Extended General Input Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
9.9.4 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank . . . . . . 419
9.9.5 Extended Input Options for Scung Load Capacity . . . . . . . . . . . . . . . . . . . 422
9.9.6 Input Options for Load Capacity According to ISO 6336 Method B . . . . . . . . . . . 427
9.9.7 Scung Load Capacity According to ISO/TR 13989 . . . . . . . . . . . . . . . . . . 430

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9.9.8 Input Options for Load Capacity According to ANSI/AGMA 2101-D04 . . . . . . . . . 434
9.9.9 Input Options for Load Capacity According to VDI 2736 for Plastic Gears . . . . . . . 437
9.10 Input of Gear Tooth Prole and Gear Flank Modications . . . . . . . . . . . . . . . . . . . . 439
9.10.1 Gear Tooth Prole Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
9.10.2 Gear Flank Modications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
9.11 Meshing Interferences for Planetary Gear Trains . . . . . . . . . . . . . . . . . . . . . . . . . 447
9.12 Additional Information On Planetary Gear Trains . . . . . . . . . . . . . . . . . . . . . . . . 449
9.12.1 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.12.2 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.12.3 Planetary Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.12.4 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.13 Dimensioning for Gear Pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
9.14 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
9.15 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
9.16 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
9.17 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
9.18 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
9.19 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
9.20 The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
9.20.1 DXF Output for Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . 456
9.20.2 STEP/IGES Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
9.20.3 GDE Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
9.20.4 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
9.20.5 Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
9.20.6 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
9.21 The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

10 Three- and Four-Gear Train Systems 462

10.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
10.2 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
10.2.1 Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
10.2.2 Helix Angle and Helix Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
10.2.3 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
10.2.4 Standard Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
10.2.5 Working Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
10.2.6 Comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
10.2.7 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
10.2.8 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
10.2.9 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
10.2.10 Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
10.2.11 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
10.2.12 Modication of Tip Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
10.2.13 Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
10.2.14 Root Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
10.2.15 Allowances of Root . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
10.2.16 Inner Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
10.2.17 Web Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
10.2.18 Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
10.2.19 Addendum Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
10.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
10.3.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
10.3.2 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
10.3.3 Tip Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
10.3.4 Addendum Coecient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
10.3.5 Semi Topping Flank and Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
10.3.6 Protuberance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
10.3.7 Machining Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
10.4 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 482
10.4.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

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10.4.2 Backlash Allowance and Tolerance Sequence . . . . . . . . . . . . . . . . . . . . . . . 484

10.4.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
10.4.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
10.4.5 Measurement of Tooth Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
10.4.6 Tolerance Field for Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
10.4.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
10.4.8 Backlash Normal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
10.4.9 Backlash Pitch Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
10.4.10 Radial Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
10.5 Representation of Gear Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
10.5.1 Representation of Cylindrical Gear Pair . . . . . . . . . . . . . . . . . . . . . . . . . . 492
10.5.2 Representation of Tooth Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
10.5.3 Rotating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
10.5.4 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
10.5.5 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
10.5.6 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
10.5.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
10.6 Calculation of Gear Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
10.6.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
10.6.2 Inputs for Load Capacity According to DIN 3990 Method B . . . . . . . . . . . . . . 498
10.6.3 Extended General Input Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
10.6.4 Extended Input Options for Tooth Root and Tooth Flank . . . . . . . . . . . . . . . . 510
10.6.5 Extended Input Options for Scung Load Capacity . . . . . . . . . . . . . . . . . . . 513
10.6.6 Input Options for Load Capacity According to ISO 6336 Method B . . . . . . . . . . . 518
10.6.7 Scung Load Capacity According to ISO/TR 13989 . . . . . . . . . . . . . . . . . . 521
10.6.8 Input Options for Load Capacity According to ANSI/AGMA 2101-D04 . . . . . . . . . 525
10.6.9 Input Options for Load Capacity According to VDI 2736 for Plastic Gears . . . . . . . 528
10.7 Input of Gear Tooth Prole and Gear Flank Modications . . . . . . . . . . . . . . . . . . . . 530
10.7.1 Gear Tooth Prole Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
10.7.2 Gear Flank Modications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
10.8 Meshing Interferences for External Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.8.1 Meshing Interferences Due to Low Contact Ratio . . . . . . . . . . . . . . . . . . . . 538
10.9 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.10Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.11Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.12Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
10.13How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
10.14The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
10.15The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
10.15.1 DXF Output for the Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . 542
10.15.2 STEP/IGES Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
10.15.3 GDE Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
10.15.4 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
10.15.5 Manufaturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
10.15.6 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
10.16The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546

11 Straight and Helical Bevel Gears According to ISO 23509 547

11.1 Start Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
11.2 Basic Conguration of a Bevel Gear Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
11.2.1 Type of Bevel Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
11.2.2 Form of Tooth Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
11.2.3 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
11.2.4 Shaft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
11.2.5 Oset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
11.2.6 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
11.2.7 Reference Cone Diameter and Reference Cone Angle . . . . . . . . . . . . . . . . . . 551
11.2.8 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
11.2.9 Mean Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552

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11.2.10 Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552

11.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
11.3.1 Manufacturing of Straight and Helical Gears . . . . . . . . . . . . . . . . . . . . . . . 553
11.3.2 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
11.4 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
11.4.1 Helix Angle Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
11.4.2 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
11.4.3 Thickness Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
11.4.4 Angle Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
11.4.5 Bottom Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
11.4.6 Face Angle and Root Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
11.4.7 Cone Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
11.5 Input of Data for the Gear Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
11.5.1 Mounting Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
11.5.2 Plane Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
11.5.3 Tip Circle Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
11.5.4 Curve Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
11.5.5 Tooth Tip Chamfering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
11.6 Input of Data for the Determination of Tolerances and Backlash . . . . . . . . . . . . . . . . 559
11.6.1 Shaft Angle Deviation and Common Apex Deviation . . . . . . . . . . . . . . . . . . 560
11.6.2 Normal Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
11.6.3 Circumferential Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
11.6.4 Tooth Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
11.6.5 Application Factor q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
11.7 Calculation of Load Capacity of Straight and Helical Bevel Gears . . . . . . . . . . . . . . . . 562
11.7.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
11.7.2 Inputs for Load Capacity According to ISO 10300 Method B1 . . . . . . . . . . . . . 564
11.7.3 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank . . . . . . 570
11.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
11.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
11.10Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
11.11Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
11.12How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
11.13The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
11.14The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
11.14.1 STEP/IGES-Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
11.14.2 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
11.15The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580

12 Spiral Bevel Gears According to Klingelnberg KN 3028 and ISO 23509 581
12.1 Start Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
12.2 Basic Conguration of Bevel Gear Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
12.2.1 Types of Bevel Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
12.2.2 Tooth Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
12.2.3 Constant Tooth Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
12.2.4 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
12.2.5 Shaft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
12.2.6 Oset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
12.2.7 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
12.2.8 Reference Cone Diameter and Reference Cone Angle . . . . . . . . . . . . . . . . . . 585
12.2.9 Facewidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
12.2.10 Mean Normal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
12.2.11 Mean Spiral Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
12.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
12.3.1 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
12.3.2 Machine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
12.3.3 Cutter Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
12.3.4 Number of Blade Groups and Machine Distance . . . . . . . . . . . . . . . . . . . . . 590
12.4 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591

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12.4.1 Spiral Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591

12.4.2 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
12.4.3 Thickness Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
12.4.4 Angle Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
12.4.5 Bottom Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
12.4.6 Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
12.4.7 Root Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
12.4.8 Cone Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
12.5 Input of Data for the Gear Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
12.5.1 Mounting Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
12.5.2 Plane Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
12.5.3 Tip Circle Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
12.5.4 Curve Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
12.5.5 Tooth Tip Chamfering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
12.6 Input of Data for the Determination of Tolerances and Backlash . . . . . . . . . . . . . . . . 596
12.6.1 Shaft Angle Deviation and Common Apex Deviation . . . . . . . . . . . . . . . . . . 597
12.6.2 Normal Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
12.6.3 Circumferential Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
12.6.4 Tooth Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
12.6.5 Application Factor q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
12.7 Calculation of Load Capacity of Spiral Bevel Gears . . . . . . . . . . . . . . . . . . . . . . . 599
12.7.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
12.7.2 Inputs for Load Capacity According to ISO 10300 Method B1 . . . . . . . . . . . . . 601
12.7.3 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank . . . . . . 607
12.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
12.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
12.10Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
12.11Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
12.12How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
12.13The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
12.14The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
12.14.1 STEP/IGES-Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
12.14.2 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
12.15The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617

13 Cylindrical Worms with Globoid Worm Wheel 618

13.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
13.2 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
13.2.1 Flank Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
13.2.2 Lead direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
13.2.3 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
13.2.4 Axial Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
13.2.5 Facewidth/Tooth Length of the Worm . . . . . . . . . . . . . . . . . . . . . . . . . . 623
13.2.6 Rim Width of the Worm Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
13.2.7 Prole Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
13.2.8 Pressure Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
13.2.9 Lead Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
13.2.10 Worm Reference Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
13.2.11 Centre Distance and Shaft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
13.2.12 Web Width on Worm Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
13.2.13 Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
13.2.14 Worm Wheel Throat Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
13.2.15 Chamfer Angle and Chamfer Distance . . . . . . . . . . . . . . . . . . . . . . . . . . 627
13.2.16 Diameter/Centre Distance Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
13.2.17 Form Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
13.2.18 Tip Clearance of Worm and Worm Wheel . . . . . . . . . . . . . . . . . . . . . . . . 629
13.3 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
13.3.1 Standard Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
13.3.2 Own Input of Basic Rack Tooth Prole . . . . . . . . . . . . . . . . . . . . . . . . . 630

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13.4 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 631

13.4.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
13.4.2 Backlash Allowance and Tolerance Sequence . . . . . . . . . . . . . . . . . . . . . . . 632
13.4.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
13.4.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
13.4.5 Three-Wire Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
13.4.6 Tolerance Field for Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
13.4.7 Centre Distance Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
13.4.8 Backlash Normal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
13.4.9 Backlash Pitch Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
13.5 Calculation of Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
13.5.1 Activate Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
13.5.2 Inputs for Load Capacity According to DIN 3996 and ISO 14521 . . . . . . . . . . . . 637
13.5.3 Extended Input Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
13.5.4 Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
13.6 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
13.7 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
13.8 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
13.9 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
13.10How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
13.11The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
13.12The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647

14 Interference Fits According to DIN 7190 648

14.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
14.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
14.3 Selection of Fit/Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
14.3.1 Selection of Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
14.3.2 Calculation of Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
14.4 Automatic Dimensioning Functions (Calculator Button) . . . . . . . . . . . . . . . . . . . . . 652
14.5 Inuence of Centrifugal Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
14.6 Additional External Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
14.7 Operating Factor (Application Factor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
14.7.1 Working Characteristics of the Driving Machine . . . . . . . . . . . . . . . . . . . . . 654
14.7.2 Working Characteristics of the Driven Machines . . . . . . . . . . . . . . . . . . . . . 654
14.8 Coecients of Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
14.9 Stepped Hub Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
14.10Subsidence/Surface Smoothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
14.11Modication of Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
14.12Fretting Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
14.13Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660
14.13.1 Shrink ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660
14.13.2 Force Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
14.14Example of Interference Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
14.15How to Change the Unit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
14.16The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
14.17Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
14.18Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
14.19Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
14.20Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
14.21Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
14.22How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666
14.23The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667
14.24Calculation Example: Interference Fit According to DIN 7190 . . . . . . . . . . . . . . . . . . 669
14.24.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
14.24.2 Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
14.24.3 Start the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
14.24.4 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672
14.24.5 Documentation: Calculation report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672

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14.24.6 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673

15 Parallel Keys According to DIN 6892 674

15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
15.2 Scope of DIN 6892 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
15.3 Types of Parallel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
15.4 Surface Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
15.5 Permitted Surface Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
15.6 Application Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
15.6.1 Working Characteristics of the Driving Machine . . . . . . . . . . . . . . . . . . . . . 678
15.6.2 Working Characteristics of the Driven Machines . . . . . . . . . . . . . . . . . . . . . 679
15.7 Load Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
15.8 Load Distribution Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
15.9 Friction Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
15.10Load Direction Changing Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
15.11Load Peak Frequency Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
15.12Support Factor and Hardness Inuence Factor . . . . . . . . . . . . . . . . . . . . . . . . . . 682
15.13Inputs for Calculation Method B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
15.14Some Additional Information On Method C . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
15.15Design Recommendations of Parallel Keys According to DIN 6892 . . . . . . . . . . . . . . . 684
15.15.1 Hub Geometry and Load Output from the Hub . . . . . . . . . . . . . . . . . . . . . 684
15.15.2 Parallel Key Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
15.15.3 Shaft Shoulders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
15.15.4 Keyway Form in the Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
15.15.5 Parallel Key Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
15.16Automatic Dimensioning Functions (Calculator Button) . . . . . . . . . . . . . . . . . . . . . 685
15.17Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
15.18Selection and Geometry of Parallel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
15.19Input of Individual Parallel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
15.19.1 Supporting Length of Individual Parallel Keys . . . . . . . . . . . . . . . . . . . . . . 688
15.20The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688
15.21Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688
15.22Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
15.23Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
15.24Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
15.25How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690
15.26The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
15.27Calculation Example: Parallel Key According to DIN 6892 . . . . . . . . . . . . . . . . . . . 692
15.27.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
15.27.2 Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
15.27.3 Start the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
15.27.4 Calculation Method B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
15.27.5 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
15.27.6 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
15.27.7 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698

16 Involute Splines According to DIN 5480 and Other Standards 699

16.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
16.2 Field of Application of DIN 5480 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
16.3 Input of Geometry Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
16.3.1 Prole Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
16.3.2 More Inputs for the Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
16.3.3 Dene Your Own Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
16.4 Input of Tool Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
16.4.1 Tool Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
16.4.2 Tool Standard Basic Rack Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
16.4.3 Broaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
16.4.4 Gear Hobbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
16.4.5 Gear Shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
16.4.6 Cold-Rolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708

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16.4.7 Dene Your Own Tool Standard Basic Rack Prole . . . . . . . . . . . . . . . . . . . 709
16.4.8 Dimensioning of Tool Standard Basic Rack Prole . . . . . . . . . . . . . . . . . . . . 709
16.4.9 Machining Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
16.5 Input of Data for the Determination of Allowances . . . . . . . . . . . . . . . . . . . . . . . 710
16.5.1 Gear Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
16.5.2 Backlash Allowance Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
16.5.3 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
16.5.4 Tooth Space Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
16.5.5 Span Measurement across Several Teeth . . . . . . . . . . . . . . . . . . . . . . . . . 713
16.5.6 Ball Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
16.5.7 Backlash Normal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
16.5.8 Backlash Pitch Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
16.6 Representation of Gear Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
16.6.1 Representation of the Shaft-Hub Connection . . . . . . . . . . . . . . . . . . . . . . . 715
16.6.2 Representation of Tooth Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
16.6.3 Rotating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
16.6.4 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
16.6.5 Tooth Thickness Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
16.6.6 Tip Diameter Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
16.7 Calculation of Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
16.7.1 Application Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
16.7.2 Examples for Driving Machines with Various Working Characteristics . . . . . . . . . . 719
16.7.3 Examples of Working Characteristics of Driven Machines . . . . . . . . . . . . . . . . 719
16.7.4 Nominal Operation Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
16.7.5 Share Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
16.7.6 Load Peaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
16.7.7 Maximum Load Peak Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
16.7.8 Kind of Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722
16.7.9 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
16.7.10 Stepped Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
16.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726
16.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726
16.10Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726
16.11Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
16.12How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
16.13The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
16.14The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
16.14.1 DXF Output for Accurate Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . 729
16.14.2 STEP/IGES Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
16.14.3 GDE Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
16.14.4 eAssistant CAD Plugin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732
16.14.5 Coordinate Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732
16.15The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733

17 Serrated Shaft and Splined Shaft Connection According to Niemann 734

17.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
17.2 Prole Geometry Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
17.2.1 Serrated Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736
17.2.2 Splined Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737
17.3 How to Change the Unit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739
17.4 Application Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739
17.4.1 Examples for Driving Machines with Various Working Characteristics . . . . . . . . . . 740
17.4.2 Examples of Working Characteristics of Driven Machines . . . . . . . . . . . . . . . . 740
17.5 Load Peaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741
17.5.1 Maximum Load Peak Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741
17.6 Kind of Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742
17.7 Stepped Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
17.8 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744
17.9 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746

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17.10Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746

17.11Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746

17.12Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747

17.13How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748

17.14Automatic Dimensioning Functions (Calculator Button) . . . . . . . . . . . . . . . . . . . . . 749

17.15The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750

17.16The Button `CAD' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750

17.17The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751

17.18Calculation Example: Splined Shaft for Lifting Gear . . . . . . . . . . . . . . . . . . . . . . . 752

17.18.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752

17.18.2 Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752

17.18.3 The Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753

17.18.4 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756

17.18.5 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 756

17.18.6 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758

18 Bolts and Pins 760

18.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760

18.2 Kind of Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761

18.2.1 Longitudinal Pin under Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761

18.2.2 Guide Pin under Bending Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762

18.2.3 Cross Pin under Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762

18.2.4 Bolt Connection under Shearing Force . . . . . . . . . . . . . . . . . . . . . . . . . . 762

18.3 Pin Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763

18.3.1 Solid Pin/Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763

18.3.2 Grooved Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 763

18.3.3 Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764

18.3.4 Coiled Spring Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764

18.4 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764

18.5 Application Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765

18.6 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766

18.7 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767

18.8 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768

18.9 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769

18.10The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770

18.11The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770

19 Clamp Connections 771

19.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771

19.2 Kind of Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772

19.2.1 Separated Hub Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772

19.2.2 Split Hub Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773

19.3 Application Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773

19.4 Coecients of Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774

19.5 Required Clamping Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775

19.6 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775

19.6.1 Dene Your Own Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776

19.7 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776

19.8 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776

19.9 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777

19.10Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777

19.11How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778

19.12The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779

19.13The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779

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20 Bolted Joints according to VDI 2230 780

20.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780
20.2 Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781
20.2.1 Setup of Bolted Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782
20.2.2 Minimum Clamp Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
20.2.3 Number of Alternating Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
20.2.4 Bolt Temperature and Parts Temperature . . . . . . . . . . . . . . . . . . . . . . . . 784
20.3 Assembly Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
20.3.1 Tightening Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
20.3.2 Tightening Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
20.3.3 Utilization of the Yield Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
20.3.4 Assembly Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
20.3.5 Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 790
20.3.6 Embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
20.3.7 Loss of Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
20.4 Input of the Clamped Parts and Denition of the Basic Solid . . . . . . . . . . . . . . . . . . 793
20.4.1 Clamped Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794
20.5 Selection and Input of the Connecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . 797
20.5.1 Type of Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797
20.5.2 Bolt Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
20.5.3 Dene Your Own Bolt Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
20.5.4 Strength Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
20.5.5 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
20.5.6 Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
20.5.7 Thread Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
20.5.8 Friction Coecients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
20.5.9 Roughnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
20.5.10 Washers Under the Bolted Head/Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 809
20.6 Input of the Load Introduction and the Load Application . . . . . . . . . . . . . . . . . . . . 811
20.6.1 Eccentric Clamping and Eccentric Load Application . . . . . . . . . . . . . . . . . . . 812
20.7 The Display of the Joint Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
20.7.1 Further Operating Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
20.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
20.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
20.10Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
20.10.1 Utilization Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
20.11Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
20.12How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819
20.13The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
20.14The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820

21 Compression Springs According to DIN EN 13906-1-2002 822

21.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 822
21.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 823
21.3 Input Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 823
21.3.1 Input of Spring Force and Spring Deection . . . . . . . . . . . . . . . . . . . . . . . 823
21.3.2 Transverse Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
21.3.3 Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
21.3.4 Spring End Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825
21.3.5 Support of Spring End Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826
21.3.6 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826
21.3.7 Input of Lengths and Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827
21.4 Spring Geometry Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
21.5 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
21.5.1 Dene Your Own Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
21.6 How to Change the Unit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830
21.7 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831
21.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831
21.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831

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21.10Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 832

21.11Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 832
21.12Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 832
21.13How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 833
21.14The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 834
21.15Calculation Example: Compression Spring According to DIN EN 13906-1, Edition 2002 . . . . 836
21.15.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836
21.15.2 Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836
21.15.3 The Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 837
21.15.4 Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 838
21.15.5 Documentation: Diagrams and Calculation Report . . . . . . . . . . . . . . . . . . . 840
21.15.6 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841

22 Tension Springs According to DIN EN 13906-2-2002 842

22.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 842
22.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
22.3 Input Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
22.3.1 Input of Spring Forces and Deections . . . . . . . . . . . . . . . . . . . . . . . . . . 843
22.3.2 Wire Diameter and Spring Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844
22.3.3 Input of Diameters and Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844
22.3.4 Coil Clearance and Initial Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845
22.3.5 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845
22.4 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846
22.4.1 Dene Your Own Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847
22.5 Spring end types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847
22.5.1 Input of Distance from Inner Radius of Loop to Spring Body . . . . . . . . . . . . . . 849
22.6 How to Change the Unit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849
22.7 The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850
22.8 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850
22.9 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851
22.10Calculation Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851
22.11Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851
22.12Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 852
22.13How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853
22.14The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854

23 Timing Belt Drives 856

23.1 Start the Calculation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856
23.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856
23.3 Advantages and Disadvantages of Timing Belt Drives . . . . . . . . . . . . . . . . . . . . . . 857
23.3.1 Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 857
23.3.2 Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 857
23.4 Pre-Selection of a Timing Belt Prole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 857
23.5 Conguration of Geometry of a Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 859
23.5.1 Belt Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 859
23.5.2 Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 859
23.5.3 Timing Belt Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 860
23.5.4 Position of the Timing Belt Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 862
23.5.5 Number of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 863
23.5.6 Pitch Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 864
23.5.7 Adding or Removing a Timing Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . 864
23.5.8 Graphic Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865
23.5.9 Additional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 866
23.6 Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867
23.6.1 Quick Info: Tooltip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 868
23.7 Input of Power Data Of the Timing Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 868
23.7.1 Belt Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 869
23.7.2 Safety Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 870
23.8 Documentation: Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 871
23.9 How to Save the Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 872

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23.10The Button `Redo' and `Undo' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 873

23.11The Button `Options' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 873

24 Tolerance Fit Calculator DIN ISO 286, Edition 1990 874

24.1 Selection of Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 874
24.2 Calculation of Possible Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 876
24.3 Example for Cylindrical Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 878
24.3.1 Examples for Interference Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 878
24.3.2 Examples for Transition Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 879
24.3.3 Examples for Clearance Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 879
24.4 Further Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 881

25 Approximate Shaft Dimensioning According to Niemann 2001 882

25.1 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 883
25.1.1 Dene your Own Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 883
25.2 Material Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 884
25.3 Load Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 884
25.4 Further Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 885

26 Rough Estimation of Bolted Joints According to VDI 2230 Sheet 1 (2003-02) 886
26.1 Axial Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887
26.2 Transverse Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887
26.3 Strength Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 888
26.4 Load Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 888
26.5 Tightening Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890
26.6 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890
26.7 Further Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 891

27 Hardness Conversion According to DIN 50150: 2000-10 892

27.1 Kind of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 892
27.2 Hardness Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 893
27.3 Further Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894

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Chapter 1

A Helpful Guideline to the Manual

The eAssistant manual contains information on all aspects of using. Having this information available right
from the start makes it easier to work with the eAssistant. The eAssistant consists of various calculation
modules and the manual provides all information about the modules. Furthermore, you will get calculation
examples for every calculation module. Our examples will show how easy it is to work with the eAssistant
software. Our manual oers you a very fast access to all information. To get to the manual you have dierent
possibilities:

(1) Visit our web site www.eAssistant.eu. The navigation bar `Help' takes you to the manual.

Figure 1.1: Menu item `Help' on the web site

(2) Click on the `Help' button which you will nd directly in the program.

Figure 1.2: `Help' button in the program

(3) Click on the `Help' button which you will nd directly in all calculation modules.

Figure 1.3: `Help' button in every calculation module

Our manual is improved continually. Of course we are always interested in your opinion, so we would like to
know what you think. We appreciate your feedback and we are looking for ideas, suggestions or criticism. If
you have anything to say, please let us know by phone +49 (0) 531 129 399-0 or email [email protected].
You will always nd a sympathetic ear, no matter what the problem is.

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2. Registration 23

2.1 How to Register

Click the link `Free test account'.

Figure 2.2: Registration for a free test account

Click on the link `Please click here to register for a free test account'.

Please note: In order to complete your registration, you need to accept our general terms and conditions.

The registration window is started.

Figure 2.3: Enter your personal data

Enter the required user data and conrm with the button `Create new user'.

Please Note: Private users should enter `private' into the input eld `Company'. You can select your
username by yourself, but please note that you cannot change your username at a later date. But there is still
the possibility to change your personal data in the project management. In case your username is assigned to
someone else, you will get the appropriate information in the message window.

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2. Registration 24

Please Note: Your registration data will be veried. Registrations with false or incorrect
information will be deleted automatically. Your password will be mailed to you, usually
within 24 hours and you can login immediately.

Once you have successfully registered, you can login. To login, please visit www.eAssistant.eu and click on
the button `Login for registered users'.

2.2 Login for Registered Users

If you have already received an email message from us with your password, simply log in. Click on the link
`Login for registered users'.

Figure 2.4: Login for registered users

Please login with your username and your password and conrm with the button `Login'.

Figure 2.5: Enter login and password

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2. Registration 25

Now you are in the project management.

Figure 2.6: Project management

2.3 Lost Your Password?

If you cannot remember your username or your password, use the `Forgot your password?' link. Enter your
email address in the following form. Please note that you need the same email address you have entered for
your rst registration. Then click on the button `Request new password'. You will get a new password via
email. After a successful registration, you can change your password to one that is easier to remember.

Figure 2.7: Request a new password

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Chapter 3

General Functions

3.1 Project Management

As soon as you have successfully signed in with your username and password, you are presented with the
project management screen where you can start all calculation modules. With the project manamgement tool
it becomes easy to manage all your projects and calculation les. The project management helps you to open,
save, delete, copy or rename projects or calculation les. You can change your personal data or your password
here if necessary.

Figure 3.1: Project management

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3. General Functions 27

3.2 Projects
Here you can manage your projects. You can create a new project, you can copy, rename, or delete projects.
The window `Files' lists the content of the selected project.

3.2.1 Creating a New Project

Click in the `Projects' window and click the right mouse button. Select the menu item `New project' from the
context menu.

Figure 3.2: Create a new project

A new input window is opened. Enter a name into the input eld and click the button `Ok'.

Figure 3.3: Name the new project

The input window is closed. Now your `New project' is created in the list window `Projects'.

Figure 3.4: New project was created

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3. General Functions 28

3.2.2 Copying and Pasting a Project

Select the project you would like to copy and click the right mouse button. Select the menu item `Copy' from
the context menu.

Figure 3.5: Copy the project

Click in the window `Projects' and click the right mouse button. Select the menu item `Paste' from the context
menu.

Figure 3.6: Menu item `Paste'

The copied project has got still the title `Copy'. You can change the name of that project later. If you copy a
project, the content (les) of this project will copied too.

Figure 3.7: Paste the project

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3.2.3 Renaming a Project

Select the project you would like to rename and click the right mouse button. Select the menu item `Rename'
from the context menu.

Figure 3.8: Rename a project

Change the name of the project and conrm with `Ok'.

Figure 3.9: New name

3.2.4 Deleting a Project

Select the project you would like to delete and then a right-click on this project. Select the menu item `Delete'
from the context menu. Answer the prompt with `Yes'.

Figure 3.10: Delete the project

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3. General Functions 30

3.2.5 Project Folder `Default'

The folder `Default' is a default setting. If you close a calculation module, the current state of the calculation
will be saved automatically as a calculation le called `last Calculation' in the project folder `Default'. In case
you forgot to save your calculation, no data get lost. The calculation modules of the same module will be
overwritten when opening and closing the modules. You cannot rename, delete or cut the folder `Default'.

Figure 3.11: Project folder `Default'

3.2.6 Calculation Modules

The module tree on the left side shows all calculation modules. Click the arrow to the left to display the
modules of each module group. One click starts the module.

Figure 3.12: Start calculation modules

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3. General Functions 31

To narrow down the selection to one particular type, choose the calculation type from the list. Click `All Files'
to display all calculation les.

Figure 3.13: Calculation type

To close the calculation module, click the menu item `File', then click `Quit calculation'.

Figure 3.14: Quit the calculation module

The eAssistant framework provides the exibility to easily change between the modules. A previously opened
module does not need to be reloaded again and is immediately available without waiting. The last calculation
will be loaded automatically.

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3. General Functions 32

3.3 Files
The window `Files' displays all calculation les. By using a lter function, the saved calculation les can be
displayed within a specic module or across modules. Choose a calculation module and see all les which
belong to the respective calculation module.

3.3.1 Copying and Pasting a File

Select the le you would like to copy and click the right mouse button on this le. Select the menu item
`Copy' from the context menu.

Figure 3.15: Copy a le

Select the project where you would like to copy the le. Click the right mouse button in the eld `Files' and
click the menu item `Paste' from the context menu.

Figure 3.16: Paste a le

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3. General Functions 33

3.3.2 Renaming a le

Select the le you want to rename and click the right mouse button on this le. Select the menu item `Rename'
from the context menu.

Figure 3.17: Rename a le

Change the name of the le and click the button `Ok'.

Figure 3.18: Enter a new name

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3. General Functions 34

3.3.3 Cutting a File

Select the le you would like to cut and click the right mouse button on this le. Select the menu item `Cut'
from the context menu.

Figure 3.19: Cut a le

Select the project where you would like to paste the le and click the right mouse button. Select the menu
item `Paste' from the context menu.

Figure 3.20: Paste a le

3.3.4 Deleting a File

Select the le you would like to delete and click the right mouse button on this le. Select the menu item
`Delete' from the context menu. Answer the prompt with `Yes'.

Figure 3.21: Delete a le

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3. General Functions 35

3.4 The Button `File'

3.4.1 New
Clicking the menu item 'New' closes the current calculation and opens the calculation module with the internal
default setting for all values. If you have dened your own template le, this template le will then be used
when you open the calculation module.

Figure 3.22: Menu item `New'

3.4.2 Quit the Calculation Module

The menu item `Quit the Calculation module', which you´ll nd under the `File' menu item, just closes the
current calculation module and not the whole program.

Figure 3.23: Close the calculation module

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3. General Functions 36

3.4.3 Quit the Application

Click the menu item `File' and then the `Exit' button to quit the application. If you close the software without
logging out, you will be automatically logged out. But you can immediately return to the eAssistant and
re-login with your username and password.

Figure 3.24: Quit the application

3.5 The Button `Extras'

3.5.1 Language
It is easy to switch from one language to another. click the menu item `Language' and select the required
language. The software is available in English and German.

Figure 3.25: Change the language

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3. General Functions 37

3.5.2 Settings
The menu item `Settings' controls the properties of the software as a whole, while the menu item `Options'
controls the properties of the individual calculation module. This is where you congure settings like adding
a project info, enabling/disabling job data or selecting a short calculation report. If you ever need to change
your password, you can do that here.

Figure 3.26: Settings

Job Data
Entering the job data allows to specify an order. In this way you can describe each job in detail and properly
document it. In the tree structure on the left side, click `General' and set the checkmark `Show a dialog to
edit the job data before generating the report'. If you enable this option, the job data is displayed on the
screen before the calculation report is opened. That also means that a window is displayed in which you can
enter the job data every time a calculation report is generated.

Figure 3.27: Enter and enable order data

The job data can be saved to the calculation, meaning that you do not have to enter the job data again every
time. To do so, please enable the checkbox `Save with calculation'. If you save the calculation, the job data is

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3. General Functions 38

also saved. If you disable the function `Show in report', the job data is not displayed in the calculation report.

Figure 3.28: Report including job data

User Data
In case several users share the same password and user name, a single user can congurate own user data on
the workstation. Later, the data will appear at the top of the generated calculation report and you will be
able to see who has created the calculation. The conguration manager is particularly helpful for companies
who have multiple parallel accounts. When you start the conguration manager, the module rst shows the
user data that is saved in the eAssistant `User data'. You can customize the user data. Click the button `OK`
to save the modications.

Figure 3.29: Modify the user data

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3. General Functions 39

Open a calculation module from the project management, for example cylindrical gears. You can leave the
conguration manager open. Click the button `Report' to generate the calculation report. The modied user
data appear in the header section of the calculation report. The general user data will remain in place.

Figure 3.30: Create a calculation report

Login Data
The password can be modied by clicking the menu item `Login Data'. Enter the new password into the input
eld `New password'. Conrm the password in the input eld `Repeat password' and click the button `Change
Password'. Conrm with the button `OK'.

Figure 3.31: Change the password

Project Info
The program allows you to create a project info. For any project, you can add a describing text, for example
order data or other project-related information (e.g., drive shaft). The text then appears in the header section
on each page of the PDF calculation report. The conguration of the project info allows you to choose whether
to be prompted for conrmation before generating the project info.

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3. General Functions 40

Server
On the left-hand side in the tree view under `Project info' you can nd the menu item `Server'. If you click
this menu item, all existing project les saved in the project management under `Projects' are listed.

Figure 3.32: Project info

Select a project, for example `Project 1'. The text eld `Project info' lets you add some text. This text will
appear in the header section of the calculation report. Click the button `Save project info' in order to save
your text. The added text then applies to all calculation les that belong to this project.

Figure 3.33: Add some text

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3. General Functions 41

Select the project `Project 1' from the project management and open the calculation `Shaft with Gear' either
by double-clicking the le or click the button `Open Calculation'.

Figure 3.34: Project Management

In order to generate the calculation report, click the button `Report' in the calculation module. You can see
the newly added text in the upper left corner. If you open the PDF calculation report, then the text will appear
at the top of every page in your calculation report.

Figure 3.35: Create a calculation report

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3. General Functions 42

If you check the checkbox `Show a dialog to conrm...', you receive a dialog each time before the generation
of the calculation report starts. You can then decide whether to use the added project info or not. If this
checkbox is clear, the calculation report is automatically generated and no prompt is displayed.

Figure 3.36: Enable the option

If you choose to place a check mark here, a message window will be opened each time before the generation
of the calculation report begins. In this window you can check the project info again and decide if the text
contains the information you want. If not, you can overwrite and quickly replace the text. Conrm with the
`OK' button and the calculation report including the new project info will be created. But the saved project
info in the conguration manager cannot be overwritten and remains unchanged.

Figure 3.37: Overwrite project info

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3. General Functions 43

Local
On the left-hand side in the tree view under `Project info' you can nd the menu item `Local'. If you click this
menu item, you can add a project info for all calculation les that are saved locally to your computer.

Please note: The eAssistant software exports the project info as an XML le. The locally saved eAssistant
calculation and the XML le must be in the same directory.

To save the project info locally, please click the menu item `New Project'.

Figure 3.38: Projekt info local

Please enter a project name into the input eld `Project'. Click the button `Browse' and save the le where
the eAssistant calculation le is stored. Click the `Open' button.

Figure 3.39: Set save location

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3. General Functions 44

Add some text to the text eld `Project info'. This text will appear in the header section of the calculation
report. Click the button `OK' in order to save your text.

Figure 3.40: Add text for project info

Open a calculation module (e.g., for shafts). Now open the calculation le that is saved locally to your
computer.

Please note: When opening the calculation, please keep in mind to activate the option `Local' in the top
menu bar of the calculation module.

Figure 3.41: Open local calculation

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3. General Functions 45

In order to generate the calculation report, click the button `Report' in the calculation module. You can see
the newly added text in the upper left corner. If you open the PDF calculation report, then the text will appear
at the top of every page in your calculation report.

Figure 3.42: Create calculation report

As with the menu item `Server', you can activate the option `Show a dialog to conrm...'. If you check the
checkbox, you receive a dialog each time before the generation of the calculation report starts. You can
then decide whether to use the added project info or not. If this checkbox is clear, the calculation report is
automatically generated and no prompt is displayed.

Figure 3.43: Enable option

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3. General Functions 46

If you choose to place a check mark here, a message window will be opened each time before the generation
of the calculation report begins. In this window you can check the project info again and decide if the text
contains the information you want. If not, you can overwrite and quickly replace the text. Conrm with the
`OK' button and the calculation report including the new project info will be created. But the saved project
info in the conguration manager cannot be overwritten and remains unchanged.

Figure 3.44: Overwrite saved project info

You can quickly and easily delete the local project info le from your computer. To do so, please click the the
button `Delete'. The XML le automatically disappears from your computer.

Figure 3.45: Delete le with project info

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3. General Functions 47

Report Templates
The conguration manger provides report templates for each calculation module. Individual reports can be
also integrated. If you have any questions or if you need further information, please feel free to contact us.

Figure 3.46: Protokollvorlage

Click the tree view on the left-hand side to select a calculation module, for example shaft calculation. Click
the listbox `Standard report template' and choose either `Standard' or `Short report'. Click on the button
`Save settings'. If you select `Short report', then a short report is generated for all calculation les that belong
to the shaft module. A short report is not available for all calculation modules.

Figure 3.47: Short report

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3. General Functions 48

If you check the checkbox `Show a dialog to conrm...', you receive a selection list each time before the
generation of the calculation report starts. This list will help you decide which report template should be used
for the report generation. If this checkbox is clear, the calculation report is automatically generated and no
prompt is displayed.

Figure 3.48: Enable option

If you choose to place a check mark in the checkbox, a message window will be opened each time before
the generation of the calculation report begins. In this window you can decide whether to create a standard
calculation report or a short report. Conrm with the button `OK' and the desired calculation report is
generated.

Figure 3.49: Notication message

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3. General Functions 49

3.6 Button `Help'

Click the button `Help' to open the user manual in HTML and PDF format. It also contains the eAssistant
Terms and Conditions.

Figure 3.50: Button `Help'

3.7 File Info

Here you get further information about the les. Click on a le, the `File info' appears. You will get the name
of the le, the calculation type as well as the date and time of your calculation that is saved to the eAssistant
server.

Figure 3.51: File info

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3. General Functions 50

3.7.1 Time Account

The time left is displayed in the information area. As long as you work in the project management, no time will
be lost or deducted from your account during this time. But when you open one of the calculation modules,
the usage time will be automatically deducted from your account. Please visit www.eAssistant.eu to get
further information.

Please note: The project management provides calculation modules for free: t calculation according to DIN
ISO 286, shaft dimensioning according to Niemann, hardness conversion according to DIN 50150 as well as a
lubricant selection. When you start these modules from the eAssistant web site, it is not necessary to register
for the eAssistant. If you open the free modules using the project management, no usage time will be deducted
from your account. With ate rate accounts, the time is disabled, too.

Figure 3.52: Time account

3.8 Logging Out

Click on the button `Logout' to leave the program. You will be taken back to the login page and you can
re-login.

Figure 3.53: Logging out

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3. General Functions 51

3.9 General eAssistant Functions

The top menu bar includes all general functions that are identical in every calculation module. Some calculation
modules provide (e.g., shaft and cylindrical gear pair) the button `CAD'. Based on your calculation, parts can
be generated automatically as a feature-based 3D part in a 3D system. Find more information in the calculation
modules as well as in the section 3.16 `The Button CAD'.

Figure 3.54: Calculation module

3.10 Opening a Calculation from the eAssistant Server

Click the `Open' button in the top menu bar and choose the le that you want to open. Click the button
`Open'.

Figure 3.55: Open the le

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3.11 Opening a Calculation From Your Computer

Activate the checkbox `Local' and click the button `Open'.

Figure 3.56: Activate the checkbox `Local'

Select the le you want to open and click the `Open' button.

Figure 3.57: Standard Windows dialog

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3.12 Saving a Calculation to the eAssistant Server

In general there are two dierent possibilities to save a calculation. Save your calculation either to the
eAssistant server or to your computer. Click on the button `Save' to store the calculation to the eAssistant
server. The checkbox Local is not set.

Figure 3.58: Button `Save'

A new window appears. Select a project where you want to save the le and type a name for the le. Click
on the `Save' button.

Figure 3.59: Save the le

Please note: eAssistant identies the calculation module automatically, so it is not necessary to specify the
le extension.

3.13 Saving a Calculation to Your Computer

Activate the checkbox `Local' and click the button `Save'.

Figure 3.60: Save the le locally

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3. General Functions 54

A standard Windows dialog for saving les will appear. Now you will be able to save the calculation to your
computer.

Figure 3.61: Standard Windows dialog

3.14 The Button `Calculate'

All results will be calculated during every input and will be displayed in the result panel. A recalculation
occurs after every data input. Any changes that are made to the user interface take eect immediately. In
case a minimum safety is not fullled, the result will be marked red. Press the Enter key or move to the
next input eld to complete the input. Alternatively, use the Tab key to jump from eld to eld or click
the `Calculate' button after every input. Your entries will be also conrmed and the calculation results will
displayed automatically.

Figure 3.62: Button `Calculate'

3.15 The Button `Redo' and `Undo'

The button `Undo' allows you to reset your inputs to an older state. The button `Redo' reserves the undo.

Figure 3.63: Button `Undo' and `Redo'

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3.16 Button `CAD'

The top menu bar of some calculation modules provides the button `CAD'. The CAD plugins for various CAD
systems (e.g., SOLIDWORKS, Solid Edge, Autodesk Inventor, NX and Creo Parametric) oer a great way to
connect calculation and design. Based on the eAssistant calculation, you can create shafts, cylindrical gears,
bevel gears, involute splines, splined shaft or serrated shaft connections as a 3D part within seconds. The
individual features of the CAD plugin depend on the CAD system. eAssistant also supports the output format
DXF.

Figure 3.64: Button `CAD'

Before you can start using the CAD plugin, you need to download and install the plugin from
our web site www.eAssistant.eu.

3.16.1 DXF Output for Exact Tooth Form

Click on the button `CAD', then click on the menu item `DXF-Output'. An accurate tooth form for any
involute gears in DXF format can be generated.

Figure 3.65: DXF output

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3. General Functions 56

For the DXF output the following settings are possible:

- Output as DXF le for gear 1 or gear 2

- Output in normal section or transverse section (both options will be active when an helix angle is entered)

- Output of the tooth form in the DXF le as points

- Output of the tooth form in the DXF le as lines

- Output of the tooth form in the DXF le as polylines

- Output of the tooth form in the DXF le as arcs

- Number of teeth

- Name of DXF layer

- Save DXF le with header

Figure 3.66: Settings for DXF output

If you have changed your settings, then click on the button `OK'. A standard Windows dialog for saving the
data le will appear.

Figure 3.67: Save the DXF le

Now you can save the DXF le to your computer. Enter a name and click on the button `Save'. It is not
necessary to specify the le extension `dxf ', because the extension will be attached automatically to the le
name.

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3.16.2 3D CAD Plugins

The CAD plugins for various CAD systems oer a great way to connect calculation and design. Together with
the software, the CAD plugins allow to dimension, calculate and optimize various machine elements directly
in the CAD system (SOLIDWORKS, Solid Edge, Autodesk Inventor, NX or Creo). The plugins enables the
user to open all eAssistant calculation modules directly through the CAD menu. At the push of a button, the
part can be created as a 3D part on the basis of the previously calculated data. First, you have to download
and install the CAD plugin. You can nd the plugin on our web site www.eAssistant.eu. After installation,
an integrated button called `eAssistant' appears in the CAD system.

Figure 3.68: 3D CAD Plugin

Run the calculation using the eAssistant and click on the button `CAD'. Please select the appropriate CAD
system from the list. The values are transferred to the CAD system where you can generate the 3D models
through the eAssistant menu. By taking a step-by-step process dening the gears or pinions geometry, tol-
erances and tooth prole, you can create gears automatically as a 3D part. Based on the calculation, shafts
with an unlimited number of cylindrical and conical segments can be created as a 3D part. The attractiveness
of the CAD plugin is additionally enhanced by the bidirectional connection between eAssistant and the CAD
system. As changes are made to a calculation, the 3D model can be updated. With just one click, the design
table with all manufacturing details can be placed on the manufacturing drawing. The calculation information
is saved in the 3D model and can be opened at any time throughout the entire design phase. Please visit
www.gwj.de to get further information.

Figure 3.69: CAD Plugin in the CAD system

Please Note: Before you click the CAD button for involute gears, please click the button Tooth form. Select

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Detail view and set the desired allowance (min./middle/max).

3.16.3 Manufacturing Data

The button `CAD ⇒ Manufacturing data' allows to save the manufacturing data to a text le.

Figure 3.70: Output of manufacturing data

3.16.4 Coordinate Table

The gear tooth form geometry of a tooth space can be exported as a coordinate text le in transverse section
as well as in normal section.

Figure 3.71: Coordinate table

3.17 The Button `Report'

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.

Figure 3.72: Button `Report'

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You can navigate through the report via the table of contents that provides links to the input values, results
and gures. This calculation report contains all input data, the calculation method as well as all detailed
results. The report is available in HTML and PDF format. The calculation report saved in HTML format can
be opened in a web browser or in Word for Windows. The reports are structured dierently in the various
calculation modules.

Figure 3.73: Calculation report

The calculation module includes:

- Calculation method

- Address

- Date / Time

- Print, PDF or Save: Here you have the possibility to save and print the report or to generate a PDF
document.

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu
bar. Select the le type `Webpage complete', then just click on the `Save' button.

- If you click on the symbol `Print', then you can print the report very easily.

- If you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will
see the Windows save dialog.

- Name of the project

- Content: The table of contents is linked. So you can always go to the most important data immediately.

- Messages: Here all messages from the message window will be listed.

- Input data: Here all input data are available. So you can check the input data again.

- Graphical representation: In case a graphical representation is available, you will see it here.

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3. General Functions 60

- Calculation results: Here you get all calculation results.

- Hints: The report contains a reference to the used literature and standards.

3.18 The Button `Options'

Some settings of the calculation modules have default values and by clicking the button `Options' you can
change these settings. For example, you can change the system of units, the minimum safeties for cylindrical
gears, the operating temperature for springs or set the number of decimal places for the calculation report.

Figure 3.74: Button `Options'

3.19 The button `Help'

Click the button `Help' to open the user manual. This takes you directly to the user manual of the respective
module.

Figure 3.75: Button `Help'

3.20 Message Window

Every calculation module contains a message window. This message window displays detailed information,
helpful hints or warnings about problems. One of the main benets of the program is that the software provides
suggestions for correcting errors during the data input. If you check the message window carefully for any
errors or warnings and follow the hints, you are able to nd a solution to quickly resolve calculation problems.

Figure 3.76: Message window

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3. General Functions 61

3.21 Quick Info: Tooltip

he quick info feature gives you additional information about all input elds and buttons. Move the mouse
pointer to an input eld or a button, then you will get some additional information. This information will be
displayed in the quick info line.

Figure 3.77: Quick info

3.22 How to Change the Unit System

eAssistant provides two unit systems: the metric system and the U.S. customary unit system. You can quickly
switch between the units. To select the unit system, click the button `Options' and decide for a unit.

Figure 3.78: Select the unit system

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3. General Functions 62

It is also possible to change the unit by clicking the label eld. When you click the label eld, a context menu
will open providing all available units within the unit system. The change should take eect immediately.
All settings will be saved to the calculation le. As soon as you select a unit, the current eld value will be
converted automatically into the chosen unit.

Figure 3.79: Change the unit

3.23 Automatic Dimensioning Functions (Calculator Symbol)

The button for the dimensioning functions is marked by a calculator symbol. Via the `Calculator' button
next to the input elds, you can have the program suggest appropriate values for you. In some modules, the
maximum possible values are calculated by using the respective minimum safety.

Figure 3.80: Example for a dimensioning button

3.24 User-Dened Input

eAssistant enables you to specify your user-dened inputs. There you get the possibility to calculate non-
standard parallel keys or to calculate involute splines which dier from the standard. In case you cannot nd
the material you are looking for in our extensive material database, you can dene your individual material.
You will nd the entry `User-dened' or the entry `User dened input' in the listboxes. If you select one of
these already mentioned options, the according input elds will be enabled, so that you can specify your own
input values. Examples for the user-dened input:

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3. General Functions 63

Examples for the user-dened input:

- Interference t: Surface quality

Figure 3.81: Interference t

- Parallel key: Own input of load peaks

Figure 3.82: Own input

- Roller bearings: Lubricant selection

Figure 3.83: Lubricant selection

- Cylindrical gear pair: Selection of basic rack tooth prole

Figure 3.84: Own basic rack tooth prole

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3. General Functions 64

3.25 The Button `Question Mark'

In some calculation modules (e.g., spur gear pair or parallel key module) you will nd question mark buttons.
If you click on these buttons, you will get additional information, for example gures or tables.

Figure 3.85: Button `Question mark'

3.26 Calculation Results

All results will be calculated during every input and will be displayed in the result panel. A recalculation
occurs after every data input. Any changes that are made to the user interface take eect immediately. In
case a minimum safety is not fullled, the result will be marked red. Press the Enter key or move to the
next input eld to complete the input. Alternatively, use the Tab key to jump from eld to eld or click
the `Calculate' button after every input. Your entries will be also conrmed and the calculation results will
displayed automatically.

Figure 3.86: Calculation results

3.27 Template Files

If you have to enter the same data very often, we recommend you to dene a template le. That saves both
time and work. All you have to do is to dene a template. Enter your input data once into the calculation

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3. General Functions 65

module. When you are ready to save the le, please name it `standard'. If you now open the calculation
module, the module starts with your individual values. Please note that the template le can be saved only to
the eAssistant server. You can dene a template le specically to a project or you can save the template le
to the folder `Default' for a general use. It is possible to dene a template le for each calculation module.
The default search follows the following order:

1. The search always starts in the current project folder.

2. The search continues to the next level, the project folder `Default'.

3. If no template le is found, the eAssistant default conguration will be used.

The template le, which was found rst, is taken over. For example: If a template le is dened in the current
folder, then the le will be primarily accepted. But in case this template le does not exist, the le will be
searched in the project folder `Default'. There the template le is taken over again. If the le also cannot be
found there, then the central eAssistant standard is used.

Create a Template File for a Parallel Key Calculation

Start the calculation module `Parallel key'. Change and dene your input data. Click on the button `Save'
and select a project folder to save the le. Now enter the le name `standard' into the input eld.

Figure 3.87: Save the template le

Please Note: It is not necessary to specify the le extension. The eAssistant identies the calculation module
automatically.

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3. General Functions 66

If you select the project `Default', the template le applies for all projects, except for the
projects where a template le was dened separately. Please also pay attention to the lower
case of `standard'.

Close the calculation module `Parallel key'.

Figure 3.88: Template le `standard' is created

The calculation le `standard' appears in the window `Files'. When you open the module `Parallel key', the
module starts with your previously dened values.

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Chapter 4

Shafts with Strength According to

DIN 743

4.1 Start the Calculation Module

Please login with your username and your password. To start the calculation module for shafts, please click
the menu item `Shaft/Bearings' on the left side and select `Shaft'.

Figure 4.1: General overview

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4. Shafts with Strength According to DIN 743 68

This module provides a geometry and a calculation part. The geometry part is the part where you dene the
shaft geometry, the bearings, the loads as well as the notch eects. The actual calculation then takes place
in the calculation part. The calculation part allows to determine bearing forces, deection, strength or static
torsion. Click on the `Calculate' button to switch between the geometry and calculation part.

4.2 The Geometry Part

The geometry part allows you to dene the entire shaft geometry including bearings, force elementes and force
eects. The upper part of the module provides dierent input options. The lower part includes the coordinate
system as well as the shaft symmetry axis. The input values are taken over immediately and are represented
graphically in the lower part. The representation is interactive. That means, you can select, move, copy or
delete shaft elements. Use the `3D' view button to move quickly between 2D and 3D view.

Figure 4.2: Geometry part

4.2.1 Shaft Properties

When you start the calculation module, the general shaft properties are automatically displayed. Use the
`Shaft properties' button to modify the properties at any time you want.

Figure 4.3: Shaft properties

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4. Shafts with Strength According to DIN 743 69

The shaft properties allows you to select the shaft material. You can also specify your own material. Dene
speed, direction of rotation and the position of the shaft in space. The speed is dened as revolutions per
minute. Please keep in mind: When you change the speed of the shaft, the torques will change because of
the entered power and speed. This happens when a power instead of a torque is given for the force elements.
Select the material by using the listbox or material number. Click the button `Material selection' and you get
detailed information on the material (e.g., material type, density, yield point).

Figure 4.4: Material selection

In case there is no material that will fulll the design requirements, then simply dene your individual material.
Select `User-dened` from the listbox and click the button `Material selection' or click directly on the button
`Material selection' to open the material database. Select the option `User dened' and all inputs and options
are enabled and you can specify your individual material very easily. Click on the button `OK' to conrm your
entries and to return to the shaft geometry part. Please be advised that changing the material will delete your
dened inputs and you have to enter the inputs again.

Figure 4.5: Materal selection

Please note: It is important to consider the fact that the integrated strength calculation according to DIN
743 is valid or steels only.

4.2.2 Coordinate System

The calculation module uses a coordinate system that is a clockwise system where the Y-axis is the axis of
symmetry as well as the axis of rotation of the shaft. In the two-dimensional view, the Z-axis shows upwards
and the X-axis shows out of the screen. A rotation of the shaft around the Y-axis is dened as a clockwise
rotation. The left end of the shaft is the point of origin. The forces and torques have to be entered in positive
direction without signs and in negative direction with a minus sign.

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Please Note: The direction of torques is usually dened by the input `driving' and `driven'. The input `driving'
means that the shaft is driving and the torque counteracts the direction of rotation.

Figure 4.6: The coordinate system

4.2.3 Relative and Absolute Position

You get more information about the respective elements, for example about the absolute position. It is
important that you have to dierentiate between a relative position and an absolute position.

Figure 4.7: The relative and absolute position

Relative Position
The positioning of an element occurs always from a shaft section related to the left side of the element. This
means that the relative position corresponds to the input value `Position' of the respective element.

Figure 4.8: Relative position

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Absolute Position
The position of an element is displayed from the origin of the coordinate system to the left side of the element.

Figure 4.9: Absolute position

4.2.4 Creating a Shaft Segment

There are segments for the outer contour and axial holes for the inner contour available. Click on the button
`Segment' to create a shaft segment.

Figure 4.10: Create a shaft segment

The segment is represented.

Figure 4.11: Representation of the shaft segment

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4. Shafts with Strength According to DIN 743 72

Input elds for the entry of length and diameter are displayed. To add a conic segment, activate the option
`Conic segment'.

Figure 4.12: Activate conic segment

If this option is activated, enter a left diameter `1' and a right diameter `2' for the segment. To add another
segment, please click on the `Segment' button again.

4.2.5 Creating a Hole

To create a hole (an inner contour), click on the button `Hole (axial)'. The dierent possibilities for a data
input are now displayed.

Figure 4.13: Add an axial hole

In addition, you can extend the axial hole by clicking the button `Adjust to shaft length'. This button adapts
the length of the axial hole to the shaft length automatically. Then the entire inner contour goes exactly to
the end of the outer contour.

Figure 4.14: Adjust to shaft length

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4. Shafts with Strength According to DIN 743 73

Please Note: For the strength calculation notch eects, such as shoulders, are not considered in the inner
contour. There is no applicable calculation method right now.

4.2.6 Creating a Bearing

You can add as many bearings as you need. A calculation of statically over-determined shafts with more than
two bearings is possible. Select a shaft segment to position the bearing on the shaft, then click on the button
`Bearing'.

Figure 4.15: Button `Bearing'

Now the bearing is added to the shaft.

Figure 4.16: Add bearing

To dene the bearing, dierent options for an input are available: position, width, diameter, stiness, and
pressure angle. Further you can dene the kind of bearing arrangement: xed bearing, movable bearing, axial
bearing or oating bearing.

Figure 4.17: Dene a bearing

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4. Shafts with Strength According to DIN 743 74

Please note that the position refers to respective shaft segment, that means a relative position has to be
entered. The absolute position, related to the point of origin and with it related to the left end of the shaft,
is indicated with the element info (see section 4.2.3 `Relative and absolute position').

The width is the overall width of the bearing and the diameter is the outer diameter of the bearing for the
correct representation. For bearings with a pressure angle the changed point of application of load can be
considered for the calculation of the support reactions. In case the (radial) stiness of the bearing is known,
the stiness can be considered by appropriate settings for the calculation as well.

Please Note: Bearings cannot be positioned over a shaft segment.

4.2.7 Force Elements: Cylindrical Gear

The shaft module oers dierent possibilities to dene loads. Besides a direct input of forces and torques in
coordinate direction, so-called intelligent elements for application of load can be positioned on the shaft. Click
on the `Force elements' button and you can select cylindrical gear, bevel gear, coupling/motor and load.

At rst select the shaft segment on which you want to create the cylindrical gear. Click on the button `Force
elements' and select the menu item `Cylindrical gear'.

Figure 4.18: Select `Cylindrical gear'

The cylindrical gear is added to the shaft.

Figure 4.19: Add the cylindrical gear

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4. Shafts with Strength According to DIN 743 75

For the positioning of the shaft, the relative position of the left shaft side is given. Based on further inputs for
pitch circle, helix angle, pressure angle, position of action and power/torque, the calculation of forces, that
inuence the shaft, is determined.

Figure 4.20: Dene the cylindrical gear

In particular the input of power of action is important for the point of application of load. The power of action
indicates the position of the point of the interference with the gear pair.

Figure 4.21: Power of action

For cylindrical gears with a prole shift modication, reference circle and pitch circle are not equal. When
you enter the reference circle of the cylindrical gear, the calculated forces are not completely accurate - in
particular with very large prole shift modications. For an exact calculation of the forces, you have to enter
the pitch circle diameter instead of the reference diameter and instead of the pressure angle you have to enter
the working transverse pressure angle.

The Button `T/P'

The `T/P' button allows you to enter either the power or torque. The description of the input eld will be
changed accordingly in torque or power.

Figure 4.22: Input of power or torque

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4. Shafts with Strength According to DIN 743 76

Multiple Position of Action

Here you can dene a multiple position of action, that means that the cylindrical gear, which is on the shaft, is
in mesh with several cylindrical gears. Set a checkmark into the eld next to `Use multiple position of action'
and click on the button `Multiple position of action'.

Figure 4.23: Button `Multiple position of action'

Select the number of position of action from the listbox. Further you can indicate either `Power' or `Torque'.
Conrm your inputs with the button `Ok'.

Figure 4.24: Dene multiple position of action

Helix Angle and Direction of Helix Angle

If two helical gears are in mesh, both gears have the same, but opposite direction of the helix angle β. The
direction of the helix angle has to be opposite that a left-hand mates a right-hand. Therefore, you have
to dierentiate between right-handed helix angle and left-handed helix angle. Please specify here right or
left-hand helix angle.

Figure 4.25: Right-handed or left-handed

Driving and Driven Gear

A driving gear and a driven gear always co-operate and form a gear pair. For the most force elements the
direction of torques is specied by the input of driving and driven. The input `driving' means that the shaft
drives or that the moment counteracts the direction of rotation.

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4. Shafts with Strength According to DIN 743 77

Dene here the driving and driven cylindrical gear. You can also dene it with the `Multiple position of action'.

Figure 4.26: Driving and driven cylindrical gear

4.2.8 Force Elements: Bevel Gear

To add a bevel gear, please mark the shaft segment onto which you want to generate the bevel gear. Then
click on the button `Force elements'. Select the menu item `Bevel gear'.

Figure 4.27: Select `Bevel gear'

The bevel gear is added to the shaft.

Figure 4.28: Add bevel gear

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4. Shafts with Strength According to DIN 743 78

When you add a bevel gear, additionally inputs are available, for example an input for a bevel angle or for the
direction of the bevel angle.

Figure 4.29: Dene bevel gear

4.2.9 Force Elements: Coupling/Motor

The force element `Coupling/Motor' allows the input and output of torques. Just like the spur and bevel gears
you can enter a mass additionally. The positioning occurs relative to the selected shaft segment. The position
refers to the left side of the force element. First select a shaft segment to position the force element.

Figure 4.30: Select `Coupling'

The coupling is added to the shaft.

Figure 4.31: Add coupling

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4. Shafts with Strength According to DIN 743 79

4.2.10 Force Element: Load

The general force element `Load' can be positioned freely on the shaft independently from a selected shaft
segment. Click on the button `Force elements' and select the menu item `Load'.

Figure 4.32: Select `Load'

The load is added to the shaft.

Figure 4.33: Add load

The specication of the position occurs absolutely to the point of origin (left shaft end) and refers, like the
other elements, to the left side of the element.

Figure 4.34: Dene load

The element can be dened as a concentrated load (width = 0) or as a stretch load. This general force
element oers the possibility to specify lateral forces in X and Z-direction, a axial forces as well as bending
moments around the X and Z-axis as a load. Further you can dene the power or the torque as driving and
driven. The meaning of driven and driving applies here similarly to the other force elements.

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4.2.11 Extra Mass

The button `Extra mass' allows you to add a several mass.

Figure 4.35: Select `Extra mass'

Please enter here position, width and mass. An extra mass can be dened as a concentrated load or as a
stretch load.

Figure 4.36: Add extra mass

4.2.12 Notch Eect

The denition of notch eects is necessary for the strength calculation according to DIN 743. In case you
have calculated the equivalent stress before, then it is not necessary to enter all notch eects. Based on the
tension peaks, which appear in the process of the equivalent stress, the critical cross sections can be identied
very easily and the notch factors can be dened only for these cross sections. All dened types of notch eect
according to DIN 743 are available.

The notch factors dened in DIN 743 apply to solid and hollow shafts with wall thicknesses where no interfer-
ence of the notch by the hole is existing. For rotating notches the condition is used, according to DIN 743-2
(eld of application),

D − di
≥3
2×t

for orientation (q.v. DIN 743-1, Appendix A)

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4. Shafts with Strength According to DIN 743 81

Dimensions for Cross Sections

Figure 4.37: Dimensions for cross sections

When adding a notch eect, please select the shaft element and click the button `Notch eects'.

Figure 4.38: Select `Notch eects'

The notch eect is added to the shaft.

Figure 4.39: Add notch eect

To run a strength calculation for highly loaded smooth shafts, select the notch eect `Smooth shaft' from the
listbox. For this type of notch eect, the notch factor is set to `1'. Notch eects can be placed easily on the
shaft, independent of a shaft segment. The notch eects can be positioned absolutely to the point of origin
(to the left shaft end).

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4. Shafts with Strength According to DIN 743 82

You can enter the exact position into the input eld `Position', use the two arrow keys to move the notch
eect from one shaft section to the other shaft section. With the left mouse button it is easy to place the
notch eects on the shaft.

Figure 4.40: Dene notch eects

Types of Notch Eects

Select the following types of notch eects from the listbox:

- Smooth shaft and parallel key keyway

Figure 4.41: Smooth shaft Figure 4.42: Parallel key keyway

- Interference t and splinded shaft

Figure 4.43: Interference t Figure 4.44: Splinded shaft

- Serrated shaft and involute splines

Figure 4.45: Serrated shaft Figure 4.46: Involute splines

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4. Shafts with Strength According to DIN 743 83

- V-groove and square groove

Figure 4.47: V-groove Figure 4.48: Square groove

- Shoulder and round groove

Figure 4.49: Shoulder Figure 4.50: Round groove

- Shoulder with undercut and cross hole

Figure 4.51: Shoulder with undercut Figure 4.52: Cross hole

Set load and notch factors manually

The button `Set load and notch factors manually (optional)' allows you to enter notch factors manually (in
addition to the automatic calculation of the notch factors). Here the possibility exists to use experimentally
calculated notch factors.

Figure 4.53: Set load and notch factors manually

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4. Shafts with Strength According to DIN 743 84

Click the button `Set load and notch factors manually (optional)', the following window opens.

Figure 4.54: Dene individual loads

Overlapping Notch Eects

For overlapping notch eects (two notches with notch factors β1 and β2 ), the notch factors can be estimated
according to Niemann `Maschinenelemente' Vol. 1, page 134, equation 3.115 (3rd Edition) as follows:

β = β1 + β2 − 1

Notches on the Inner Contour

Please note that you cannot use the notch factors according to DIN 743 for notches on the inner contour.

4.3 General Functions

4.3.1 How to Select an Element
Use your left mouse button to select the shaft or force elements. When choosing an element, the color of the
selected element changes and it is easier to recognize it.

Please Note: It is also possible to select individual elements by using your keyboard. If you would like to
change, for example from the value input of shaft segments to the selection mode, you have to press the
`Page-down' key. Afterwards, the two arrow keys enable you to move the elements to the left or to the right
side. To move from the shaft segments to the axial hole, please use the cursor keys `Up' and `Down'. By
using the `Page-up' key you can change to the input value of a selected element.

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4. Shafts with Strength According to DIN 743 85

4.3.2 How to Shift an Element

If an element is selected, then dierent input possibilities for the element appear in the upper area of the
calculation module. The input eld `Position' helps to place an element on the shaft. For positioning the
element, you can also click on an element, continue holding the left mouse button and then drag the mouse.
The arrow keys below the element info allows you to move to the next segment. It is possible to skip certain
elements on the shaft. If a shaft segment is selected, then the segment can be shifted using the arrow key
including all elements sitting on the segment. Thus, you can easily re-sort shaft segments.

Figure 4.55: Arrow keys

4.3.3 How to Copy and Add an Element

The two buttons `Copy' and `Add' allow to copy and add segments, bearings or force elements. If you copy an
element, all inputs will be conrmed and you do not have to re-dene the element again. Place the element
by using the input eld `Position' or by clicking or dragging your left mouse button or by clicking the arrow
keys on your keyboard.

Figure 4.56: `Copy' and `Add'

Select an existing bearing which you would like to copy.

Figure 4.57: Select the rst bearing

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4. Shafts with Strength According to DIN 743 86

Click on the button `Copy'.

Figure 4.58: Button `Copy'

Select the shaft segment on which you would like to place the bearing.

Figure 4.59: Select the shaft segment

Click on the button `Add'.

Figure 4.60: Button `Add'

The previously copied bearing is added.

Figure 4.61: Add the second bearing

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Please Note: If you select an element and click the right mouse button, a new context menu will open.
Choose the menu items `Copy' and `Add'.

Figure 4.62: Right-click to open context menu

4.3.4 How to Cut Out an Element

Select a segment or an element and click the right mouse button to open the context menu. Choose the menu
item `Cut out'.

Figure 4.63: Menu item `Cut out'

4.3.5 How to Delete an Element

This button allows you to delete an element. To delete an element, select the element and click the button
`Delete'. You can also click the right mouse button to open the context menu and to select the menu item
`Delete'.

Figure 4.64: Button `Delete'

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4.3.6 Menu Item `Delete All'

Clicking the `Delete all' button deletes not just one element but the entire shaft geometry. Right-clicking
opens the context menu where you can select the menu item `Delete all'.

Figure 4.65: Button `Delete all'

4.4 2D and 3D View

Clicking this button displays the three-dimensional presentation. This function is available in the geometry
part as well as in the calculation part. Using this button, the deection (inculding the selected planes) of the
shaft can be visualized in a three-dimensional manner.

Figure 4.66: 2D and 3D view

The three-dimensional view allows to modify the elements. Select the element and change, for example, the
position, length or diameter. To do so, please use the appropriate input elds. Click on the `2D / 3D view'
button again to switch back to the two-dimensional representation.

Figure 4.67: 3D view of the shaft

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4.5 Toolbar
The toolbar on the left side contains buttons that let you toggle between dierent views of your shaft quickly.
There are zoom options available that allow you to zoom in and out.

Figure 4.68: Toolbar

Reset view and show the entire shaft

Activate zoom selection with mouse click: By dragging the cursor with the left mouse button,
you can select parts of the shaft and enlarge them. Click the button `Reset view', then you can
restore the original view of the shaft.

Move view with mouse: Click into the graphical representation, hold the mouse button and move
the shaft.

Figure 4.69: Zoom selection with mouse

Orthogonal view

Perspective view

Perspective wide angle view

3D view of the shaft from left upside

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Frontal 3D view of the shaft

3D view of the shaft from right

3D view of the shaft from rear

3D view of the shaft from left

3D view of the shaft from upside

3D view of the shaft from downside

4.6 Message Window

The calculation module provides a message window. This message window displays detailed information,
helpful hints or warnings about problems. One of the main benets of the program is that the software
provides suggestions for correcting errors during the data input. If you check the message window carefully
for any errors or warnings and follow the hints, you are able to nd a solution to quickly resolve calculation
problems.

Figure 4.70: The message window

4.7 Quick Info

The quick info feature gives you additional information about all input elds and buttons. Move the mouse
pointer to an input eld or a button, then you will get some additional information. This information will be
displayed in the quick info line.

Figure 4.71: The quick info

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4.8 Calculation Part

After dening the entire shaft geometry, bearings, loads and notch eects, you can start your calculation. To
start the calculation, click the button `Calculate'. The button changes then its description into `Geometry'
and you get into the calculation part. The calculation part enables you to carry out the calculation. If you
want to modify the geometry of the shaft, you have to go back to the geometry part. To do so, please click
the button `Geometry'.

Figure 4.72: The calculation part

In addition to the determination of the bearing forces and static torsion, dierent diagrams for forces, moments,
deection, bending angle, equivalent stress or torque will be displayed. Move the mouse over the graphical
representation to see the values for the deection at any shaft position. With just one click, the following
calculations can be carried out:

- Bearing forces

- Deection, bending angle, bending moment,...

- Strength

- Critical speed (bending)

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4. Shafts with Strength According to DIN 743 92

- Critical speed (torsion)

Figure 4.73: Dierent calculations

4.8.1 Bearing Forces

Click the button `Bearing forces' in order to start the calculation of the bearing forces.

Figure 4.74: Bearing forces

4.8.2 Deection
Click the button `Deection' in order to start the calculation of the deection, bending angle and bending
moment. Select the forces and moments for dierent planes.

Figure 4.75: Deection

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4. Shafts with Strength According to DIN 743 93

The values for the deection can be selected directly from the graphical representation. The values appear in
the text eld. Click the button 3D view to toggle between the 2D and 3D view.

Figure 4.76: Select values with a mouse click

Please note: There is the possibility to compare dierent deections (e.g., for shafts with a modied geom-
etry) based on the graphical representation. Go back to the geometry part and change a value. Click on the
Calculate button to go to the calculation part again. Click on the `Redo' and `Undo' buttons in the menu bar.
Now you can compare the results

4.8.3 Strength
Click the button `Strength' in order to start the strength calculation. The strength calculation provides a
complete static and fatigue proof of strength according to DIN 743. The exact values appear in the text eld
and can be selected with a mouse click from the graphical representation.

Figure 4.77: Strength calculation according to DIN 743

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The calculation report provides all detailed calculation results. In addition, the results for the cross sections
are represented in three dierent colors:

- Red marked cross section: The minimum safety is not achieved.

- Green marked cross section: The safety is fullled (up to three times higher than the dened minimum
safety).

- Blue cross section: The saftey is more than three times higher than the minimum safety.

Figure 4.78: A graphical representation

Please note: Click the button `Options' to modify the settings for the minimum safety, the stress conditions
and mechanical kind of material treatment (see section 4.13 `The Button Options').

4.8.4 Critical Speed (Bending)

Click the button `Critical speed (bending)' in order to start the calculation of the critical speed. Gyroscopic
eects, moments of inertia, deection due to shear can be taken into consideration. To do so, please activate
the appropriate checkbox.

Figure 4.79: Calculation of critical speed (bending)

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4. Shafts with Strength According to DIN 743 95

4.8.5 Critical Speed (Torsion)

Click the button `Critical speed (torsion)' in order to start the calculation of the critical speed.

Figure 4.80: Calculation of critical speed (torsion)

Please note: Please click the button `Options' to modify the default settings regarding the critical speeds
(see section 4.13 `The Button Options').

4.9 Documentation: Calculation Report

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.

Figure 4.81: Button `Report'

First the report congurator appears. The report congurator allows you to select which diagrams should
appear in the calculation report and if the results of the strength calculation should be in the report, too.

Figure 4.82: Report conguration

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During the generation of the report, a waiting screen appears. But you can continue to work with the
calculation module. The length of time for the generation of the report depends on the number of diagrams
which have to be generated. You can navigate through the report via the table of contents that provides links
to the input values, results and gures. This calculation report contains all input data, the calculation method
as well as all detailed results. The report is available in HTML and PDF format. The calculation report saved
in HTML format, can be opened in a web browser or in Word for Windows. In HTML format, the gures
are displayed in `gif ' format. In case a SVG viewer is available, you can display all graphics in SVG format.
Right-clicking on the picture allows to zoom in and zoom out.

Figure 4.83: Calculation report

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the button `Save'.

- If you click on the symbol `Print', then you can print the report very easily.

- When you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
dialog box for saving the report.

4.10 How to Save the Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 4.84: Button `Save'

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4. Shafts with Strength According to DIN 743 97

Before you can save the calculation to your computer, you need to activate the checkbox `Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 4.85: Standard Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 4.86: Save the calculation

4.11 The Button `Redo' and `Undo'

The button `Undo' allows you to reset your input to an older state. The button `Redo' reverses the undo.

Figure 4.87: Button `Redo' and `Undo'

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4.12 The Button `CAD'

The top menu bar of the calculation module provides the button `CAD'.

Figure 4.88: Button `CAD'

The eAssistant plugin for various CAD systems (e.g., SOLIDWORKS, Solid Edge, Autodesk Inventor) enables
you to combine calculation and design fast and easily. Based on your eAssistant calculation, you can create
the shaft as a 3D part within seconds.

4.12.1 eAssistant 3D CAD Plugin

Solid and hollow shaft with an unlimited number of cylindrical and conical elements can be generated with
just a click. Click the button `CAD'. Please select the appropriate CAD system from the list, for example
SOLIDWORKS or Solid Edge.

Figure 4.89: Data output CAD plugin

Open your CAD system. The top menu bar of the CAD system shows a button called `eAssistant'. Please
click this button to start the generation of the 3D model.

Please note: Before you can start using the CAD plugin, you need to download and install the plugin from
www.eAssistant.eu.
our web site

A simple mouse-click allows to add all necessary manufacturing data of a gear wheel to the drawing.

In case you need further information about the eAssistant CAD plugin, please feel free to contact us. The web
site www.eAssistant.eu also contains detailed information. There you can also nd the CAD plugin manuals
for the various CAD systems.

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4. Shafts with Strength According to DIN 743 99

4.13 The Button `Options'

Click the button `Options' in order to change the default settings for the strength calculation according to
DIN 743 as well as for the calculation of the critical speeds.

Figure 4.90: Button `Options'

Here are the default settings that you can modify:

(a) Settings for the strength calculation according to DIN 743:

- Stress condition

- Mechanical kind of material treatment

- Shaft diameter before treatment

- Dynamic safety

- Static safety

- Stress ratio

- Maximum load factor

(b) Settings for the calculation of the critical speeds:

- Increment

- Minimum increment

- Search of critical speeds

(c) Unit switch between the metric system and the U.S. customary unit system

(d) Activate consideration of shaft weight

(e) Adjust number of decimal places in calculation report

Figure 4.91: Additional settings

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4.14 Calculation Examples: Shaft According to DIN 743

4.14.1 Start the Calculation Module
Please login with your username and your password. To start the calculation module for shafts, please click
the menu item `Shaft/Bearings' on the left side and then select `Shaft'.

Figure 4.92: Start the calculation module

4.14.2 First Calculation Example

This calculation example shows a winding shaft with a xed and movable bearing and an extra mass.

Create Shaft Segments

Click the button `Segment' in order to create the rst shaft segment. Enter a length of 50 mm and a diameter
of 20 mm into the input elds.

Figure 4.93: Create the rst segment

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4. Shafts with Strength According to DIN 743 101

The rst segment is represented.

Figure 4.94: Representation of the created and dened shaft segment

To create the second shaft segment, click the button `Segment' again. The second segment has a length of
400 mm and a diameter of 50 mm.

Figure 4.95: Create the second segment

This second segment is represented.

Figure 4.96: Representation of the second segment

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4. Shafts with Strength According to DIN 743 102

The third shaft segment gets the same dimensions as the rst shaft segment. That is why we can use the
`Copy' and `Add' function to create the third segment. Click on the rst segment.

Figure 4.97: Select the rst segment

Click on the button `Copy'.

Figure 4.98: Copy the rst segment

Select the second segment and place the third segment next to it.

Figure 4.99: Select the second segment

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4. Shafts with Strength According to DIN 743 103

Click on the button `Add'.

Figure 4.100: Add the segment

The copied segment is added as a third shaft segment.

Figure 4.101: Add the third shaft segment

Please note: If you select a segment and you click the right mouse button, a new context menu will open.
Choose the menu items `Copy' and `Add'.

Figure 4.102: Right-click to open context menu

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4. Shafts with Strength According to DIN 743 104

Create Axial Hole

Click the button `Hole (axial)' in order to create the rst hole. Enter a length of 70 mm and a diameter of 0
mm into the input elds.

Figure 4.103: Create the rst axial hole

Click the button `Hole (axial)' again in order to create a second hole. Enter a length of 360 mm and a diameter
of 40 mm into the input elds.

Figure 4.104: Dene the second axial hole

The hollow shaft is represented.

Figure 4.105: Representation of the axial hole

Please note: Use your keyboard to select the individual elements. For example, if you want to change from
the value input of a shaft segment to the selection mode, then press the `Page down' key. Then use the two
arrow keys to select the elements. Use the cursor keys `Up' and `Down' to move from the shaft segments to
the axial holes. In order to change the input values of an element, press `Page up'.

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Add Bearing
Select the rst shaft segment to add the bearing to the shaft.

Figure 4.106: Select a segment

Click on the button `Bearing'.

Figure 4.107: Button `Bearing'

A bearing is added. Enter 20 mm for the bearing position, 10 mm for the bearing width and 40 mm for the
bearing diameter. As bearing arrangement, select `Fixed bearing' from the listbox.

Figure 4.108: Add the rst bearing

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4. Shafts with Strength According to DIN 743 106

In order to add the second bearing, select the rst bearing and click the button `Copy'.

Figure 4.109: Select the rst bearing

Select the third shaft segment and click the `Add' button. Because the bearing is copied, it is not necessary
to dene the position, width and diameter of the bearing, you just need to dene the bearing arrangment.
Select `Movable bearing' from the listbox.

Figure 4.110: Dene the second bearing

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4. Shafts with Strength According to DIN 743 107

Dene Load as Extra Mass

To position the load, select the second shaft segment.

Figure 4.111: Select a shaft segment

Click on the button `Extra mass'.

Figure 4.112: Button `Extra mass'

The extra mass will be positioned on the shaft segment. Please dene the extra mass with 50 mm for position,
300 mm for width and 950 kg for mass.

Figure 4.113: Extra mass is added

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Dene Notch Eect

Click on the button `Notch eect' in order to add the notch eects.

Figure 4.114: Button `Notch eect'

A notch eect is added and can be placed on the shaft. Enter the position of the notch eect or change the
postion with the two arrow keys. Selct the notch eect from the listbox.
Dene the following notch eects:

- First notch eect: On left shaft section - notch eect type `Shoulder' with roughness Rz = 5 mm and
radius r = 10 mm

- Second notch eect: On right shaft section - enter the same values as for the notch eect on the left
shaft section

- Third notch eect: On shaft center: select the notch eect type `Interference t'

Figure 4.115: Notch eects

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4.14.3 Start Calculation

After dening the entire shaft geometry with bearings, loads and notch eects, you can start your calculation.
To start the calculation, click the button `Calculate'. The button changes then its description into `Geometry'
and you get into the calculation part. The calculation part enables you to carry out the calculation. If you
want to modify the geometry of the shaft, you have to go back to the geometry part. To do so, please click
the button `Geometry'.

Figure 4.116: Calculation part

When you are in the calculation part of the module, it is not possible to change the geometry. In
order to change the geometry, please go back to the geometry part by clicking the `Geometry'
button.

Here, you can carry out the dierent calculations, e.g., the strength calculation according to DIN 743.

Figure 4.117: Dierent calculations

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4. Shafts with Strength According to DIN 743 110

Calculation of Bearing Forces

In order to start the calculation of bearing forces, click the button `Bearing forces'.

Figure 4.118: Calculation of bearing forces

Calculation of Deection
Click the button `Deection' to start the calculation of the deection, bending angle and bending moment.
Open the dierent diagrams for forces and moments.

Figure 4.119: Interactive diagrams of forces and moments

You can select all values for deection directly from the representation with just a mouse click. The values
appear in the text eld.

Figure 4.120: Select values by mouse-click

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4. Shafts with Strength According to DIN 743 111

Calculation of Strength According to DIN 743

Start the strength calculation by clicking the button `Strength'. The strength calculation provides a complete
static and fatigue proof of strength according to DIN 743. The exact values appear in the text eld and can
be selected with a mouse click from the graphical representation.

Figure 4.121: Strength calculation with a representation of the cross sections

The text eld shows the most important calculation results. The calculation report provides all detailed
calculation results. In addition, the results for the cross sections are represented in three dierent colors:

- Red marked cross section: The minimum safety is not achieved.

- Green marked cross section: The safety is fullled (up to three times higher than the dened minimum
safety).

- Blue cross section: The saftey is more than three times higher than the minimum safety.

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Calculation of Critical Speed (Bending)

Start the calculation of the critical speeds by clicking the button `Critical speed (bending)'. Gyroscopic eects,
moments of inertia, deection due to shear can be taken into consideration. To do so, please activate the
appropriate checkbox.

Figure 4.122: Critical speed (bending)

Calculation of Critical Speed (Torsion)

Click the button `Critical speed (torsion)' in order to start the calculation of the critical speed.

Figure 4.123: Critical speed (torsion)

4.14.4 Documentation: Calculation Report

Now you can create the calculation report. Click on the button `Report'.

Figure 4.124: Button `Report'

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First the report congurator appears. The report congurator allows you to select which diagrams should
appear in the calculation report and if the results of the strength calculation should be in the report, too.

Figure 4.125: Report conguration

During the generation of the report, a waiting screen appears. During the generation of the report, a waiting
screen appears. But you can continue to work with the calculation module. The length of time for the gener-
ation of the report depends on the number of diagrams which have to be generated.

You can navigate through the report via the table of contents that provides links to the input values, results
and gures. This calculation report contains all input data, the calculation method as well as all detailed
results. The report is available in HTML and PDF format. The calculation report saved in HTML format,
can be opened in a web browser or in Word for Windows. In HTML format, the gures are displayed in `gif '
format. In case a SVG viewer is available, you can display all graphics in SVG format. Right-clicking on the
picture allows to zoom in and zoom out.

Figure 4.126: Calculation report

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4. Shafts with Strength According to DIN 743 114

You may also print or save the calculation report:

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the button `Save'.

- If you click on the symbol `Print', then you can print the report very easily.

- When you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
dialog box for saving the report.

4.14.5 Save Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 4.127: The button `Save'

Before you can save the calculation to your computer, you need to activate the checkbox `Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 4.128: Standard Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 4.129: Save the calculation

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4.14.6 Second Calculation Example

Here you nd another example that shows how easy it is to create a shaft.

Figure 4.130: Shaft

Create Shaft Segments

Create three shaft segments. Please enter the following input values:

1. Shaft segment: Length l1 = 100 mm Diameter d1 = 30 mm

2. Shaft segment: Length l2 = 40 mm Diameter d2 = 45 mm
3. Shaft segment: Length l3 = 100 mm Diameter d3 = 30 mm

Figure 4.131: Shaft segments

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Add Bearings
Then add the two bearings. Please enter the following input values:

1. Bearing: Position = 10 mm Width b1 = 15 mm Diameter d1 = 60 mm Fixed bearing

2. bearing: Position = 80 mm Width b2 = 15 mm Diameter d2 = 60 mm Movable bearing

Figure 4.132: Bearing

Create First Cylindrical Gear

In order to create the cylindrical gear, select the rst shaft segment. Click on the button `Force elements' and
select the menu item `Cylindrical gear' from the submenu. Use the input mask to dene the cylindrical gear.
Enter the following input values:

Position = 60 mm
Width b1 = 40 mm
Reference circle dT 1 = 180 mm
Helix angle β1 25◦
=
◦
Pressure angle α1 = 20
◦
Position of action = 90
Torque T1 = 320 Nm
Mass m1 = 0.0 kg

Figure 4.133: Dene the rst cylindrical gear

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4. Shafts with Strength According to DIN 743 117

The rst cylindrical gear is represented.

Figure 4.134: First cylindrical gear

Create Second Cylindrical Gear

To create the second cylindrical gear, select the third shaft segment. Click on the button `Force elements' and
select the menu item `Cylindrical gear' from the submenu. Please enter the following values into the input
mask:

Position = 0 mm
Width b2 = 40 mm
Reference circledT 2 = 80 mm
Helix angle β2 25◦
=
◦
Pressure angle α2 = 20
◦
Power of action = 270
Torque T2 = 320 Nm
Mass m2 = 0.0 kg

Figure 4.135: Dene the second cylindrical gear

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4. Shafts with Strength According to DIN 743 118

Both cylindrical gears will be represented.

Figure 4.136: Two spur gears created

Then you can display the shaft in dierent views. Click the button `3D view' and select the dierent views
from the toolbar and zoom into the graphic. Click on the button `Calculate' and switch from the geometry
part into the calculation part. There you can run the calculations (nd detail information in the section `How
to start the calculation'). The button `Report' allows you to generate a report.

Result
Clicking the `3D view' button displays the three-dimensional presentation. The three-dimensional view allows
to modify the elements. Select the element and change, for example, the position, length or diameter. To do
so, please use the appropriate input elds. Click on the `2D / 3D view' button again to switch back to the
two-dimensional representation.

Figure 4.137: 3D view of the shaft

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4.14.7 Start Calculation

After dening the entire shaft geometry with the cylindrical gears and the bearings, you can start your cal-
culation. To start the calculation, click the button `Calculate'. The button changes then its description into
`Geometry' and you get into the calculation part. The calculation part enables you to carry out the calculation.
If you want to modify the geometry of the shaft, you have to go back to the geometry part. To do so, please
click the button `Geometry'. With just one click, the following calculations can be carried out:

- Bearing forces

- Deection, bending angle, bending moment,...

- Strength

- Critical speed (bending)

- Critical speed (torsion)

Figure 4.138: Start of calculation

When you are in the calculation part of the module, it is not possible to change the geometry. In
order to change the geometry, please go back to the geometry part by clicking the `Geometry'
button.

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4.14.8 Documentation: Calculation Report

Now you can create the calculation report. Click on the button `Report'.

Figure 4.139: Button `Report'

First the report congurator appears. The report congurator allows you to select which diagrams should
appear in the calculation report and if the results of the strength calculation should be in the report, too. You
can navigate through the report via the table of contents that provides links to the input values, results and
gures. This calculation report contains all input data, the calculation method as well as all detailed results.
The report is available in HTML and PDF format. The calculation report saved in HTML format, can be
opened in a web browser or in Word for Windows. In HTML format, the gures are displayed in `gif ' format.
In case a SVG viewer is available, you can display all graphics in SVG format. Right-clicking on the picture
allows to zoom in and zoom out.

Figure 4.140: Calculation report

You may also print or save the calculation report:

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the button `Save'.

- If you click on the symbol `Print', then you can print the report very easily.

- When you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
dialog box for saving the report.

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4. Shafts with Strength According to DIN 743 121

4.14.9 Save Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 4.141: Button `Save'

Before you can save the calculation to your computer, you need to activate the the option `Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 4.142: Standard Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 4.143: Save the calculation

Our manual is improved continually. Of course we are always interested in your opinion, so
we would like to know what you think. We appreciate your feedback and we are looking
for ideas, suggestions or criticism. If you have anything to say or if you have any questions,
please let us know by phone +49 (0) 531 129 399-0 or email [email protected].

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Chapter 5

Rolling Bearings According to DIN

ISO 281

5.1 Start the Calculation Module

Please login with your username and your password. To start the calculation module for rolling bearings,
please click the menu item `Shaft/Bearings' on the left side and then select `Rolling bearings calculation'.

Figure 5.1: General overview

Please Note: All results will be calculated during every input and will be displayed in the result panel. A
recalculation occurs after every data input. Any changes that are made to the user interface take eect
immediately. Press the Enter key or move to the next input eld to complete the input. Alternatively, use the
Tab key to jump from eld to eld or click the `Calculate' button after every input.

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5. Rolling Bearings According to DIN ISO 281 123

5.2 General Inputs

5.2.1 Number of Bearings
The calculation module allows to dene any number of bearings.

Figure 5.2: General inputs

The following listbox `Current view' allows you to select between the several bearings.

Figure 5.3: Number of bearings

You can add a description or a short comment to the bearing.

Figure 5.4: Description of the respective bearing

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5. Rolling Bearings According to DIN ISO 281 124

5.2.2 How to Delete a Bearing

If you want to delete a bearing, please enter the new number of bearings and conrm the input with the Enter
key.

Figure 5.5: Reduce the number of bearings

Now select the bearing you want to delete and click the button `Delete the selected bearings!'.

Figure 5.6: Delete a bearing

Please note: If you want to delete multiple bearings at once, select the bearings you want to delete. Click
the button `Delete the selected bearings!'.

5.3 Selection of Manufacturer and Bearing Type

5.3.1 Bearing Manufacturer
The extensive bearing database provides over 20,000 bearings from dierent manufacturers. Select the bearing
manufacturer (NSK, SNR, SKF, KOYO) from the listbox.

Figure 5.7: Manufacturer

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5. Rolling Bearings According to DIN ISO 281 125

5.3.2 Fatigue Limit Load

The stress of the raceway fatigue depends primarily on the internal load distribution in the bearing. In order to
simplify the calculation, the fatigue limit load Cu was introduced. Usually, the bearing manufacturer species
the values for Cu . In case these values are missing, the equations dened in DIN ISO 281 will be used. These
equations apply for bearings Dpw < 150 mm.

Roller bearings:

1 1
Cur ≈ × C0r and Cua ≈ × C0a
8.2 8.2
Ball bearings:

1 1
Cur ≈ × C0r and Cua ≈ × C0a
27 27

The bearing selection allows to dene your own fatigue limit load. Open the bearing selection and activate
`User dened', select the option `Specify Cu '. Enter the value for the fatigue limit load. If you do not specify
the fatigue limit load or if the bearing selection does not include the fatigue limit load, then fatigue limit load
is calculated in accordance with DIN ISO 281.

Figure 5.8: Own input of Cu in bearing selection

5.3.3 Bearing Types

Rolling bearings are ready-to-t machine elements. Rolling bearings are an assembly of several parts - rings
with raceway, rolling elements (a set of balls or rollers) and a cage which separates the rolling elements and
holds them in place. The rings of radial rolling bearings are called inner and outer rings. Generally, the outer
ring ts on the housing, the inner ring on the shaft. For axial bearings, the inner ring is called shaft washer and
the outer ring is called housing washer. Because of the very small contact surface, balls cause high Hertzian
stresses. Rollers have lower Hertzian stresses and are suitable for high loads.

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5. Rolling Bearings According to DIN ISO 281 126

Rolling bearings can be also classied according to the direction in which the load is applied. Radial bearings
carry radial loads and axial bearings carry axial loads. Rolling bearings divide into two main classications:
ball bearings and roller bearings. A further feature is how the bearings guide a shaft. There are bearings that
allow axial displacements and bearings that guide a shaft in one or both axial directions. Types of rolling
bearings are given in the following gure below.

Figure 5.9: Classication of rolling bearings

The following bearing types can be selected from the listbox:

- Single row radial deep groove ball bearing: Can accommodate radial and axial loads and can be used at
high speed operations.

- Double row radial deep groove ball bearing: Manufactured with and without lling slots. Filling slot
bearings have low axial load capacity.

- Single row angular contact ball bearing: Can bear axial loads only in one direction. Bearings are adjusted
against a second bearing in O or X arrangement.

- Double row angular contact ball bearing: Is capable of bearing loads in both the radial and axial direction.
Design corresponds to a pair of single row angular contact ball bearings in O arrangement.

- Self-aligning ball bearing: Has two-row balls and one concave outer raceway, it is able to compensate
for misalignments, shaft deections and housing deformations up to 4◦ .

- Four-point contact bearing: Is one-row angular contact ball bearing, can support axial loads in both
directions. The inner ring is in two pieces. Bearings can accommodate a large number of balls.

- Single row tapered roller bearing: Is capable of supporting large loads and can take a combination
of radial and axial loads. The bearings can only support axial loads in one direction and a second,
symmetrically arranged tapered roller bearing is required for counter guidance.

- Single row cylindrical roller bearing: Designed for very high radial loads, only suitable for low axial loads.

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5. Rolling Bearings According to DIN ISO 281 127

- Spherical roller bearing: Is capable of supporting heavy loads, rollers are guided by solid ribs and the
bearing can accommodate a slight axial load.

- Single row axial ball bearing: Can support high axial loads while radial load is poorly supported.

- Axial spherical roller bearing: Is suitable for high axial loads and high speed operations. With the inclined
raceways, the bearing can carry radial loads, the radial load may not exceed 55 percent of the axial force.

Please Note: There is a graphical representation for every bearing type.

Figure 5.10: Representation of a deep groove ball bearing

5.4 Specication of Bearing Load

Here you can dene the radial force, the axial force and speed.

Figure 5.11: Radial force, axial force, speed

How to Change the Unit System

eAssistant provides two unit systems: the metric system and the U.S. customary unit system. You can quickly
switch between the units. To select the unit system, click the button `Options' and decide for a unit.

Figure 5.12: Change the unit

It is also possible to change the unit by clicking the label eld. When you click the label eld, a context menu
will open providing all available units within the unit system. The change should take eect immediately.
All settings will be saved to the calculation le. As soon as you select a unit, the current eld value will be
converted automatically into the chosen unit.

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5. Rolling Bearings According to DIN ISO 281 128

5.4.1 Calculation with Load Collectives

If you activate the option `Use load collective', you can consider load collectives for your calculation.

Figure 5.13: Use load collectives

You can dene any number of load cases. For every loading case a specication for time slice, speed, radial
force, axial force, temperature and cleanness is possible. A listbox shows you the degree of impurities.

Figure 5.14: Load collectives

The respective lubrication method or the contamination coecient is available by using the listbox. If you
select `User dened' from the listbox, you can enter your own contamination factor ec .

Figure 5.15: Degree of impurities

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5. Rolling Bearings According to DIN ISO 281 129

The load collectives can be opened and saved independently from the underlying bearing calculation. For that
purpose use the button `Open' and `Save'.

Figure 5.16: Open and save the load collectives

Please note: With the denition of the load cases, the entries for the modied rating life will be set.

5.4.2 Lubricant Contamination Factor

According to DIN ISO 281, contaminations in the lubricant cause dents in the raceways and can damage the
smooth surfaces of the bearing components. Rough surfaces tent to cause stress concentrations resulting in
shorter bearing life. The lubricant contamination factor ec considers the inuence of the contaminants on the
rating life.

Lubricant Contamination Factor ec According to DIN ISO 2811

Lubricant Contamination Factor ec
Grade of Contaminations
Dpw < 100 mm Dpw ≥ 100 mm
Extreme Cleanliness: 1 1

Particle size within the height of the lubricant lm under lab-
oratory conditions

High Cleanliness: 0.8 to 0.6 0.9 to 0.8

Oil is ltered by extremely ne lters, sealed, greased bearings

Standard Cleanliness: 0.6 to 0.5 0.8 to 0.6

Oil is ltered by ne lters, greased bearings with shields

Slight Contaminations: 0.5 to 0.3 0.6 to 0.4

Slight contamination of oil

Typical Contaminations: 0.3 to 0.1 0.4 to 0.2

Bearing contaminated with abraded material from other ma-

chine elements

Strong Contaminations: 0.1 to 0 0.1 to 0

Bearing environment is strongly contaminated, inadequate

sealing of bearing arrangement

Very strong contaminations 0 0

1 from: DIN ISO 281 Rolling Bearings - Dynamic Load Ratings and Rating Life (ISO 281: 2007),

2010, p. 33, table 13

The values given in the table above apply for solid particles. Other contaminations such as water or liquids
are not taken into account.

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5. Rolling Bearings According to DIN ISO 281 130

5.5 Nominal Rating Life

The following factors have a signicant inuence on the rating life of bearings:

- Bearing load

- Lubrication conditions (viscosity and type of lubricant, speed, bearing size, additives)

- Material properties (cleanliness, hardness, fatigue limit)

- Bearing type (internal load distribution, frictional conditions in the bearing)

- Residual stress in the material (from manufacturing and heat treatment)

- Ambient environment (contamination of lubricant, moisture)

The calculation method for the nominal rating life L10 is dened in DIN ISO 281. The rating life L10 of a
large group of identical ball bearings is the life in millions of revolutions that 90 percent of the group will
complete or exceed before material fatigue occurs.

Reference Values for Required Rating Life2

Vehicles (full load)
Passenger cars 900 to 1,600 hours

Trucks and busses 1,700 to 9,000 hours

Railway vehicles
Axle bearing mine cars 10,000 to 34,000 hours

Streetcars 30,000 to 50,000 hours

Passenger carriages 20,000 to 34,000 hours

Locomotives 30,000 to 100,000 hours

Gears for railway vehicles 15,000 to 70,000 hours

Agricultural machinery 2,000 to 5,000 hours

Construction machinery 1,000 to 5,000 hours

Electric motors for household appliances 1,500 to 4,000 hours

Series engines 20,000 to 40,000 hours

Large engines 50,000 to 100,000 hours

Machine tools 15,000 to 80,000 hours

Gears for general mechanical engineering 4,000 to 20,000 hours

Large gearboxes 20,000 to 80,000 hours

Ventilators, fans 12,000 to 80,000 hours

Gear pumps 500 to 8,000 hours

Crushers, mills, sieves 12,000 to 50,000 hours

Paper and printing machines 50,000 to 200,000 hours

Textile machinery 10,000 to 50,000 hours

2 from: Taschenbuch fuer den Maschinenbau/Dubbel, 1997, p. G173, appx. G4 table 2

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5. Rolling Bearings According to DIN ISO 281 131

5.6 Modied Rating Life Theory

In some cases it can be sucient to determine the nominal rating life. The nominal rating life is associated
with 90 percent reliability. But for some applications it can be very insightful to determine the rating life for
a higher reliability and to consider the inuence of the bearing quality and operating conditions. By using the
modied rating life, these criteria can be further investigated.

The modied rating life theory is activated by default. If the load collectives are not activated, then enter you
individual specications for the requisite reliability, operating temperature or cleanness. You can enter your
own cleanness factor for the grade of contaminations. Select `User-dened' from the listbox.

Figure 5.17: Modied rating life theory

5.6.1 Lubricant Selection

The purpose of lubricating the bearing is to cover the rolling and sliding contact surfaces with a thin oil lm
to avoid direct metal to metal contact. The most important function of a lubricant is to protect the sliding
and rolling surfaces from wear and friction. The extensive lubricant database provides dierent kind of oils
and greases for the calculation of the modied rating life. In case you are missing the right lubricant for your
calculation, please dene your own lubricant. The lubrication has a considerable inuence on the operating life
of the bearing. Oil and greases are the most common lubricants for rolling bearings. In special cases, rolling
bearings are lubricated with solid or dry lubricants. The choice of lubrication and lubricant depends on speed
and operating temperature of the bearing. The selection of the lubrication method depends on operating
conditions and environmental inuences.

Most rolling bearings are lubricated using grease. Grease lubrication consists of a base oil and a thickener.
There are two main types of base oil: mineral and synthetic oil. The thickener and the additives in the grease
enhance the lubricating eect so that no life reduction has to be expected. Calcium, aluminum, sodium and
lithium soap greases can be used for heavy-loaded rolling bearings. Most of greases contain additives in order
to improve the properties of the grease. It is necessary to renew the lubricating grease at regular intervals.
The lubrication interval depends on many factors, such as the grease type, bearing and working conditions.
Grease lubrication is easy to handle and provides excellent protection against contamination.

Grease lubrication is widely used. Approximately 90 percent of all bearings are lubricated with grease. The
main advantages of grease lubrication are (according to Braendlein `Die Waelzlagerpraxis'):

- Reasonable costs

- Simple construction

- Provides good sealing

- Long service life

- Low maintenance

- Low frictional torque

Oil lubrication is generally used for rolling bearings when adjacent system components are lubricated with oil
or when cooling is required. Oil lubrication is also used when very high speeds or very high loads preclude the
use of grease as a lubricant. The selection of the oil type depends on the requirements of the components. For
the lubrication of rolling bearings, mineral oils and synthetic oils are suitable. Oils with a mineral oil base are

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5. Rolling Bearings According to DIN ISO 281 132

most common. The better the contact surfaces are separated by the lubricating lm, the better the bearing
life and safety against wear. The lubricating lm thickness increases with the oil viscosity, so an oil with a
high operating viscosity should be selected.

The viscosity, as well the dependence of the density and viscosity on the pressure and the temperature play
an important role for the technical application of lubricants. Viscosity is one very important property of a lu-
bricant and determines the oils lubricating eciency. Thin oils have low viscosities while thicker oils have high
viscosities. In addition to the base oil viscosity, thickener and additives have a decisive inuence on greases.
The density of lubricating oils is between 0.86 and 0.93 kg/dm3 . The viscosity of the oil decreases with
increasing temperature. As the temperature falls, the viscosity of the oil increases. It is therefore necessary to
indicate the temperature dependence of an oil's kinematic viscosity. The viscosity at 40◦ C and at 100◦ C (for
thicker oils) are typical values.

About 150 products of the following manufacturer are available:

- Aral

- BP

- Fuchs Lubritech

- Klueber

- Lubricant Consult

Select a lubricant from the listbox.

Figure 5.18: Lubricants from a listbox

Select the lubricant directly from the listbox or click the button `Lubricant'.

Figure 5.19: Button `Lubricant'

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5. Rolling Bearings According to DIN ISO 281 133

The lubricant selection is opened. Here you get all information to the selected lubricant.

Figure 5.20: Lubricant selection

The two cursor keys `Up' and `Down' of your keyboard allows you to navigate through the lubricant database,
so you can compare the dierent lubricant values with each other.

5.6.2 Dene Your Own Lubricant

In case you cannot nd the lubricant you are looking for in our extensive database, simply dene your individual
lubricant. You will nd the entry `User-dened' in the listbox. If you select this option, the according input
elds will be enabled, so that you can specify your own input values or add a comment. In order to conrm
your inputs, click the button `OK'. Please be advised that changing the lubricant will delete your dened inputs
and you have to enter the inputs again.

Figure 5.21: Dene your own inputs

5.7 Bearing Selection

After you choose the manufacturer and the bearing type, please select the bearing from the list or use bearing
selection search to nd the right bearing. Click the button `Bearing selection'.

Figure 5.22: Bearing selection

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5. Rolling Bearings According to DIN ISO 281 134

5.7.1 Bearing Database

Click the button `Bearing selection' to open the bearing database.

Figure 5.23: Bearing selection

We have an extensive range of bearings but search lters have been developed to assist in searching the
extensive amount of bearings and to quickly nd the bearing you are looking for. You might lter bearing
types by diameter or rating life so that you can only see bearing types with this particular diameter or rating
life. The following parameters can be provided to further rene the search:

- Inner diameter of bearing

- Outer diameter of bearing

- Bearing width

- Calculated nominal and modied rating life (on the basis of the dened loads)

- Max. speed for oil and grease lubrication

Figure 5.24: Dierent parameters

Use the Tab key to move from input eld to input eld. The more values you enter into the input elds the
more you will narrow your search. If you have already entered values into the input elds and you now wish
to add again an arbitrary inner or outer diameter, then delete your own value and click on any input eld.
You can also press the Tab key. The option `Any' will then be used again and the number of bearings also
increases again. After entering all reqired data, click the `Search' button.

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5. Rolling Bearings According to DIN ISO 281 135

With the display of the found bearings you can re-sort the list by clicking on the column headers. If the
bearings are to be sorted in reverse order, then click on the column headers again.

Figure 5.25: Found bearings

Here you can get additional information on the selected bearing.

Figure 5.26: Bearing details

Please note: For radial deep groove ball bearings the selection for increased bearing clearance C3 or C4 is
additionally integrated in the bearing selection search, which is taken into account in the rating life calculation.
When using this option, it should be noted that the bearing clearance should be selected which is present in
operation after the bearing has been tted.

For SKF bearing data, there is a lter function that simplies nding common bearings (button `popular
item') in the bearing selection search. In addition, SKF Explorer bearings are marked accordingly and the
corresponding page of the SKF online catalog can be opened for the selected bearing. The appropriate button
is located in the bearing database in the lower left corner. After determining the desired bearing type, it may
be helpful to select a suitable bearing from the manufacturer's range of common bearings. Popular items have
a high level of availability and generally provide a cost-eective solution. SKF Explorer bearings are designed
for heavy-duty applications. They run with less friction and have longer rating lifes than standard rolling
bearings.

Figure 5.27: Popular item

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5. Rolling Bearings According to DIN ISO 281 136

5.7.2 Dene Your Own Bearing

You can select a bearing from the bearing database or you can dene your individual bearing. Activate the
option `User dened', the input elds will be enabled and you can enter your own input values. Please conrm
your inputs with the `OK' button.

Figure 5.28: Activate `User dened'

5.8 Message Window

The calculation module provides a message window. This message window displays detailed information,
helpful hints or warnings about problems. One of the main benets of the program is that the software
provides suggestions for correcting errors during the data input. If you check the message window carefully
for any errors or warnings and follow the hints, you are able to nd a solution to quickly resolve calculation
problems.

Figure 5.29: Message window

5.9 Quick Info: Tooltip

The quick info feature gives you additional information about all input elds and buttons. Move the mouse
pointer to an input eld or a button, then you will get some additional information. This information will be
displayed in the quick info line.

Figure 5.30: The quick info

5.10 Calculation Results

All results will be calculated during every input and will be displayed in the result panel. A recalculation occurs
after every data input. Any changes that are made to the user interface take eect immediately. Press the

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5. Rolling Bearings According to DIN ISO 281 137

`Enter' key or move to the next input eld to complete the input. Alternatively, use the Tab key to jump
from eld to eld or click the `Calculate' button after every input. Your entries will be also conrmed and the
calculation results will displayed automatically.

Figure 5.31: The results

5.11 Diagrams
For a further illustration the following diagrams are available:

- Radial force

- Axial force

- Speed

- Contamination factor

- Temperature

- Lubricant viscosity

The listbox contains the dierent diagrams and you can decide which diagram should be displayed.

Figure 5.32: Selection of diagrams

Choose the diagram and click on the button `Diagram' next to the listbox.

Figure 5.33: Button `Diagram'

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5. Rolling Bearings According to DIN ISO 281 138

The diagram with the values for the rating life and for the modied rating life will be displayed immediately.

Figure 5.34: Diagram radial force

Figure 5.35: Diagram axial force

5.12 Documentation: Calculation Report

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.

Figure 5.36: Degree of impurities

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5. Rolling Bearings According to DIN ISO 281 139

You can navigate through the report via the table of contents that provides links to the input values, results
and gures. This calculation report contains all input data, the calculation method as well as all detailed
results. The report is available in HTML and PDF format. The calculation report saved in HTML format,
can be opened in a web browser or in Word for Windows.

Figure 5.37: Calculation report

You may also print or save the calculation report:

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the button `Save'.

- If you click on the symbol `Print', then you can print the report very easily.

- When you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
dialog box for saving the report.

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5. Rolling Bearings According to DIN ISO 281 140

5.13 How to Save the Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 5.38: Button `Save'

Before you can save the calculation to your computer, you need to activate the checkbox `Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 5.39: Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 5.40: Save the calculation

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5. Rolling Bearings According to DIN ISO 281 141

5.14 The Button `Redo' and `Undo'

The button `Undo' allows you to reset your input to an older state. The button `Redo' reverses the undo.

Figure 5.41: The button `Redo' and `Undo'

5.15 The Button `Options'

Click the button `Options' to change the default settings, for example the unit system or the number of decimal
places for the calculation report. The unit can also be changed directly for each individual input value. Simply
click on the label of the corresponding input eld and select the unit from the context menu. You will see the
change of the unit of measurement immediately in the label of the input eld. The current eld value will be
converted to the corresponding unit.

Figure 5.42: Button `Options'

A new window opens up that provides a possibility to choose the diagrams that shall be added to the calculation
report.

Figure 5.43: Settings for the calculation report

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5.16 Calculation Examples: Rolling Bearing According to DIN

ISO 281
5.16.1 Start the Calculation Module
Please login with your username and your password. To start the calculation module for rolling bearings,
please click the menu item `Shaft/Bearings' on the left side and then select `Rolling bearings'.

Figure 5.44: Start the calculation module

5.16.2 First Calculation Example

Bearing for a Rope Sheave of a Pulley Block
The wrap angle for rope sheaves of pulley blocks is 180◦ . Therefore, the load on the bearing is twice the rope
pull. The axial forces and the resulting moments are low. When the diagonal pull is 5◦ , then the axial forces
have to be considered for the calculation of the rating life. Adequate bearing spread for load accommodation
is achieved by mounting either two bearings or one double-row bearing. In the following example the rating
life and modied rating life are to be calculated. We have taken this example from: J. Braendlein: Die
Waelzlagerpraxis: Handbuch zur Berechnung und Gestaltung von Waelzlagern (1995, p. 466-470).

Please enter the following input values:

Bearing load 65 kN
Type of bearing Tapered roller bearing (single row)
−1
Speed n 30 min
Built-in bearing Tapered roller bearing (100 x 150 x 67)
For-life lubrication Grease with EP-additive

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5. Rolling Bearings According to DIN ISO 281 143

Illustration of a rope sheave of a pulley block including the tapered roller bearing. (The following gure: J.
Braendlein: Die Waelzlagerpraxis, p. 467).

Figure 5.45: Rope sheave of a pulley block

5.16.3 The Calculation

Dene Number of Bearings
In this example we would like to calculate one bearing of a tapered roller bearing pair. When you open the
calculation module, usually one bearing is shown. So it is not necessary to change the number of the bearings.
You can enter a description into the comment eld, for example `Bearing of the rope sheave'.

Figure 5.46: Number of bearings

Select Manufacturer and Bearing Type

The extensive bearing database provides over 20,000 bearings from dierent manufacturers. Select the bearing
manufacturer `SKF 2007' from the listbox. Next, choose the bearing type `Tapered roller bearing (single row)'.

Figure 5.47: Select the manufacturer and bearing type

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5. Rolling Bearings According to DIN ISO 281 144

Specication of Bearing Load

Enter the values for the bearing load now. Please keep in mind that the values will be entered in `kN'.
Right-clicking allows you to change the unit.

Figure 5.48: Values for the bearing load in kN

Bearing Selection
Click on the button `Bearing selection' to open the bearing database.

Figure 5.49: Button `Bearing selection'

There are `578' bearings in the database right now. Search lters have been developed to assist in searching
this extensive amount of bearings and to quickly nd the bearing you are looking for. You can lter the bearing
types by the inner and outer diameter so that you can only see bearing types with this particular diameter.
Enter the inner and outer diameter and click the button `Search'.

Inner diameter of bearing = 100 mm

Outer diameter of bearing = 150 mm

Select the bearing `32020 X*' and conrm with the button `OK'.

Figure 5.50: Found bearings

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5.16.4 Calculation Results

Rating Life
All results will be calculated during every input and will be displayed in the result panel. A recalculation occurs
after every data input. Any changes that are made to the user interface take eect immediately. First, you
get the result for the rating life as well as the static identication number.

Figure 5.51: Result for the rating life

The result of the rating life is L10 = 27.258,6 h

For rope sheaves, a rating life from 5,000 to 20,000 hours is required. The bearing is suciently dimensioned.
You will nd a note in the message window but you can ignore this message. When the pair is tted together,
then the correct axial clearance and the necessary axial force for the tapered roller bearing occur.

Modied Rating Life Theory

After you get the result for the rating life, please have a look at the modied rating life theory Lnm regarding
the operating conditions (lubrication, clearance). The option `Use modied rating life theory' is activated by
default.

Now you an dene the requisite reliability and the cleanness as well as a lubricant. Please select the grease
`Klueber Kluebersynth BMQ 72-162 (094073)'. Select this lubricant directly from the listbox. If you need
detailed information, please click on the button `Lubricant'.

Figure 5.52: Modied rating life theory

Clicking the button `Lubricant' opens the lubricant database. Here you can see that the grease contains active
EP additive.

Figure 5.53: Lubricant database

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5. Rolling Bearings According to DIN ISO 281 146

Next, you have to estimate the inuence of possible impurities by using the cleanness factor. Actually, it is
assumed that the `highest cleanness' is used for sealed and greased bearings (for-life-lubrication). But during
the entire operating time, a certain wear of the seals could occur which can let light impurities into the bearing.
In this case you can assume light impurities. Therefore, choose `Light impurities' from the listbox.

Now you get immediately the result for the modied rating life.

Figure 5.54: Modied rating life

The result of the modied rating life is Lnm = 19.713,6 h. Finally, the modied rating life Lnm is in the range

of the rating life L10 .

Please note: Press the `Up' and `Down' arrow to move through the listbox of cleanness parameters. Moving
through the listbox changes the modied rating life and the results will be displayed immediately in the result
panel, making it very easy to compare the modied rating life with dierent levels of cleanness. You can also
navigate through the lubricant listbox.

Diagrams
Click on the button `Diagram' next to the listbox. The diagram includes the values for the rating life and for
the modied rating life. The exact values can be selected directly from the graphical representation. Clicking
the `Close' button leads you back to the main mask and you can open another diagram. Use the `Options'
button to specify which diagrams should be displayed in your calculation report.

Figure 5.55: Button `Diagram'

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5.16.5 Documentation: Calculation Report

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.

Figure 5.56: Button `Report'

You can navigate through the report via the table of contents that provides links to the input values, results
and gures. This calculation report contains all input data, the calculation method as well as all detailed
results. The report is available in HTML and PDF format. The calculation report saved in HTML format,
can be opened in a web browser or in Word for Windows.

Figure 5.57: Calculation report

You may also print or save the calculation report:

- To save the report in the HTML format, please select `File' → `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the button `Save'.

- If you click on the symbol `Print', then you can print the report very easily.

- When you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
dialog box for saving the report.

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5.16.6 Save the Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 5.58: Button `Save'

Before you can save the calculation to your computer, you need to activate the checkbox `Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 5.59: Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 5.60: Save the calculation

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5.16.7 Second Calculation Example

Bearing of a Fan
The impeller of fans can be arranged either between two bearings or in an overhung position. The impeller of
small and medium-sized fans is generally overhung. Two separated plummer block housings are suitable for
supporting the fan drive shaft.

This calculation example we have taken from: J. Braendlein: Die Waelzlagerpraxis: Handbuch zur Berechnung
und Gestaltung von Waelzlagern (1995, p. 516-520, gures: p. 517).

Figure 5.61: Bearing unit for fan

The unit (gure 5.61) contains a cylindrical roller bearing A and a deep groove ball bearing B in one housing
(gure 5.62). The bearing diameter is 70 mm.

Figure 5.62: Bearing of a fan

Input Values
The input values for bearing A (Cylindrical roller bearing NU 314 ECP)

Load Case No. 1 Load Case No. 2

Time slice q1 = 50% Time slice q2 = 50%

Speed n1 = 3,000 min-1 Speed n2 = 4,500 min-1

Fr1
Radial force = 8,500 N Fr2
Radial force = 11,000 N

Fa1
Axial force = 0 N Fa2
Axial force = 0 N
◦
Temperature T1 = 70 C Temperature T2 = 70◦ C

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All input values for bearing B (deep groove ball bearing 6314)

Load Case No. 1 Load Case No. 2

Time slice q1 = 50% Time slice q2 = 50%

Speed n1 = 3,000 min-1 Speed n2 = 4,500 min-1

Fr1
Radial force = 2,000 N Fr2
Radial force = 5,000 N

Fa1
Axial force = 5,000 N Fa2
Axial force = 5,000 N
◦
Temperature T1 = 70 C Temperature T2 = 70◦ C

5.16.8 The Calculation

Dene the Number of Bearings
In this example we want to calculate the rating life of the cylindrical roller bearing and the deep groove ball
bearing. We have to dierent bearings and we need to change the number of bearings. So enter `2' into the
input eld `Number of bearings to calculate'. Please calculate the bearings one after another separately. The
listbox `Current view' allows you to switch between the two bearings.

Figure 5.63: Number of bearings and add a comment

Add a comment for the rst bearing.

Select Manufacturer and Bearing Type

Now select the manufacturer `SKF'. Choose the cylindrical roller bearing from the listbox.

Figure 5.64: Selection of the manufacturer and bearing type

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5. Rolling Bearings According to DIN ISO 281 151

Specication of Bearing Load with Load Collectives

Dene the load collective for the rst bearing. Activate the option `Use load collective'. The input options for
the radial and axial force as well as for the speed will be deactivated. Dene two load cases for the bearing.
Enter the time slice, the radial force, axial force, the temperature and cleanness for each load case. After you
made all entries, click the button `OK' to conrm your inputs.

Figure 5.65: Dene the load collective

Bearing Selection
Click on the button `Bearing selection'. It is increasingly convenient to use the search lter to quickly nd the
bearing you are looking for. Enter `70 mm' for the inner diameter and click the button `Search'. Now you
can choose the cylindrical roller bearing `NU 314 ECP' from the list. Clicking the button `OK' conrms the
bearing and leads you back to the main mask.

Figure 5.66: Bearing selection

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5. Rolling Bearings According to DIN ISO 281 152

5.16.9 Calculation Results

Rating Life of the Cylindrical Roller Bearing (Bearing Location A)
All results will be calculated during every input and will be displayed in the result panel. A recalculation occurs
after every data input. Any changes that are made to the user interface take eect immediately. First, you
get the result for the rating life as well as the static identication number.

Figure 5.67: Rating life

The result of the rating life is L10 = 188,391.8 h

The cylindrical roller bearing is suciently dimensioned.

Rating Life for the Deep Groove Ball Bearing (Single Row) (Bearing Location B)
Calculate now the rating life for the deep groove ball bearing. Please pay attention that you select `Bearing
No. 2' from the listbox `Current view'. Select the manufacturer `SKF' and the bearing type `Deep groove ball
bearing (single row)'.

Figure 5.68: Bearing selection

Activate the option `Use load collective' and dene the load cases. After you made all entries, click the button
`OK' to conrm your inputs.

Figure 5.69: Dene the load collective'

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5. Rolling Bearings According to DIN ISO 281 153

Click on the button `Bearing selection'. Choose the bearing `6314*' from the list. It is increasingly convenient
to use the search lter to quickly nd the bearing you are looking for. Enter `70 mm' for the inner diameter
and click the button `Search'. Then you can select the bearing `6314' from the list. Clicking the button `OK'
conrms the bearing and leads you back to the main mask.

Figure 5.70: Deep groove ball bearing

The result for the rating life is L10 = 5.928,1 h

Figure 5.71: Nominal rating life

The rating life of the deep groove ball bearing B is lower than the rating life of the cylindrical roller bearing
A. This means that bearing B is subjected to higher stresses than bearing A. At least 220,000 hours are
required for the rating life of deep groove ball bearings. But with this result, the rating life is not suciently
dimensioned. It is necessary to take a closer look at the modied rating life Lnm of bearing B.

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5. Rolling Bearings According to DIN ISO 281 154

Modied Rating Life of the Deep Groove Ball Bearing

The next step is to determine the modied rating life for the deep groove ball bearing. The option `Use
modied rating theory' is activated by default. Select the grease `Lubcon Turmogrease Highspeed L 252 (K
HC P 2/3 K-50)' from the listbox or click on the button `Lubricant' to open the lubricant selection. Choose
the lubricant and conrm with the button `OK'.

Figure 5.72: Modied rating life

The result of the modied rating life is Lnm = 49.223,4 h.

Figure 5.73: Result for the modied rating life

At least 22,000 hours are required and the bearing is suciently dimensioned. For the calculation with load
collectives, you cannot open all diagrams. But you can open the diagram for the lubricant viscosity.

5.16.10 Documentation: Calculation Report

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.
Click the button `Options' and activate the diagram for the `Lubricant viscosity'. This diagram will then appear
in the calculation report.

Figure 5.74: Calculation report

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5. Rolling Bearings According to DIN ISO 281 155

You can navigate through the report via the table of contents that provides links to the input values, results
and gures. This calculation report contains all input data, the calculation method as well as all detailed
results. The report is available in HTML and PDF format. The calculation report saved in HTML format,
can be opened in a web browser or in Word for Windows. You may also print or save the calculation report:

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the button `Save'.

- If you click on the symbol `Print', then you can print the report very easily.

- When you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on
the PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
dialog box for saving the report.

5.16.11 Save the Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'. Before you can save the calculation to your
computer, you need to activate the checkbox `Local' in the calculation module. A standard Windows dialog
for saving les will appear. Now you will be able to save the calculation to your computer.

Figure 5.75: Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 5.76: Save the calculation

Our manual is improved continually. Of course we are always interested in your opinion, so
we would like to know what you think. We appreciate your feedback and we are looking
for ideas, suggestions or criticism. If you have anything to say or if you have any questions,
please let us know via telephone +49 (0) 531 129 399-0 or email [email protected].

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Chapter 6

Single External and Internal

Cylindrical Gears According to DIN
3960 and Other Standards

6.1 Start the Calculation Module

Please login with your username and your password. To start the calculation module for single cylindrical
gears, please click the menu item `Gear calculation' on the left side and then select `Cylindrical gear (external)'
or `Cylindrical gear (internal)'.

Figure 6.1: Single external cylindrical gear: General overview

The eAssistant module allows an easy and fast calculation of the geometry of single cylindrical gears according
to DIN 3960, DIN 3961, DIN 3964, DIN 3967, DIN 3977 and DIN 868. External spur and helical gears as well
as internal gears can be calculated. Prole shift or addendum chamfer will be taken into consideration. The

156
6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 157

geometry, test dimensions and allowances of a single external or internal cylindrical gear will be determined. In
order to calculate a single internal cylindrical gear, please open the module `Single cylindrical gear (internal)'.

Figure 6.2: Single internal cylindrical gear: General overview

6.2 Input of Geometry Data

All important calculation results will be calculated during every input and will be displayed in the result panel.
A recalculation occurs after every data input. Any changes that are made to the user interface take eect
immediately. Press the Enter key or move to the next input eld to complete the input. Alternatively, use
the Tab key to jump from eld to eld or click the `Calculate' button after every input. Your entries will be
also conrmed and the calculation results will displayed automatically. If the result exceeds certain values, the
result will be marked red.

6.2.1 Normal Module

The normal module mn is one of the basic parameters in the gear geometry and describes the size of a gear.
The module is dened as the ratio of the pitch diameter to the number of teeth of a gear. Note that the
larger the module the larger the teeth. The value of the module is dened in millimeters. In order to limit the
number of the gears, the module has been standardised in preferred series 1 and 2 (see following tables). The
calculation with the eAssistant software is possible with any modules including several decimal places.

Series of Modules in mm According to DIN 780 Series 1 (Part 1)

0,05 0,06 0,08 0,10 0,12 0,16 0,20 0,25

0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

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Series of Modules in mm According to DIN 780 Series 1 (Part 2)

1,25 1,5 2 2,5 3 4 5 6 8

10 12 16 20 25 32 40 50 60

Series of Modules in mm According to DIN 780 Series 2 (Part 1)

0,055 0,07 0,09 0,11 0,14 0,18 0,22 0,28 0,35

0,45 0,55 0,65 0,75 0,85 0,95 1,125 1,375 1,75

Series of Modules in mm According to DIN 780 Series 2 (Part 2)

2,25 2,75 3,5 4,5 5,5 7 9 11

14 18 22 28 36 45 55 70

6.2.2 Pressure Angle

With an increasing distance from the base circle, the prole angles αy increase too. The most common pres-
sure angle now in use for spur gears is 20◦ . The default startup setting for the pressure angle is set to 20◦ .

6.2.3 Helix Angle

For spur gears the helix angle is β = 0◦ , for helical gears the angle β is up to 45◦ due to the fact that the
◦
teeth for a helical gear are inclined by the angle. 45 is also the maximum value that you can enter into the
input eld for the helix angle. For an external gearing a right-hand teeth and a left-hand teeth can only mesh
correctly. For internal gearings pinion and gear must have the same direction.

Helical Gears
Helical gears are used to transmit power or motion between parallel shafts. Helical gears dier from spur gears
in that they have teeth that are cut in the form of a helix on their pitch cylinders instead of parallel to the
axis of rotation. As two teeth on the gear engage, it starts a contact on one end of the tooth which gradually
spreads with the gear rotation, until the time when both the tooth are fully engaged. Finally, it recedes until
the teeth break contact at a single point on the opposite side of the wheel. Thus force is taken up and released
gradually. Helical gears oer a renement over spur gears. The angled teeth engage more gradually than do
spur gear teeth. This causes helical gears to run quieter and smoother than spur gears. Helical gears are used
in areas requiring high speeds, large power transmission or where noise prevention is important.

Figure 6.3: Module, pressure angle, helix angle

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 159

6.2.4 Direction of Helix Angle

Enter a value for the direction of the helix angle. When the gear is placed on a at surface, the teeth of a
left-hand gear lean to the left and the teeth of a right-hand gear lean to the right. It should be noted that a
pair of helical gears on parallel shafts must have the same helix angle β. However, the helix directions must
be opposite, i.e., a left-hand mates with a right-hand helix. For an external gear pair the engaged gearings
have dierent directions, internal gears have the same direction with the same helix angle.

Figure 6.4: Left and right-hand teeth

Entering an helix angle automatically activates the option to specify the direction of the helix angle and to
select the checkbox.

Figure 6.5: Direction of helix angle

6.2.5 Number of Teeth

The number of teeth of a gear describes the number of the teeth on the full rim. The number of teeth is
positive for external gears and negative for internal gears.

Figure 6.6: Number of teeth for single external cylindrical gear

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 160

Please note that the smaller the number of teeth the larger the inuence of the prole shift. By default, a
positive number of teeth appears when you open the module for single external cylindrical gears. A negative
number of teeth appears when you open the module for single internal cylindrical gears. Please see section
6.8.3 `Some Notes for Internal Gears' to get more information on this kind of gear.

6.2.6 Facewidth
The facewidth b is the length of the gear teeth as measured along a line parallel to the gear axis.

Figure 6.7: Facewidth

Enter a value for the facewidth. The following table shows some additional information about the facewidth
b as well as minimum number of teeth z.

Standard Values for the Facewidth b and Minimum Number of Teeth z 1

Gears on rigid shafts, that run in roller or excellent plain bearings,
b ≤ 30 . . . 40 · m
Teeth, machine-cut rigid substructure

Gears in usual gear boxes, roller or plain bearings b ≤ 25 · m

Gears on steel constructions, beams and suchlike b ≤ 15 · m
Gears with excellent bearing in high duty gearings b ≤ 2 · d1
Teeth, cast roughly Overhung gears b ≤ 10 · m
Gears with high circumferential velocity(υ > 4 m/s) and considerable z1 ≥ 16
power, when εα > 1.5
Gears with mean circumferential velocity(υ = 0.8 . . . 4 m/s) z1 ≥ 12
Gears with low circumferential velocity(υ < 0.8 m/s) or for low power for subor-
z1 ≥ 10
dinated purposes

Basically external gearings z1 + z2 ≥ 24

Basically internal gearings z2 ≥ z1 + 10
1 from: Karl-Heinz Decker: Maschinenelemente: Gestaltung und Berechnung, 1992, p. 506, table 23.2

6.2.7 Prole Shift Coecient

Prole shift can make spur gears or helical gears run more quietly and carry more load. If spacing errors
of some magnitude are present, proper prole shift will give the teeth a little clearance at the rst point of

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 161

contact. If a pair of teeth are spaced too close together, there is a bump as the tooth comes into mesh. With
the modication there is a little relief at the rst point of contact. The prole shift aects the tooth form
because the tool is shifted by the value xm towards or away from the tip circle. The calculation of the tip
diameter da and root diameter df includes the prole shift coecient x. According to DIN 3960 the prole
shift is

- positive if the prole reference line is shifted from the reference circle towards the tip circle,

- negative if the prole reference line is shifted from the reference circle towards the root circle.

Figure 6.8: Change the tooth form with the prole shift: number of teeth z = 10; tooth 1: x = 0.5; tooth 2:
x = 0; tooth 3: x = -0.5

Characteristics of the Prole Shift

- A positive prole shift increases the tooth thickness, a negative prole shift decreases the tooth thickness.

- With an increasing positive prole shift, the tooth tip thickness and the root llet become smaller, the
load capacity increase. This advantage occurs especially for a smaller number of teeth.

- The minimum permitted tooth tip thickness determines the limit for a very large prole shift, in particular
for very small number of teeth.

- The prole shift aects the operating pressure angle as well as the load capacity.

- For a small number of teeth and with a negative prole shift, an undercut becomes a problem (see above
gure). The undercut weakens the tooth root and a part of the tooth ank is cut o.

Here you have the option of dimensioning or optimizing the prole shift coecient. To optimize the prole
shift coecient, click on the `Calculator' button. In addition to the option `user-dened input', the following
two options are available for selection: `Geometric minimum' and `Geometric maximum'. Here the possible
limits of the prole shift, i.e. the minimum and maximum prole shift that can be executed with respect to
the undercut limit and topland limit.

Figure 6.9: Dimensioning of the prole shift

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 162

6.2.8 Tip Diameter

The tip diameter da depends on the module and will be determined by the program automatically. If you
change the prole shift, the tip diameter will change, too. There is the possibility to enable the tip circle
using the `Lock' button. Now you can add and modify the tip diameter very easily. Please note that the tip
diameter has an inuence on the modication of the tip diameter. Click on the button again to disable the
input eld. The value is determined again according to DIN. In case you use a special tool, the tip diameter can
be changed by a tool customization. Find out more about the tool data in the section `The input of tool data'.

6.2.9 Tip Diameter Allowance

The tip diameter allowance is determined according to DIN. Click on the `Lock' button to enable the input
eld and enter your own value. If your values are out of range of the DIN, you will get an information in
the message window. Click on the `Lock' button and the input eld is disabled again. The allowances are
determined according to DIN.

6.2.10 Modication of Tip Diameter

The modication of the tip diameter k is automatically determined by the program that a sucient tip
clearance is available. For external gears the modication of the tip diameter is k ≤ 0, for internal gears,
the value is often set to k=0 in order to avoid meshing interferences. Click on the `Lock' button to enable
the input eld and enter your own value. Such a modication of the tip diameter has an eect on the tip
diameter.

Figure 6.10: Tip diameter, tip diameter allowance, modication of tip diameter

6.2.11 Root Diameter

The root diameter df depends upon the module, the prole shift and addendum coecient of the basic rack
prole. The root diameter is determined by the program. Therefore, the root diameter occurs as a result of
the calculation.

6.2.12 Allowances of Root

The allowances of root result from your calculation and will be determined automatically. The allowances
depend upon the tooth thickness allowances. For instance, if you enter the value `0' for a gear, then the
allowances of root become `0' for this gear as well.

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 163

6.2.13 Innen and Outer Diameter

Here you can enter an inner diameter (for external gears) and outer diameter (for internal gears). It should be
kept in mind that the inner diameter has to be smaller than the root diameter df . In case the inner diameter
is larger than df , then the program automatically corrects the value and enters the maximum value for the
inner diameter. An appropriate message appears in the message window.

Figure 6.11: Inner and outer diameter

6.2.14 Web Width

The web width can be considered here. The web width is shown in the gure next to the input eld. There
is the possibility to modify the web width by using the `Lock' button.

Figure 6.12: Web width

The `Lock' button is still disabled. Enter the values for the inner or outer diameter into the input eld. Then
the `Lock' button is enabled and the web width gets the same value as the facewidth. In case the web width
is smaller than the facewidth, then the gear body stiness is aected due to the gear body coecient CR .
The tooth spring stiness changes which aects again the load capacity.

Figure 6.13: Web width

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 164

6.2.15 Chamfer
The chamfer can be considered. This reduces the calculated facewidth for the calculation of the load capacity
of the tooth root and tooth ank.

Figure 6.14: Chamfer

6.2.16 Addendum Chamfer

The tooth ends of a gear are often rounded or chamfered. A chamfer is a small angled surface added on
the end of a shaft along an edge. For the calculation you can consider the addendum chamfer. Meshing
interferences can be removed by the addendum chamfer.

Figure 6.15: Addendum chamfer

Please Note: If you dene the geometry of the gear , you are able to look at the tooth form. Click on the
button `Tooth form' and select `Total view' or `Detail view'. Click the button `Geometry' and you get to the
geometry input again.

As an alternative to the addendum chamfer, a tip corner radius can be specied. This can be dened either
as a radial amount or directly as a radius. The selection is marked by the colored arrow. The radius is entered
directly for the tip radius, the radial amount is entered for the tip radius (Rad.).

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 165

If you enter the tip radius directly as a value, you will receive the corresponding radial amount in the calculation
report.

Figure 6.16: Switch between input of addendum chamfer, tip corner radius (radial amount and radius)

In the case of tip corner radius or addendum chamfer, the tip form diameter is smaller than the tip circle
diameter by twice the radial amount hK .

Figure 6.17: Spur gear with addendum chamfer, hK = Radial amount of the tip corner radius, dF a = Tip form
diameter

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6.3 Input of Tool Data

For the selection of the manufacturing process you have to consider the material, size of the gear, quantity, gear
type (external or internal gears) and accuracy. The many methods of making gear teeth must be considered
as well. The calculation program distinguishes between gear-tooth cutting and gear hobbing.

Figure 6.18: Input mask for tool data

Please note: If you want to add some own notes, comments or a description, then use the comment line.

6.3.1 Tool
The most important manufacturing processes are gear hobbing and gear shaping. Select either the tool `Hob' or
`Gear shaper cutter' by clicking the listbox. A `Constructed involute' is also available. Basically, the selection
of the tool depends on the gear type (external or internal gears). The external gears can be produced by
cutting wherein the gear cutting tool is a hob. For internal gears a gear shaper cutter is used (see section 6.9
`Manufacturing Process for Internal Gears').

Figure 6.19: Selection of tool

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 167

Gear Hobbing
The hobbing is the most widely used method of cutting gear teeth. The hobbing process is quite advantageous
in cutting gears with very wide facewidth. A very high degree of tooth-spacing accuracy can be obtained with
hobbing. With regard to accuracy, hobbing is superior to the other cutting processes. A wide variety of sizes
and kinds of hobbing machines are used. The rotating hob has a series of rack teeth arranged in a spiral
around the outside of a cylinder, so it cuts several gear teeth at one time. To generate the full width of the
gear, the hob slowly traverses the face of the gear as it rotates. Thus, the hob has a basic rotary motion and
an unidirectional traverse at right angles. Both movements are relatively simple to eect, resulting in a very
accurate process.

Field of Application of the Hob:

- Recommended for gears with very wide facewidth

- Recommended for external spur and helical gears up to module `40' (Please keep in mind: it is an
expensive tool for large modules)

- Recommended for all basic rack proles

- The helix angle is arbitrary.

Figure 6.20: Hob and gear shaper cutter

Gear Shaping
The shaping process is a gear-cutting method in which the cutting tool is shaped like a pinion. If a gear is
provided with cutting clearance and is hardened, it may be used as a generating tool in a gear shaper. The
cutter reciprocates while it and the gear blank are rotated together at the angular-velocity ratio corresponding
to the number of teeth on the cutter and the gear. The teeth on the gear cutter are appropriately relieved
to form cutting edges on one face. Although the shaping process is not suitable for the direct cutting of
ultra-precision gears and generally is not as highly rated as hobbing, it can produce precision quality gears.
Usually it is a more rapid process than hobbing. Two outstanding features of shaping involve shouldered and
internal gears. For internal gears, the shaping process is the only basic method of tooth generation.

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 168

Field of Application of the Gear Shaper Cutter:

- Recommended for internal and external spur and helical gears

- Racks

- Special gearings, e.g., splined shaft connections, face or chain gears

Constructed Involute
In addition to the hob and the gear shaper cutter, you can also select the entry `Constructed involute' as a
tool. In case internal gears cannot be shaped with a gear shaper cutter, the tooth form calculation is still
possible by using the constructed involute. This specically applies for applications in the precision mechanics.
This method allows a generation of the tooth form with a constant root llet radius.

Figure 6.21: Constructed involute

Representation of Hob and Gear Shaper Cutter

The representation shows either the hob basic rack prole or the gear shaper cutter tooth prole. The radio
buttons enable you to choose one of the graphical representation.

Figure 6.22: Tool

6.3.2 Standard Basic Rack Tooth Prole

To mesh two gears with each other, the parameters have to be coordinated. The standard basic rack tooth
prole is standardized in DIN 867. A gear with an innite number of teeth will have straight lines for both

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 169

the pitch and the base circles. The involute prole will be a straight line. The rack can be used to determine
the basic parameters. Racks can be both spur and helical. A rack will mesh with all gears of the same pitch.
The pressure angle and the gears pitch radius remain constant regardless of changes in the relative position of
the gear and rack. The tool standard basic rack prole is the counter prole of the standard basic rack tooth
prole. The following standard basic rack proles are available for your calculation. Choose your prole from
the listbox.

Figure 6.23: Listbox for the basic rack prole

- ISO 53 Prole A: is recommended for gears transmitting high torques

- ISO 53 Prole B: is recommended for normal service

- ISO 53 Prole C: is recommended for normal service, type C may be applied for manufacturing with
some standard hobs.

- ISO 53 Prole D: is recommended for high-precision gears transmitting high torques and consequently
with tooth anks nished by grinding or shaving. Care should be taken to avoid creating notches in the
llet during nishing which could create stress concentrations.

- DIN 3972 Prole I

- DIN 3972 Prole II

- Prole 1 DIN 867 (Numerical example from DIN 867)

- Prole 2 DIN 867 (Numerical example from DIN 867)

- Prole 3 DIN 867 (Numerical example from DIN 867)

- Prole 4 DIN 867 (Numerical example from DIN 867)

- AGMA PT (for plastic gears)

- AGMA XPT-2 (for plastic gears)

- AGMA XPT-3 (for plastic gears)

- AGMA XPT-4 (for plastic gears)

In addition to the standard basic rack proles, you can also select a protuberance tool. When part of the
involute prole of a gear tooth is cut away near its base, the tooth is said to be undercut. By using a
protuberance tool an undercut near the root can be generated. Grinding notches at the tooth ank can
be avoided during the grinding. That provides relief for subsequent nishing operations (see section 6.3.6
`Protuberance').

Figure 6.24: Selection of the protuberance tools

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 170

You can select the following proles:

◦
- Prot 1.4-6 /0,085

◦
- Prot 1.5-6 0.02

◦
- Prot 1.6-6 /0.02

◦
- Prot 1.4-8 /0.04

◦
- Prot 1.4-8 /0,066

◦
- Prot 1.4-10 /0.05

◦
- Prot 1.5-10 /0.02

◦
- Prot 1.6-10 /0.02

◦
- Prot 1.25-14 /0,024

◦
- Prot 1.4-6

◦
- Prot 1.4-10 (Fette) (Protuberance tool with shifted prole reference line with the data of the tool
manufacturer LMT Fette)

◦
- TBK Prot 10 (Protuberance tool with shifted prole reference line with data analog TBK V22)

Please Note: If you select `user dened input', then the input elds for the edge radius, the addendum
coecient and the dedendum coecient are activated. Now you can modify the basic rack prole.

Figure 6.25: Own input

Determination of the Basic Rack Prole

In case you use special tools, the eAssistant software oers an easy and comfortable solution. The basic rack
prole can be determined by clicking the `Calculator' button. Here you can change the tip circle and the
root diameter for the gear. Conrm your entries with the button `OK'. The listbox for the basic rack proles
displays then `user dened input'. The modication of the tip diameter is set to '0'.

Figure 6.26: Tool dimensioning

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6.3.3 Tip Form

For the tip form you can choose between `Full radius' and `Radius with straight line'. Normally `Radius with
straight line' is used.

Figure 6.27: Listbox for tip form

6.3.4 Addendum Coecient

eAssistant provides a functionality for tools with a shifted prole reference line. Additionally to the addendum
coecient h∗aM P 0 of the shifted prole, the dedendum coecienth∗f M P 0 is displayed and visible in the
∗
calculation report. The dedendum coecient hf M P 0 can also be dened by clicking the `Lock' button so that
∗
the dedendum coecient hf P 0 of the converted, non-shifted basic rack prole is always 1.0 according to DIN
867.

Figure 6.28: Input of the addendum coecient for tool with shifted prole reference line

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 172

Shifted Prole Reference Line

Figure 6.29: Prole reference line according to DIN and shifted prole reference line

6.3.5 Semi Topping Flank and Topping

With the denition of the semi topping ank, corresponding hobs can then be specied. These generate an
addendum chamfer during the cutting process. The option `Topping' allows to dene the tip diameter directly
with the dedendum coecient of the tool, making it impossible to subsequently modiying the tip diameter.
The result, at the same time, will be tip diameter allowances analogous to the root diameter allowances directly
from the tooth thickness allowances. The eAssistant 3D CAD plugins for various CAD systems support the
function and the semi topping ank can be considered in the 3D CAD model.

6.3.6 Protuberance
Undercut may be deliberately introduced to facilitate nishing operations. Undercut is the loss of prole in
the vicinity of involute start at the base circle due to tool cutter action in generating teeth with low numbers
of teeth. The protuberance cuts an undercut at the root of the gear tooth. The protuberance design is also
used in some cases to permit the sides of gear teeth to be ground without having to grind the root llet.

Determination of the Amount of the Protuberance from the Height of the Protuberance Flank
The following equation determines the amount of the protuberance. In case the height of the protuberance
ank is given and not the amount of the protuberance, the amount of the protuberance may be calculated by
this equation.

(h∗prP 0 − ρ∗aP 0 · (1 − sin(αp ))) · sin(αn − αp )

prP∗ 0 = + ρ∗aP 0 · (1 − cos(αn − αp ))
cos(αp )

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 173

The following gure shows a representation:

Figure 6.30: Height of the protuberance ank

To avoid grinding steps, a deviation in the tooth root area of the prole is a common and allowed method.
Because of a grinding stock allowance, an undercut must be allowed. Hence, a larger tooth root thickness is
necessary. The following table shows some determination of the undercut dependent upon the module.

Undercut spr for Ground Gears Dependent upon Module2

Module Allowance Size of Protuberance Addendum Edge Radius

m q Undercut spr prP∗ 0 h∗aP 0 ρ∗aP 0

2 0,160 0,100 0,260 2,900 0,500

2,5 0,170 0,110 0,280 3,625 0,625

3 0,180 0,120 0,300 4,350 0,750

4 0,200 0,140 0,340 5,800 1,000

5 0,220 0,160 0,380 7,250 1,250

6 0,240 0,180 0,420 8,700 1,500

7 0,260 0,200 0,460 10,150 1,7500

2 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag, Muenchen, Wien, 2nd ed. 2010, p. 68, table 2.1/2

6.3.7 Machining Allowance

You can consider an allowance for the tooth ank. The tool provides an allowance q on the ank and/or root
for the pre-cutting tool. The allowance is the smallest distance between the involutes and the pre-machining
having the same root diameter. In case you select the tool basic rack prole with protuberance, the allowance
refers to the tooth ank.

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 174

If the allowance of the tool basic rack prole is selected without protuberance, then tooth ank and tooth
root get the allowance.

Figure 6.31: The eAssistant software provides the following allowances for the grinding of a gear: a) Constant
allowance with bottom of the tooth space, b) Protuberance: Cutter tooth prole is built up on the tip to
provide an undercut near the root of the gear being generated.

Figure 6.32: Input of machining allowance

Maximum Machining Allowances3

Allowance per Tooth Flank Manufacturing Process

< 0.05 (0.10) mm Finishing operation by cold rolling, gear shaving, hon-
ing, lapping

0.05 to 0.5 (1.5) mm Grinding, prole grinding, (honing)

> 0.5 mm, pre-cutting Primary shaping, forming, cutting with geometrically
determined edges except shaving, grinding and prole
grinding in special cases

3 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag, Muenchen, Wien, 1996, p. 638

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 175

6.4 Input of Data for the Determination of Allowances

A manufacturing of work-pieces with accurate nominal dimensions is impossible. Hence, a deviation from the
nominal size has to be allowed. For a lot of applications the gear and the pinion of a pair must be independently
manufactured and meshed without any modications. That means, the parts have to be separately replaceable.
In addition to DIN 3961 for gear tolerances/gear qualities, DIN 58405 for precision engineering as well as ISO
1328 and ANSI/AGMA 2015 are available.

Figure 6.33: Input of allowances

6.4.1 Gear Quality

The choice of the right toothing quality is determined by economical aspects depending upon the intended
purpose and manufacturing process. In all elds of gearing, the control of gear accuracy is essential. Several
classes or grades of accuracy can be set. 12 grades (12 to 1) are dened according to DIN standards. High
accuracy grades can be set for a long-life, high speed gears. Lower accuracy grades will cover medium- or
slow-speed grades. Accuracy grade `1' describes the highest possible accuracy, `12' a very low accuracy. The
gear accuracy `1 to 4' is mainly used for master gears, quality `5 to 12' is used for gear wheels (gure from:
Niemann, G.: Maschinenelemente, Vol. 2, Getriebe allgemein, Zahnradgetriebe-Grundlagen, Stirnradgetriebe,
1989, p. 73, gure 21.4/1).

Figure 6.34: Tolerances according to the manufacturing process

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 176

Select the appropriate quality between 1 and 12 by using the following listbox.

Figure 6.35: Listbox for the selection of quality

The following table provides some reference values for the selection of the quality, tolerances for gearings made
of metal and plastics:

Toothing Made of Metal4

ν Machining Quality Tolerance Sequence
to m/s of Tooth Flanks (Accuracy) DIN 3967
0.8 Cast, raw 12 2x30

0.8 Rough-machined 11 or 10 29 or 28

2 Finish milled 9 27

4 Finish milled 8 26

8 Fine nished 7 25

12 Shaved or ground 6 24

20 Precision-ground 5 23

40 Precision-machined 4 or 3 22

60 Precision-machined 3 22 or 21

Toothing Made of Injection Molding Plastics

Application d Quality Tolerance Sequence
in mm (Accuracy) DIN 3967
Gearings with high requirements to 10 9 27

Gearings with high requirements 10 to 50 10 28

Gearings with normal requirements 10 to 50 11 29

Gearings with low requirements to 280 12 2 x 30

Toothing made of plastic manufactured by cutting

Gearings with high requirements to 10 8 25 to 27

Gearings with high requirements 10 to 50 9 26 to 28

Gearings with normal requirements to 50 10 27, 28

Gearings with normal requirements 50 to 125 11 27, 28

Gearings with low requirements to 280 12 28

4 from: Karl-Heinz Decker: Maschinenelemente: Gestaltung und Berechnung, 1992, p.

512, table 23.3

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 177

For the gear tolerances/gear qualities, DIN 58405 for precision engineering as well as ISO 1328 and ANSI/AGMA
2015 are also available. For ISO 1328 and ANSI/AGMA 2015, two qualities can be selected in each case. The
rst quality is comparable with the tolerances permitted according to DIN 3961, the second value inuences
the radial composite deviation as well as the roll deviations.

6.4.2 Backlash Allowance and Tolerance Sequence

The system for gearings is very similar to the DIN system of ts and tolerances. For the system of ts for
gear transmissions letters are used to indicate the deviation from basic (nominal) size, a number denes the
width. There are clearance ts for gearings, therefore, lower case characters `h' to `a' appear. If you select
the entry `user dened input', the input eld for the tooth thickness allowances is enabled and you can dene
your individual values.

Figure 6.36: Own input

6.4.3 Tooth Thickness Allowance

One of the most important criteria of gear quality is the specication and control of tooth thickness. The
magnitude of tooth thickness and its tolerance is a direct measure of backlash when the gear is assembled
with its mate. Dimensional changes, due to thermal expansion, do not allow a zero-backlash assembly. The
tooth thickness allowance has to be determined that no jamming occurs. To prevent that jamming of gears
during the operation, it is necessary to decrease tooth thickness by a minimum amount (Asne and Asn ).

Figure 6.37: Lower and upper tooth thickness allowances

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 178

The eAssistant software oers the possibility to specify the tooth thickness allowances based on measured
data or given test dimensions. Click on the `Calculator' button.

Figure 6.38: `Calculator' button

A new window is opened.

Figure 6.39: Calculation of tooth thickness allowances

Activate gear 1 and gear 2 and enter the input values. Conrm with the button `OK'. The `Lock' button next
to the input eld for the tooth space allowances is enabled. Now you can change the tooth space allowances.

6.4.4 Tooth Space Allowance

The tooth space allowance AW is the dierence between the actual dimension and the nominal dimension of
the span measurement W k. The actual measurement of the span measurement gets smaller for external gears
by negative allowances for a zero-backlash assembly. The upper and lower tooth space allowance are displayed
as well. For an own input of the tooth thickness allowances, the tooth space allowances can be dened as
well. The `Lock' button next to the input eld of the tooth space allowances is enabled. Therefore, you can
change the tooth space allowances.

Figure 6.40: Tooth space allowance for the gear

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6.4.5 Measurement of Tooth Thickness

The tooth thickness of a gear may be measured directly with calipers or it may be determined indirectly by
diameter pins. The sizing of gears may be controlled by double-ank composite checks and centre distance
settings corresponding to maximum and minimum tooth thickness specications. Dierent measurement
methods are used:

- At pitch circle (chordal),

- Span measurement across several teeth,

- Measurement over pins or balls that are placed in diametrically opposed tooth spaces,

- Check of the centre distance allowance with zero-backlash engagement by using a master gear in a ank
roll tester.

In the following you get some information on the widely used measurement methods:

- Span measurement Wk
- Measurement by diameter over balls or pins, the measurement by using balls and pins

Span Measurement across Several Teeth

Span measurement Wk is the measurement of the distance across several teeth in a normal plane. As long as
the measuring device has parallel measuring surfaces that contact on an unmodied portion of the involute,
the measurement will be along a line tangent to the base cylinder. It is a widely used method for gauging the
tooth thickness by using the span measurement. The tooth thickness of spur or helical gears is often measured
with calipers. An advantage is that the dimensions can be inuenced during the manufacturing.

Figure 6.41: Span measurement

The calculation program determines the number of teeth for the span measurement (number of teeth across
the span measurement has to be gauged). By using the `Lock' button you are able to activate the input eld
and you can enter your own input value. If you click the button again, the previous input value appears.

Figure 6.42: Number of teeth for the span measurement

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 180

Tooth Thickness Measurement by Diameter over Pins or Balls

The tooth thickness is often checked by measurement over pins MdR or balls MdK . The pins or balls are
placed in diametrically opposed tooth spaces (even number of teeth) or nearest to it (odd number of teeth).
Measurement over pins is the measurement of the distance taken over a pin positioned in a tooth space and
a reference surface. The reference surface may be the reference axis of the gear, a datum surface or either
one or two pins positioned in the tooth space or spaces opposite the rst. The measurement over pins is only
used for spur gears and external helical gears. For the measurement values a distinction is made between:

- Measurement over balls MdK

- Measurement over pins MdR
- Measurement over pins for a spur gear

- Measurement over pins for external helical gears with even number of teeth

- Measurement over pins for external helical gears with odd number of teeth

For an external gear the measurement over balls MdK is the largest outer measure. The two balls are placed
in diametrically opposed tooth spaces. The balls have to be in the same plane perpendicular to a gear axis.
For an internal gear (see gure: `Internal spur gear with odd number of teeth') the measurement over balls is
the smallest inner measure between the balls. DM is the diameter of ball or pin. The internal gear is generally
checked for tooth thickness with measuring pins, like the external gear. However, the measurement is made
between the pins instead of over pins.

Measurement over balls:External spur gear with even num-

ber of teeth

Measurement over balls: External spur gear with odd num-

ber of teeth

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 181

Measurement over balls: Internal spur gear with odd num-

ber of teeth

The eAssistant software already species the diameter of ball or pin for the test dimensions. Enable the input
eld by clicking the `Lock' button. Enter your own input value for the diameter. If you click on the button
once again, the previous input value appears.

Figure 6.43: Diameter of ball or pin

Please Note: In the calculation report you can nd all results for the span measurement or measurement
over balls and pins in section `Test dimensions'.

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6.5 Representation of Gear Tooth Form

A special highlight of this calculation module is the presentation of the accurate gear tooth form with an
animation and simulation of the tooth mesh. For the presentation you can select the lower, upper and mean
allowances for the tooth thickness, tip diameter and centre distance. When you dene the geometry for the
gear pair, then you can have a look at the tooth form at any time. Click on the `Tooth form' button and you
get a general or detailed view of the tooth form. By clicking the `Geometry' or `Tool' button, you can open
the main input masks of the calculation module again.

Figure 6.44: Tooth form

Please Note: Please keep in mind that all values are later taken over to the DXF output and CAD generation.
In case you change the tooth thickness allowance or the centre distance allowance in the tooth form mask, then
the last modication is taken over to the DXF output. The section 6.17 contains some helpful information on
this function.

Figure 6.45: DXF output

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6.5.1 Representation of Cylindrical Gear Pair

Click on the `Tooth form' button to represent the gear tooth form.

Figure 6.46: Cylindrical gear pair

Please Note: Please keep in mind that you can check the backlash and the mesh ratio only in the presentation
of the mesh. The gear mesh will be discussed in the following section `Representation of Mesh'.

6.5.2 Representation of Tooth Mesh

Click on the `Detail view' button. You get a larger representation of the gear tooth form. Now you can see
the detailed tooth mesh. Click on the `Total view' button to obtain an entire view of the cylindrical gear pair.

Figure 6.47: Detail view of the mesh

Please Note: The representation of the tooth mesh allows you to look at the tooth thickness allowances, the
tip diameter and centre distance allowances as well the tooth mesh and to check the inuence of these values.
The tooth form mask provides various functions. Find a short description of these functions in the following
section.

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 184

6.5.3 Rotating Angle

Enter an rotating angle for the rotation of the spur gear pair.

Figure 6.48: Rotating angle

Rotation of the driving gear counter-clockwise

Rotation of the driving gear clockwise

6.5.4 Rotation
When you click on one of the two arrows, a continuous rotation of the spur gears occurs.

Figure 6.49: Rotation

Continuous rotation of the driving gear counter-clockwise

Continuous rotation of the driving gear clockwise

The rotation is stopped.

6.5.5 Tooth Thickness Allowance

Click on the `Detail view' button and the tooth mesh is represented in detail. Now you can change the tooth
thickness allowance, that is already given in the main mask for the `Allowances', within the tolerance limit.
All changes are displayed immediately. For the representation of the tooth mesh, select the lower, upper and
mean tooth thickness allowances for the gear.

Figure 6.50: Tooth thickness allowance in the main mask `Allowance'

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 185

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower tooth thickness allowance. The right arrow
shows the representation for the upper tooth thickness allowance. The middle button displays the mean tooth
thickness allowance. At the rst start of the tooth form, you will get the mean tooth thickness allowance as
a standard feature.

Figure 6.51: Tooth thickness allowance

Please Note: In case you have specied the lower and upper tooth thickness allowance for gear the gear in
the input mask `Allowances' by using the `Calculator' button, then the manually dened values appear here
as lower and upper tooth thickness allowance.

6.5.6 Tip Diameter Allowance

Click the `Detail view' button and the tooth mesh is represented in detail. Now you can change the tip
diameter allowance, that is already given in the main mask for the `Geometry', within the tolerance limit. All
changes are displayed immediately. For the representation of the tooth mesh, select the lower, upper and mean
tip diameter allowances for the gear.

Figure 6.52: Tip diameter allowance in the main mask `Geometry'

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower tip diameter allowance. The right arrow shows
the representation for the upper tip diameter allowance. The middle button displays the mean tip diameter
allowance. At the rst start of the tooth form, you will get the mean tip diameter allowance as a standard
feature.

Figure 6.53: Tip diameter allowance

Please Note: In case you have specied the lower and upper tip diameter allowance for the gear in the input
mask `Geometry' by using the `Lock' button, then the manually dened values appear here as lower and upper
tip diameter allowance.

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6.6 Input of Gear Tooth Prole and Gear Flank Modications

Manufacturing errors, misalignment in the assembly of the gears as well as displacement of the gears under
load lead to non-uniform load carrying across the facewidth and move a signicant concentration of load to
the tooth edges. Intentional deviations from the involute prole (prole modication) and from the theoretical
tooth trace (ank modication) are used to minimize the manufacturing inaccuracies and elastic deformations,
to improve the running behavior and to reduce the noise of the gear pair.

Figure 6.54: Input of prole and ank modications

There are dierent types of tooth corrections. Short and long linear or short and long circular tip and root relief
are typical tooth prole modications. Lead crowning and end relief are common ank modications. These
corrections tend to give better load distribution over the facewidth and can reduce the eects of misalignment.
Using prole or ank modication requires an appropriate degree of gear accuracy. The minimum required
gear manufacturing accuracy is DIN quality 7 or better. Design details should be based on a careful estimate
of the deformations and manufacturing deviations of the gearing.

6.6.1 Gear Tooth Prole Modication

In case of gear tooth prole modication, parts of the involute prole are changed to reduce the load in that
area. Prole modications help gears to run more quietly and to regulate transmission errors.

Figure 6.55: Gear tooth prole modication

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 187

Tip Relief and Root Relief

Tip relief is a modication whereby material is removed at the tips of the gear tooth. In case of root relief, a
small amount of material is removed near the root of the gear tooth. The modied tooth prole merges as
continuously as possible into the theoretical tooth prole. Prole crowning can be seen as a combination of
tip and root relief.

Figure 6.56: Tip relief and root relief

There are dierent types that can be chosen for the prole modication. A simple type of prole modication
is the linear tip relief on pinion and gear. However, it is also possible to execute only one gear with a tip and
root relief instead of both gears. The listbox allows to select linear and circular prole modication. The linear
relief results in the greatest material removal and thus the greatest relief in the eective ank area.

When determining the lengths of the prole correction, a distinction is made between short and long prole
modication. In case of long tip and root relief, the entire double contact area is corrected, while in the case
of short execution, only half of the double contact area is removed. Either long or short reliefs are used on a
gearing. The long prole modication is usually suitable for a quiet operation, while the short prole correction
has better load behavior. As long as the overlap ratio is sucient, a long prole correction is more suitable
for helical gearing.

Figure 6.57: Selection of tip relief

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Linear Tip and Root Relief

Figure 6.58: Linear tip relief Figure 6.59: Linear root relief

Circular Tip and Root Relief

Figure 6.60: Circular tip relief Figure 6.61: Circular root relief

The linear tip and root relief is executed in the eAssistant with a transition rounding from the modied to the
unmodied area. You can enter the start and end of the transition rounding in the corresponding input elds.
For circular relief, the input of the transition start and transition end is not required.

Figure 6.62: Selection of linear tip relief

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Linear Relief with Transition Radius

Figure 6.63: Linear relief with transition radius

In case you know the relief length, you can simply enter this value into the input eld. In case the length
is unknown, select `short' or `long' from the listbox. The eAssistant software determines the relief length
automatically. If a diameter is given on the drawing, it is possible to dene the diameter. Click the `d/l'
button on the right side to switch between the input for diameter or length.

Figure 6.64: Diameter and length

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 190

When you enable the checkbox `Use theoretical length of path of contact', then the theoretical path of contact
of a gear with a rack is used.

Figure 6.65: Use theoretical length of path of contact

Prole Crowning
Prole crowning can be seen as a combination of tip relief and root relief. Material is removed from the tip
and from the root of the tooth.

Figure 6.66: Prole modication

You can select symmetric prole crowning from the listbox and add a value for Cha to the input eld.

Figure 6.67: Symmetric modication

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6.6.2 Gear Flank Modications

Gear ank modications are intentional deviations from the theoretical tooth trace. Lead crowning and
end relief are typical gear ank modications and are advantageous for a better load distribution across the
facewidth of the gear. Both can compensate for misalignment so that the stresses do not rise at the tooth
ends.

Figure 6.68: Flank modication

End Relief
Due to mesh misalignments, an overloading of the tooth ends occurs. Therefore, end relief is used to protect
the tooth ends from overloading. Usually, the relief applied is the same at both ends of the teeth. In case
crown shaving and crown grinding are not possible, then end relief is recommended.

Figure 6.69: End relief (double-sided)

End relief can be applied to both tooth ends or to the left or right end of the tooth.

Figure 6.70: Selection of end relief

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End Relief: Double-sided, Left and Right Side

Figure 6.71: End relief (left side)

Figure 6.72: End relief (right side)

Figure 6.73: End relief (double-sided)

According to DIN 3990 Part 1, the height of end relief is calculated as follows:

- For through-hardened gears: Ce ≈ Fβxcv plus a manufacturing tolerance of 5 to 10 µm. Thus, by

analogy with Fβxcv (initial equivalent misalignment) in DIN 3990, Ce should be approximately:

Ce = fsh + 1, 5 · fHβ

- For surface hardened and nitrided gears: Ce ≈ 0, 5 · Fβxcv plus a manufacturing tolerance of 5 to 10
µm. Ce should be approximately:

Ce = 0, 5 · (fsh + 1, 5 · fHβ )

- When the gears are of such sti construction that fsh can for all practical purposes be neglected or
when the helices have been modied to compensate deformation, the following is appropriate:

Ce = fHβ

- 60% to 70% of the above values is appropriate for very accurate and reliable gears with high tangential
velocities.

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Figure 6.74: End relief

According to DIN 3990 Part 1, the width (or length) of end relief can be determined as follows:

- For approximately constant loading and higher tangential velocities:

le = smaller of the values 0, 1 · b or 1·m

- The following is appropriate for variable loading, low and average speeds:

bred = (0, 5 to 0, 7) · b

Lead Crowning
Lead crowning is a common way of crowning is the so-called lead crowning. This type is employed in order
to compensate for manufacturing deviations and load-induced deformations of the gears and in particular to
relieve the tooth-endloading.

Figure 6.75: Lead crowning

Gears are usually crowned symmetrically about the mid-facewidth and the tooth center is slightly thicker than
the tooth edges. The tooth anks of the gear have a slight outward bulge in its center area. It is possible to
select symmetrical and asymmetrical lead crowning from the listbox.

Figure 6.76: Symmetrical crowning Figure 6.77: Asymmetrical crowning

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 194

According to DIN 3990 Part 1, the height of lead crowning can be determined as follows:

Cb = 0, 5 · (fsh + 1, 5 · fHβ )

- When the gears are of such sti construction that fsh can for all practical purposes be neglected or
when the helices have been modied to compensate for deformation at mid-face width, the following
value can be substituted:

Cb = fHβ

- Subject to the restriction 10 ≤ Cb ≤ 25 µm plus a manufacturing tolerance of about 5 µm, 60% to

70% of the above values are adequate for extremely accurate and reliable high speed gears.

Figure 6.78: Height of lead crowning

6.7 Some Notes for Internal Gears

The eAssistant provides the calculation of internal gears.

Figure 6.79: Internal gear in eAssistant

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6. Single External and Internal Cylindrical Gears According to DIN 3960 and Other Standards 195

A special feature of spur and helical gears is their capability of being made in an internal form, in which an
internal gear mates with an ordinary external gear. An internal involute gear has either spur or helical teeth
cut on the inside of a ring.

General advantages of internal gears:

- The centre distance is less than for external gears and makes it desirable in some applications where
space is very limited.

- Good surface endurance due to a convex prole surface working against a concave surface. The teeth
of an internal gearing are relatively thick and strong. Hence, a low tooth root stress occurs.

General disadvantages of internal gears:

- The assembly has to be considered. Due to a small dierence between the number of teeth in the pinion
and gear, internal gears will not assemble radially, but axially.

- Fewer types of machine tools can produce internal gearings, usually a special tooling is required.

- Low velocity ratios are unsuitable and in many cases impossible because of interferences. Interferences
for internal gears occur far more frequently than for external gearings.

- The use of rack-type tools is not possible for internal gearings. Only a few number of teeth provides
dened features. Hence, a check regarding meshing interferences is necessary.

6.8 Input of Geometry Data for Internal Gears

Some inputs for the internal gears dier from the inputs for external gears. Nevertheless, internal gears can
be calculated very fast. The following provides the most important changes for the input of internal gears.

Figure 6.80: Internal gearing

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6.8.1 Direction of Helix Angle

For an external gearing a right-hand teeth and a left-hand teeth can only mesh correctly. An internal gear
has the same helix angle in degrees and the same hand its mating pinion. A right-hand pinion meshes with a
right-hand gear and vice-versa.

Figure 6.81: Direction of helix angle

6.8.2 Internal Helical Gears

Internal gears may be either spur or helical. Internal helical gearings have their advantages and disadvantages
just like external helical gearings.

Figure 6.82: Internal helical gear created in 3D

General advantages over internal spur gears are:

- The gear pair oers a more quietly operation.

- Gears are capable transmitting heavier loads.

- A smaller number of teeth is possible than for internal spur gears.

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General disadvantages are:

- Axial loads cannot be avoided.

- Much more dicult to produce than internal spur gears.

For the creation of an internal helical gear, only the helix angle β has to be considered.

Figure 6.83: Helix angle

6.8.3 Number of Teeth

Because the internal gear is reversed relative to the external gear, the tooth parts are also reversed relative
to an ordinary external gear. Tooth proportions and standards are the same as for external gears except that
the addendum of the gear is reduced to avoid trimming of the teeth in the fabrication process. The number
of teeth is negative for internal gears. The tip, reference and root diameter are negative as well. By default,
a negative number of teeth appears when you open the module for single internal cylindrical gears.

Figure 6.84: Negative number of teeth

6.8.4 Prole Shift

For an internal gear the tooth tip is enlarged by shifting towards the tooth centre and the tooth root is enlarged
by shifting away from the tooth centre. The internal gear is reversed relative to the external gear. A prole
shift of an internal gear is positive in direction to the tooth tip and negative in direction to the tooth root. It
applies for both internal and external gearings:

- The prole shift is positive, x · mn > 0, when the prole reference line is shifted from the reference circle
to the pitch circle.

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- The prole shift is negative, x · mn < 0, when the prole reference line is shifted from the reference
circle to the root circle.

A positive prole shift has the following inuences:

- The tooth root becomes thinner, the dedendum hf gets smaller, the addendum ha gets larger. Due to
a thick and strong tooth root, there is no danger of tooth root breakage.

- The tip circle and the root diameter increase, but get smaller according to the absolute value. Thereby,
a smaller internal gear is developed.

The positive prole shift may be disadvantageous for internal gears. It is comparable with a negative prole
shift for external gears. A negative prole shift has the following inuences:

- The tip circle and root diameter become smaller, but get larger according to the absolute value. A larger
internal gear is developed.

- The spacewidth at the tooth root gets smaller. For a smaller number of teeth there is a risk that a
pointed tooth tip occurs, the risk of notch eects increases.

Figure 6.85: Changing the tooth form using prole shift: Number of teeth z = -50; tooth 1: x = -1.5; tooth
2: x = 0; tooth 3: x = +0.5

Please Note: A negative prole shift may be advantageous for internal gears. In this case, it is comparable
with a positive prole shift for external gears. For external and internal gear pairs the impacts of positive and
negative prole shift are similar.

Figure 6.86: Input of prole shift

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6.9 Manufacturing Process for Internal Gears

For internal gears, the shaping process is the only basic method of tooth generation. Internal gears cannot be
hobbed. Only in some very special cases rack-type tools can be used. They can be shaped, milled or cast. In
small sizes they can be broached. Both helical and spur internals can be nished by shaving, grinding, lapping
or burnishing. In case the gear shaper cutter itself is generated by using a rack tool, then the mesh of the
gear anks is limited by the proper tooth tip of the gear rack.

Figure 6.87: Selection of the tool for the gear

An internal gear mates with an ordinary external gear and the number of teeth of the external gear must
be less than that of the gear to be cut for the internal gear. A rack prole can be a basic rack prole for
internal gears. But the basic rack prole cannot be used for generating internal gears. Internal gears are
produced by a gear shaper cutter. The number of teeth of the gear shaper cutter must be, according to the
amount, smaller than the number of teeth of the internal gear. The shaping is a continuous process. The cut-
ting tool is a spur shaper cutter. During the machining, tool and gear roll on each other. A feed motion occurs.

6.10 Meshing Interferences for Internal Gears

The gear mesh of an internal gear pair can be much more dicult than for external gears. Interferences
for internal gears occur far more frequently than for external gearings. In case a meshing interference takes
place, a warning is displayed in the message window. The following meshing interferences can appear in the
calculation module:

- Generation meshing interference (tooth root meshing interference on the gear shaper cutter)

- Feed meshing interference

6.10.1 Generation meshing interference

When shaper cutter and internal gear are in mesh, the generation meshing interference occurs due to tool
cutter action in generating teeth with low numbers of teeth. Because of this interference there is a loss of the
involute prole at the tooth tip. The term of the mesh and the load capacity are decreased.

6.10.2 Feed Meshing Interference

If the chosen gear shaper cutter is too large and the teeth of the internal gear are cut o in the feed direction,
a feed meshing interference occurs. If the sum of the prole shift is decreased, feed meshing interferences can
be avoided. It is also possible to adjust the number of teeth of the gear shaper cutter.

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6.11 Message Window

The calculation module provides a message window. This message window displays detailed information,
helpful hints or warnings about problems. One of the main benets of the program is that the software
provides suggestions for correcting errors during the data input. If you check the message window carefully
for any errors or warnings and follow the hints, you are able to nd a solution to quickly resolve calculation
problems.

Figure 6.88: Message window

6.12 Quick Info: Tooltip

The quick info tooltip provides additional information about all input elds and buttons. Move the mouse
pointer over the input eld or button, then you will get the additional information. This information will be
displayed in the quick info line.

Figure 6.89: Quick info line

6.13 Calculation Results

All results will be calculated during every input and will be displayed in the result panel. A recalculation
occurs after every data input. Any changes that are made to the user interface take eect immediately. In
case a minimum safety is not fullled, the result will be marked red. Press the Enter key or move to the
next input eld to complete the input. Alternatively, use the Tab key to jump from eld to eld or click
the `Calculate' button after every input. Your entries will be also conrmed and the calculation results will
displayed automatically.

Figure 6.90: Calculation results

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6.14 Documentation: Calculation Report

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.

Figure 6.91: Button `Report'

The calculation report contains a table of contents. You can navigate through the report via the table of
contents that provides links to the input values, results and gures. The report is available in HTML and PDF
format. Calculation reports, saved in HTML format, can be opened in a web browser or in Word for Windows.

Figure 6.92: Calculation report

You may also print or save the calculation report:

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the `Save' button.

- If you click on the symbol `Print', then you can print the report very easily.

- If you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on the
PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
Windows save dialog.

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6.15 How to Save the Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 6.93: Button `Save'

Before you can save the calculation to your computer, you need to activate the checkbox Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 6.94: Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 6.95: Save the calculation

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6.16 The Button `Redo' and `Undo'

The `Undo' button allows you to reset your inputs to an older state. The `Redo' button reverses the undo.

Figure 6.96: Button `Redo' and `Undo'

6.17 The Button `CAD'

The top menu bar of the eAssistant software provides the button `CAD'.

Figure 6.97: Button `CAD'

The eAssistant plugin for various CAD systems (e.g., SOLIDWORKS, Solid Edge, Autodesk Inventor) oers
a great way to combine calculation and design. On the basis of the eAssistant calculation, you can generate
single cylindrical gears in a 2D DXF format or create as a 3D part within seconds.

6.17.1 DXF Output for the Accurate Tooth Form

Click on the menu item `CAD ⇒ DXF Output'. Now you are able to create the accurate tooth form of any
involute gearing in the 2D DXF format. Use the various settings for the DXF output.

Figure 6.98: DXF output

For the DXF output the following options are possible:

- Output in normal section or transverse section (both options will be active when an helix angle is entered)

- DXF output with points

- DXF output with lines

- DXF output with polylines

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- DXF output with arcs

- Number of teeth

- Minimum point distance

- Input of a required layer name where the contour should be placed

- Save the DXF le including the header

Figure 6.99: Settings for the DXF output

When you have dened all settings, then click on the button `OK'. A standard Windows dialog is opened to
save the le.

Figure 6.100: Saving the DXF le

Now you can save the DXF le to your computer. Enter a name for the le and click on the button `Save'. It
is not necessary to specify the le extension. The le is identied automatically.

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6.17.2 STEP/IGES Format

Using this function allows to create the geometry of cylindrical gears as 3D CAD models in STEP or IGES
format. STEP as well as IGES are two standardised neutral le formats for CAD models. Almost every 3D
CAD system can import STEP les.

Figure 6.101: STEP format

The settings menu for the STEP and IGES output has a few dierent functions and allows to adjust the export
options as needed. The geometry can be generated as a solid model with one or all teeth or as a surface
model of the tooth space geometry. When exporting to a CAD system, you can also set the level of accuracy
to a desired value.

Figure 6.102: Inputs for STEP output

6.17.3 GDE Format

With the integration of the standardised GDE format into the modules for gears and involute splines, eAssistant
takes a step closer to a seamless data workow. GDE stands for Gear Data Exchange. This format, which is
dened in VDI/VDE guideline 2610, is already supported by many measuring machine manufacturers. With
the GDE format, geometries of cylindrical gears and involute splines can be loaded directly from the software
into the measuring machine. It only takes a few clicks to create a measuring program. This avoids transmission
errors and allows to work with standard measuring instructions.

Figure 6.103: GDE format

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6.17.4 eAssistant CAD-PlugIn

The eAssistant plugin for various CAD systems (e.g., SOLIDWORKS, Solid Edge, Autodesk Inventor) enables
you to combine calculation and design very easily and fast. Based on your eAssistant calculation, you can
generate external and internal spur and helical gears as a 3D part within seconds. Allowances, addendum
chamfer, prole shift and prole modications (tip and root relief ) are taken into consideration. A single menu
pick in the eAssistant software transfers the eAssistant calculation data to the CAD system. Based on these
parameters, the automatic creation of a 3D parametric model starts in the CAD system.

Figure 6.104: CAD plugin

The CAD model stores all features and dimensions as design parameters. The eAssistant calculation is linked
and associated to the part and can be opened at any time throughout the entire design phase. This is also
possible if one part contains dierent calculations. Click the button `CAD' and select the CAD plugin. Open
the CAD system and start the generation by clicking the integrated button `eAssistant'.

Please note: First you need to download and install the right CAD plugin for your CAD system. The plugin
is available on our web site www.eAssistant.eu. After installation, an integrated button called `eAssistant'
appears in the CAD system.

With just one click, the design table with all manufacturing details can be placed on the sheet. The appearance
and size of that table is individually congurable. There is no need to manually add all design table param-
eters to the drawing. For further information, please visit our web site www.eAssistant.eu or read the manual.

6.17.5 Manufacturing Data

The button `CAD ⇒ Manufacturing data' allows to save the manufacturing data to a text le.

Figure 6.105: Output of manufacturing data

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6.17.6 Coordinate Table

The gear tooth form geometry of a tooth space can be exported as a coordinate text le in transverse section
as well as in normal section.

Figure 6.106: Coordinate table

6.18 The Button `Options'

Click on the button `Options' in the top menu bar of the eAssistant software.

Figure 6.107: Button `Options'

This option allows you to change some general settings:

- Unit switch between the metric system and the U.S. customary unit system, the unit can also be changed
directly for each individual input value. Simply click on the label of the corresponding input eld and
select the unit from the context menu. You will see the change of the unit of measurement immediately
in the label of the input eld. The current eld value will be converted to the corresponding unit.

- Factor for minimal gear ring thickness: the factor can be specied by the user. This factor controls
the value for the largest possible bore diameter (inner diameter) for external gears and the smallest
possible outer diameter for internal gears. The default value 2.0 refers to forged gears (see main mask
`Geometry'), recommendations according to Schlecht (Maschinenelemente 2, 2010): gear ring thickness
for extreme lightweight constructions < 2 · m, cast constructions 5...8 · m, for welded constructions
3...5 · m.
- Number of decimal places for the calculation report

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Chapter 7

Rack/Pinion Pairings According to

DIN 3990, ISO 6336 and Other
Standards

7.1 Start the Calculation Module

Please login with your username and your password. To start the calculation module for gear racks, please
click the menu item `Gear calculation' on the left side and then select `Gear rack'.

Figure 7.1: General overview

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 209

This gear calculation module allows a simple calculation of the geometry and load capacity of rack-pinion
gear pairs. The geometry calculation is based on DIN 3960, DIN 3961, DIN 3964, DIN 3967, DIN 3977 and
DIN 868, the calculation of the load capacity is based on DIN 3990 Method B, ISO 6336 Method B and
ANSI/AGMA 2101-D04. Spur and helical involute pinions are possible to calculate. Prole shift, addendum
chamfer and allowances will be taken into consideration. The number of teeth or alternatively, the length of
the gear rack can be specied. Rectangular or round cross section gear rack designs are possible.

Figure 7.2: Gear rack with pinion

In theory a gear rack is a section of a spur gear with an innitely large pitch diameter, resulting in an involute
prole that is essentially a straight line. Gear-rack pairings are important components in that they are a
means of converting rotational motion into linear motion and vice versa. The rack can be used to determine
the basic gear parameters. Gear racks mate with an external spur gear (pinion) and can be both spur and helical.

7.2 Input of Geometry Data

All important calculation results will be calculated during every input and will be displayed in the result panel.
A recalculation occurs after every data input. Any changes that are made to the user interface take eect
immediately. Press the Enter key or move to the next input eld to complete the input. Alternatively, use
the Tab key to jump from eld to eld or click the `Calculate' button after every input. Your entries will be
also conrmed and the calculation results will displayed automatically. If the result exceeds certain values, the
result will be marked red.

7.2.1 Normal Module

The normal module mn is one of the basic parameters in the gear geometry and describes the size of a gear.
The module is dened as the ratio of the pitch diameter to the number of teeth of a gear. Note that the
larger the module the larger the teeth. The value of the module is dened in millimeters. In order to limit the
number of the gears, the module has been standardised in preferred series 1 and 2 (see following tables). The
calculation with the eAssistant software is possible with any modules including several decimal places.

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Series of Modules in mm According to DIN 780 Series 1 (Part 1)

0.05 0.06 0.08 0.10 0.12 0.16 0.20 0.25

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Series of Modules in mm According to DIN 780 Series 1 (Part 2)

1.25 1.5 2 2.5 3 4 5 6 8

10 12 16 20 25 32 40 50 60

Series of Modules in mm According to DIN 780 Series 2 (Part 1)

0,055 0.07 0.09 0.11 0.14 0.18 0.22 0.28 0.35

0.45 0.55 0.65 0.75 0.85 0.95 1,125 1,375 1.75

Series of Modules in mm According to DIN 780 Series 2 (Part 2)

2.25 2.75 3.5 4.5 5.5 7 9 11

14 18 22 28 36 45 55 70

7.2.2 Pressure Angle

The pressure angle is the angle between the line-of-action and the common tangent to the pitch circles. With
an increasing distance from the base circle, the prole angles αy increase too. The most common pressure
angle now in use for spur gears is20◦ . This pressure angle is usually preferred due to its stronger tooth shape
and reduced undercutting. The 25◦ pressure angle has the highest load-carrying ability, but is more sensitive
to center-distance variation and hence runs less quietly. The choice is dependent on the application. The
default startup setting for the pressure angle is set to 20◦ .

7.2.3 Helix Angle

For spur gears the helix angle is β = 0◦ , for helical gears the angle β is up to 45◦ due to the fact that the
◦
teeth for a helical gear are inclined by the angle. 45 is also the maximum value that you can enter into the
input eld for the helix angle. For an external gearing a right-hand teeth and a left-hand teeth can only mesh
correctly. For internal gearings pinion and gear must have the same direction.

Figure 7.3: Racks with spur and helical teeth

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Please note: Calculation with helix angle greater than 45 degree is possible. If you want to use this option,
please contact us.

7.2.4 Centre Distance

The centre distance a is the distance between the axes. In case of changing the normal module mn , the centre
distance is determined automatically.

Figure 7.4: Centre distance

The centre distance can be determined from the prole shift of the pinion and vice versa. It is also possible to
specify the centre distance manually. This determines the prole shift coecient of the pinion. Click the `Lock'
button next to the input eld of the prole shift coecient. The input eld for the prole shift coecient will
be disabled and you can enter a value for the centre distance.

Figure 7.5: Centre distance

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7.2.5 Helix Direction

After adding an helix angle, you can specify the helix direction of pinion and gear rack. Please keep in mind
that both gears of a meshed pair must have the same helix angle β. However, the helix directions must be
opposite, i.e., a left-hand mates with a right-hand helix.

Figure 7.6: Helical gear rack with pinion

Select the option `left' for the pinion. That means: Pinion is left-handed, pinion is right-handed.

Figure 7.7: Option

Select the option `left' for the gear rack. That means: Pinion is right-handed, gear rack is left-handed.

Figure 7.8: Option

7.2.6 Number of Teeth

The number of teeth of a gear describes the number of the teeth on the full rim. The number of teeth is
positive for external gears and negative for internal gears. Please note that the smaller the number of teeth
the larger the inuence of the prole shift.

Please note: A calculation with non-integer number of teeth, i.e., number of teeth with decimal places. If
you want to use this option, please contact us.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 213

Click the `Calculator' button to open the window and to dimension the length or, alternatively, the number of
teeth of the gear rack.

Figure 7.9: Button for the dimensioning of the gear rack length and number of teeth

Enter the number of teeth and conrm your input by clicking the Enter key. The optimal length of the gear
rack is shown. Alternatively, you can specify the length of the gear rack in order to get a recommendation for
the number of teeth of the gear rack. To do so, click the `Lock button' to enable the input eld and enter a
value. Conrm the value with Enter. The number of teeth of the gear rack is automatically determined.

Figure 7.10: Dimensioning of gear rack length and number of teeth

7.2.7 Facewidth
The facewidth b is the length of the gear teeth as measured along a line parallel to the gear axis.

Figure 7.11: Facewidth

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The following table shows some additional information about the facewidth b as well as minimum number of
teeth z.

Standard Values for the Facewidth b and Minimum Number of Teeth z 1

Gears on rigid shafts, that run in roller or excellent plain bearings,
b ≤ 30 . . . 40 · m
Teeth, machine-cut rigid substructure

Gears in usual gear boxes, roller or plain bearings b ≤ 25 · m

Gears on steel constructions, beams and suchlike b ≤ 15 · m
Gears with excellent bearing in high duty gearings b ≤ 2 · d1
Teeth, cast roughly Overhung gears b ≤ 10 · m
Gears with high circumferential velocity(υ > 4 m/s) and considerable z1 ≥ 16
power, when εα > 1.5
Gears with mean circumferential velocity(υ = 0.8 . . . 4 m/s) z1 ≥ 12
Gears with low circumferential velocity(υ < 0.8 m/s) or for low power for subor-
z1 ≥ 10
dinated purposes

Basically external gearings z1 + z2 ≥ 24

Basically internal gearings z2 ≥ z1 + 10
1 from: Karl-Heinz Decker: Maschinenelemente: Gestaltung und Berechnung, 1992, p. 506, table 23.2

7.2.8 Prole Shift on the Pinion

The tooth form of a gear rack cannot be changed by the prole shift. The prole shift is only applied to the
pinion. Prole-shifted gears can be meshed with the gear rack. A shift in the utilized prole range compared to
the normal position is called the prole shift. The prole shift aects the tooth form because the tool is shifted
by the value xm towards or away from the tip circle. A prole shift is used to avoid meshing interferences.
The calculation of the tip diameter da and root diameter df includes the prole shift coecient x. According
to DIN 3960 the prole shift is

- positive if the prole reference line is shifted from the reference circle towards the tip circle,

- negative if the prole reference line is shifted from the reference circle towards the root circle.

Figure 7.12: Change the tooth form with the prole shift: number of teeth z = 10; tooth 1: x = 0.5; tooth
2: x = 0; tooth 3: x = -0.5

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 215

The prole shift of the pinion can be freely chosen. Please note that no meshing interferences occur. Please
note that no meshing interferences occur. In case meshing interferences occur, you will get an appropriate
message in the message window.

Figure 7.13: Prole shift on the pinion

Characteristics of the Prole Shift

- A positive prole shift increases the tooth thickness, a negative prole shift decreases the tooth thickness.

- With an increasing positive prole shift, the tooth tip thickness and the root llet become smaller, the
axle load and the load capacity increase. This advantage occurs especially for a smaller number of teeth.

- The minimum permitted tooth tip thickness determines the limit for a very large prole shift, in particular
for very small number of teeth.

- The prole shift aects the operating pressure angle as well as the load capacity.

- For a small number of teeth and with a negative prole shift, an undercut becomes a problem (see above
gure). The undercut weakens the tooth root and a part of the tooth ank is cut o.

Here you have the option of dimensioning or optimizing the prole shift coecient. To optimize the prole
shift coecient, click on the `Calculator' button. In addition to the option `user-dened input', the following
two options are available for selection: `Geometric minimum' and `Geometric maximum'. Here the possible
limits of the prole shift, i.e. the minimum and maximum prole shift that can be executed with respect to
the undercut limit and topland limit.

Figure 7.14: Dimensioning of the prole shift

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7.2.9 Tip Diameter

The tip diameter da depends on the module and will be determined by the program automatically. If you
change the prole shift, the tip diameter will change, too. There is the possibility to enable the tip circle
using the `Lock' button. Now you can add and modify the tip diameter very easily. Please note that the tip
diameter has an inuence on the modication of the tip diameter. Click on the button again to disable the
input eld. The value is determined again according to DIN. In case you use a special tool, the tip diameter can
be changed by a tool customization. Find out more about the tool data in the section `The input of tool data'.

7.2.10 Tip Diameter Allowance

The tip diameter allowance is determined according to DIN. Click on the `Lock' button to enable the input
eld and enter your own value. If your values are out of range of the DIN, you will get an information in
the message window. Click on the `Lock' button and the input eld is disabled again. The allowances are
determined according to DIN.

Figure 7.15: Enable tip diameter and tip diameter allowance

7.2.11 Modication of Tip Diameter

The modication of the tip diameter k is automatically determined by the program that a sucient tip
clearance is available. For external gears the modication of the tip diameter is k ≤ 0. Click on the `Lock'
button to enable the input eld and enter your own value. Such a modication of the tip diameter has an
eect on the tip diameter.

Figure 7.16: Enable modication of tip diameter

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7.2.12 Tip Clearance

Clearance c is the distance between the root circle of a gear and the addendum circle of its mate. A certain
clearance between the gears is necessary for a smooth operation without jamming.

Figure 7.17: Tip clearance c

A distinction is made between two dierent kind of clearances. There is the tip clearance c and the backlash j .
Standard gears have got a basic rack prole with a addendum coecient ha = m or a tool basic rack prole
with hf p = m. The dedendum coecient hf of the basic rack prole or the addendum coecient hap of the
tool basic rack prole has to be larger due to ensure that tip and root circle of the gears are not in contact.

Backlash j
If the gears are of standard tooth proportion design and operate on standard center distance, they would
function ideally with neither backlash nor jamming. The general purpose of backlash is to prevent gears from
jamming and making contact on both sides of their teeth simultaneously. Any error in machining which tends
to increase the possibility of jamming makes it necessary to increase the amount of backlash. Consequently,
the smaller the amount of backlash, the more accurate must be the machining of the gears. Runout of both
gears, errors in prole, pitch, tooth thickness, helix angle and centre distance - all are factors to consider in
the specication of the amount of backlash. In order to obtain the amount of backlash desired, it is necessary
to change the tooth thickness or tooth space allowances (please see also section 7.4.8 `Backlash Normal Plane').

7.2.13 Root Diameter and Allowances of Root

The root diameter df depends upon the module, the prole shift and addendum coecient of the basic rack
prole. The root diameter is determined by the program. Therefore, the root diameter occurs as a result of
the calculation.

The allowances of root result from your calculation and will be determined automatically. The allowances
depend upon the tooth thickness allowances. For instance, if you enter the value `0' for a gear, then the
allowances of root become `0' for this gear as well.

Figure 7.18: Root diameter and allowances of root

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7.2.14 Gear Rack Height

Enter the height of the gear rack here. Rectangular or round cross section gear rack designs are possible.

Figure 7.19: Geometry of the basic body as rectangular or round cross section

Use the button `hz /rz ' to switch between the gear rack height hz and the gear rack radius rz . An illustration
appears right next to the button.

Figure 7.20: Gear rack height

7.2.15 Addendum Chamfer

The tooth ends of a gear are often rounded or chamfered. A chamfer is a small angled surface added on
the end of a shaft along an edge. For the calculation you can consider the addendum chamfer. Meshing
interferences can be removed by the addendum chamfer. As an alternative for the addendum chamfer, it is
possible to dene a tip corner radius instead of the addendum chamfer. Click the button to choose between
addendum chamfer and tip corner radius. The tip corner radius can be specied either as a radial size or as a
radius.

Figure 7.21: Input of addendum chamfer or tip corner radius

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 219

Please Note: If you dene the geometry of the gear pair, you are able to look at the tooth form. Click on
the button `Tooth form' and select `Total view' or `Detail view' (nd more information on the tooth form and
its functions in section 7.5 `Representation of Gear Tooth Form'). Click the button `Geometry' and you get
to the geometry input again.

Figure 7.22: Addendum chamfer

As an alternative to the addendum chamfer, a tip corner radius can be specied. This can be dened either
as a radial amount or directly as a radius. The selection is marked by the colored arrow. The radius is entered
directly for the tip radius, the radial amount is entered for the tip radius (Rad.). If you enter the tip radius
directly as a value, you will receive the corresponding radial amount in the calculation report. In the case of
tip corner radius or addendum chamfer, the tip form diameter is smaller than the tip circle diameter by twice
the radial amount hK . Please see section ?? to nd an illustration.

7.2.16 Inner Diameter for the Pinion

Click the button `Details' to open additional input options, for example the input of the inner diameter.

Figure 7.23: Inner diameter

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 220

The inner diameter can only be dened for the pinion. It should be kept in mind that the inner diameter
has to be smaller than the root diameter df . In case the inner diameter is larger than df , then the program
automatically corrects the value and enters the maximum value for the inner diameter. An appropriate message
appears in the message window.

7.2.17 Web Width

The web width can be considered here. The web width is shown in the gure next to the input eld. There
is the possibility to modify the web width by using the `Lock' button.

The `Lock' button is still disabled. Enter the values for the inner or outer diameter into the input eld. Then
the `Lock' button is enabled and the web width gets the same value as the facewidth. In case the web width
is smaller than the facewidth, then the gear body stiness is aected due to the gear body coecient CR .
The tooth spring stiness changes which aects again the load capacity.

Figure 7.24: Web width

7.2.18 Chamfer
The chamfer can be considered. This reduces the calculated facewidth for the calculation of the load capacity
of the tooth root and tooth ank.

Figure 7.25: Chamfer

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7.3 Input of Tool Data

For the selection of the manufacturing process you have to consider the material, size of the gear, quantity, gear
type (external or internal gears) and accuracy. The many methods of making gear teeth must be considered
as well. eAssistant distinguishes between gear-tooth cutting and gear hobbing.

Figure 7.26: Input mask for tool data

Please note: If you want to add some own notes, comments or a description, then use the comment line.

7.3.1 Tool
The most important manufacturing processes are gear hobbing and gear shaping. Select either the tool `Hob'
or `Gear shaper cutter' by clicking the listbox. A `Constructed involute' is also available. Basically, the selection
of the tool depends on the gear type (external or internal gears). The external gears can be produced by cutting
wherein the gear cutting tool is a hob.

Figure 7.27: Selection of tool

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 222

Gear Hobbing
The hobbing is the most widely used method of cutting gear teeth. The hobbing process is quite advantageous
in cutting gears with very wide facewidth. A very high degree of tooth-spacing accuracy can be obtained with
hobbing. With regard to accuracy, hobbing is superior to the other cutting processes. A wide variety of sizes
and kinds of hobbing machines are used. The rotating hob has a series of rack teeth arranged in a spiral
around the outside of a cylinder, so it cuts several gear teeth at one time. To generate the full width of the
gear, the hob slowly traverses the face of the gear as it rotates. Thus, the hob has a basic rotary motion and
an unidirectional traverse at right angles. Both movements are relatively simple to eect, resulting in a very
accurate process.

Field of Application of the Hob:

- Recommended for gears with very wide facewidth

- Recommended for external spur and helical gears up to module `40' (Please keep in mind: it is an
expensive tool for large modules)

- Recommended for all basic rack proles

- The helix angle is arbitrary.

Figure 7.28: Hob and gear shaper cutter

Gear Shaping
The shaping process is a gear-cutting method in which the cutting tool is shaped like a pinion. If a gear is
provided with cutting clearance and is hardened, it may be used as a generating tool in a gear shaper. The
cutter reciprocates while it and the gear blank are rotated together at the angular-velocity ratio corresponding
to the number of teeth on the cutter and the gear. The teeth on the gear cutter are appropriately relieved
to form cutting edges on one face. Although the shaping process is not suitable for the direct cutting of
ultra-precision gears and generally is not as highly rated as hobbing, it can produce precision quality gears.
Usually it is a more rapid process than hobbing. Two outstanding features of shaping involve shouldered and
internal gears. For internal gears, the shaping process is the only basic method of tooth generation.

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Field of Application of the Gear Shaper Cutter:

- Recommended for internal and external spur and helical gears

- Racks

- Special gearings, e.g., splined shaft connections, face or chain gears

Constructed Involute
In addition to the hob and the gear shaper cutter, you can also select the entry `Constructed involute' as a
tool. In case internal gears cannot be shaped with a gear shaper cutter, the tooth form calculation is still
possible by using the constructed involute. This specically applies for applications in the precision mechanics.
This method allows a generation of the tooth form with a constant root llet radius.

Figure 7.29: Constructed involute

Representation of Hob and Gear Shaper Cutter

The representation shows either the hob basic rack prole or the gear shaper cutter tooth prole. The radio
buttons enable you to choose one of the graphical representation.

Figure 7.30: Tool

7.3.2 Standard Basic Rack Tooth Prole

To mesh two gears with each other, the parameters have to be coordinated. The standard basic rack tooth
prole is standardized in DIN 867. A gear with an innite number of teeth will have straight lines for both
the pitch and the base circles. The involute prole will be a straight line. The rack can be used to determine
the basic parameters. Racks can be both spur and helical. A rack will mesh with all gears of the same pitch.
The pressure angle and the gears pitch radius remain constant regardless of changes in the relative position of
the gear and rack. The tool standard basic rack prole is the counter prole of the standard basic rack tooth
prole.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 224

The following standard basic rack proles are available for your calculation. Choose your prole from the
listbox.

Figure 7.31: Listbox for the basic rack prole

- ISO 53 Prole A: is recommended for gears transmitting high torques

- ISO 53 Prole B: is recommended for normal service

- ISO 53 Prole C: is recommended for normal service, type C may be applied for manufacturing with
some standard hobs.

- ISO 53 Prole D: is recommended for high-precision gears transmitting high torques and consequently
with tooth anks nished by grinding or shaving. Care should be taken to avoid creating notches in the
llet during nishing which could create stress concentrations.

- DIN 3972 Prole I, II, III, IV

- Prole 1 DIN 867

- Prole 2 DIN 867

- Prole 3 DIN 867

- Prole 4 DIN 867

In addition to the standard basic rack proles, you can also select a protuberance tool. When part of the
involute prole of a gear tooth is cut away near its base, the tooth is said to be undercut. By using a
protuberance tool an undercut near the root can be generated. Grinding notches at the tooth ank can
be avoided during the grinding. That provides relief for subsequent nishing operations (see section 7.3.5
`Protuberance').

Figure 7.32: Selection of the protuberance tools

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 225

You can select the following proles:

◦
- Prot 1.4-6 /0,085

◦
- Prot 1.5-6 0.02

◦
- Prot 1.6-6 /0.02

◦
- Prot 1.4-8 /0.04

◦
- Prot 1.4-8 /0,066

◦
- Prot 1.4-10 /0.05

◦
- Prot 1.5-10 /0.02

◦
- Prot 1.6-10 /0.02

◦
- Prot 1.25-14 /0,024

Please Note: If you select `user dened input', then the input elds for the edge radius, the addendum
coecient and the dedendum coecient are activated. Now you can modify the basic rack prole.

Figure 7.33: Own input

Determination of the Basic Rack Prole

In case you use special tools, the eAssistant software oers an easy and comfortable solution. The basic rack
prole can be determined by clicking the `Calculator' button. Here you can change the tip circle and the root
diameter for gear 1, gear 2 and gear 3. Conrm your entries with the button `OK'. The listbox for the basic
rack proles displays then `user dened input'. The modication of the tip diameter is set to '0'.

Figure 7.34: Tool dimensioning

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 226

7.3.3 Tip Form

For the tip form you can choose between `Full radius' and `Radius with straight line'. Normally `Radius with
straight line' is used.

Figure 7.35: Listbox for tip form

7.3.4 Semi Topping Flank and Topping

With the denition of the semi topping ank, corresponding hobs can then be specied. These generate an
addendum chamfer during the cutting process. The option `Topping' allows to dene the tip diameter directly
with the dedendum coecient of the tool, making it impossible to subsequently modiying the tip diameter.
The result, at the same time, will be tip diameter allowances analogous to the root diameter allowances directly
from the tooth thickness allowances. The eAssistant 3D CAD plugins for various CAD systems support the
function and the semi topping ank can be considered in the 3D CAD model.

Figure 7.36: Semi topping ank

7.3.5 Protuberance
Undercut may be deliberately introduced to facilitate nishing operations. Undercut is the loss of prole in
the vicinity of involute start at the base circle due to tool cutter action in generating teeth with low numbers
of teeth. The protuberance cuts an undercut at the root of the gear tooth. The protuberance design is also
used in some cases to permit the sides of gear teeth to be ground without having to grind the root llet.

Determination of the Amount of the Protuberance from the Height of the Protuberance Flank
The following equation determines the amount of the protuberance. In case the height of the protuberance
ank is given and not the amount of the protuberance, the amount of the protuberance may be calculated by
this equation.

(h∗prP 0 − ρ∗aP 0 · (1 − sin(αp ))) · sin(αn − αp )

prP∗ 0 = + ρ∗aP 0 · (1 − cos(αn − αp ))
cos(αp )

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 227

The following gure shows a representation:

Figure 7.37: Height of the protuberance ank

To avoid grinding steps, a deviation in the tooth root area of the prole is a common and allowed method.
Because of a grinding stock allowance, an undercut must be allowed. Hence, a larger tooth root thickness is
necessary. The following table shows some determination of the undercut dependent upon the module.

Undercut spr for Ground Gears Dependent upon Module2

Module Allowance Size of Protuberance Addendum Edge Radius

m q Undercut spr prP∗ 0 h∗aP 0 ρ∗aP 0

2 0,160 0,100 0,260 2,900 0,500

2,5 0,170 0,110 0,280 3,625 0,625

3 0,180 0,120 0,300 4,350 0,750

4 0,200 0,140 0,340 5,800 1,000

5 0,220 0,160 0,380 7,250 1,250

6 0,240 0,180 0,420 8,700 1,500

7 0,260 0,200 0,460 10,150 1,7500

2 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag, Muenchen, Wien, 2nd ed. 2010, p. 68, table 2.1/2

7.3.6 Machining Allowance

You can consider an allowance for the tooth ank. The tool provides an allowance q on the ank and/or root
for the pre-cutting tool. The allowance is the smallest distance between the involutes and the pre-machining
having the same root diameter. In case you select the tool basic rack prole with protuberance, the allowance
refers to the tooth ank.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 228

If the allowance of the tool basic rack prole is selected without protuberance, then tooth ank and tooth
root get the allowance.

Figure 7.38: The eAssistant software provides the following allowances for the grinding of a gear: a) Constant
allowance with bottom of the tooth space, b) Protuberance: Cutter tooth prole is built up on the tip to
provide an undercut near the root of the gear being generated.

Figure 7.39: Input of machining allowance

Maximum Machining Allowances3

Allowance per Tooth Flank Manufacturing Process

< 0.05 (0.10) mm Finishing operation by cold rolling, gear shaving, hon-
ing, lapping

0.05 to 0.5 (1.5) mm Grinding, prole grinding, (honing)

> 0.5 mm, pre-cutting Primary shaping, forming, cutting with geometrically
determined edges except shaving, grinding and prole
grinding in special cases

3 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag, Muenchen, Wien, 1996, p. 638

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 229

7.4 Input of Data for the Determination of Allowances

A manufacturing of work-pieces with accurate nominal dimensions is impossible. Hence, a deviation from the
nominal size has to be allowed. For a lot of applications the gear and the pinion of a pair must be independently
manufactured and meshed without any modications. That means, the parts have to be separately replaceable.
In addition to DIN 3961 for gear tolerances/gear qualities, DIN 58405 for precision engineering as well as ISO
1328 and ANSI/AGMA 2015 are available.

Figure 7.40: Input of allowances

7.4.1 Gear Quality

The choice of the right toothing quality is determined by economical aspects depending upon the intended
purpose and manufacturing process. In all elds of gearing, the control of gear accuracy is essential. Several
classes or grades of accuracy can be set. 12 grades (12 to 1) are dened according to DIN standards. High
accuracy grades can be set for a long-life, high speed gears. Lower accuracy grades will cover medium or
slow-speed grades. Accuracy grade `1' describes the highest possible accuracy, `12' a very low accuracy. The
gear accuracy `1 to 4' is mainly used for master gears, quality `5 to 12' is used for gear wheels (gure from:
Niemann, G.: Maschinenelemente, Vol. 2, Getriebe allgemein, Zahnradgetriebe-Grundlagen, Stirnradgetriebe,
1989, p. 73, gure 21.4/1).

Figure 7.41: Tolerances according to the manufacturing process

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 230

Select the appropriate quality between 1 and 12 by using the following listbox.

Figure 7.42: Listbox for the selection of quality

The following table provides some reference values for the selection of the quality, tolerances for gearings made
of metal and plastics:

Toothing Made of Metal4

ν Machining Quality Tolerance Sequence
to m/s of Tooth Flanks (Accuracy) DIN 3967
0.8 Cast, raw 12 2x30

0.8 Rough-machined 11 or 10 29 or 28

2 Finish milled 9 27

4 Finish milled 8 26

8 Fine nished 7 25

12 Shaved or ground 6 24

20 Precision-ground 5 23

40 Precision-machined 4 or 3 22

60 Precision-machined 3 22 or 21

Toothing Made of Injection Molding Plastics

Application d Quality Tolerance Sequence
in mm (Accuracy) DIN 3967
Gearings with high requirements to 10 9 27

Gearings with high requirements 10 to 50 10 28

Gearings with normal requirements 10 to 50 11 29

Gearings with low requirements to 280 12 2 x 30

Toothing made of plastic manufactured by cutting

Gearings with high requirements to 10 8 25 to 27

Gearings with high requirements 10 to 50 9 26 to 28

Gearings with normal requirements to 50 10 27, 28

Gearings with normal requirements 50 to 125 11 27, 28

Gearings with low requirements to 280 12 28

4 from: Karl-Heinz Decker: Maschinenelemente: Gestaltung und Berechnung, 1992, p.

512, table 23.3

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For the gear tolerances/gear qualities, DIN 58405 for precision engineering as well as ISO 1328 and ANSI/AGMA
2015 are also available. For ISO 1328 and ANSI/AGMA 2015, two qualities can be selected in each case. The
rst quality is comparable with the tolerances permitted according to DIN 3961, the second value inuences
the radial composite deviation as well as the roll deviations.

7.4.2 Backlash Allowance and Tolerance Sequence

The system for gearings is very similar to the DIN system of ts and tolerances. For the system of ts for
gear transmissions letters are used to indicate the deviation from basic (nominal) size, a number denes the
width. There are clearance ts for gearings, therefore, lower case characters `h' to `a' appear. If you select
the entry `user dened input', the input eld for the tooth thickness allowances is enabled and you can dene
your individual values.

Figure 7.43: Own input

7.4.3 Tooth Thickness Allowance

One of the most important criteria of gear quality is the specication and control of tooth thickness. The
magnitude of tooth thickness and its tolerance is a direct measure of backlash when the gear is assembled
with its mate. Dimensional changes, due to thermal expansion, do not allow a zero-backlash assembly. The
tooth thickness allowance has to be determined that no jamming occurs. To prevent that jamming of gears
during the operation, it is necessary to decrease tooth thickness by a minimum amount (Asne and Asn ).

Figure 7.44: Lower and upper tooth thickness allowances

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 232

The tooth thickness allowances for teeth of external and internal gearings have to be negative. Then a backlash
occurs (nd more information on the backlash in section 10.4.8 `Backlash Normal Plane'). The eAssistant
software oers the possibility to specify the tooth thickness allowances based on measured data or given test
dimensions. Click on the `Calculator' button.

Figure 7.45: `Calculator' button

A new window is opened.

Figure 7.46: Calculation of tooth thickness allowances

Activate pinion and gear rack and enter the input values. Conrm with the button `OK'. The `Lock' button
next to the input eld for the tooth space allowances is enabled. Now you can change the tooth space al-
lowances.

7.4.4 Tooth Space Allowance

The tooth space allowance AW is the dierence between the actual dimension and the nominal dimension of
the span measurement W k. The actual measurement of the span measurement gets smaller for external gears
by negative allowances for a zero-backlash assembly. The upper and lower tooth space allowance are displayed
as well. For an own input of the tooth thickness allowances, the tooth space allowances can be dened as
well. The `Lock' button next to the input eld of the tooth space allowances is enabled. Therefore, you can
change the tooth space allowances.

Figure 7.47: Tooth space allowance for pinion and gear rack

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7.4.5 Measurement of Tooth Thickness

The tooth thickness of a gear may be measured directly with calipers or it may be determined indirectly by
diameter pins. The sizing of gears may be controlled by double-ank composite checks and centre distance
settings corresponding to maximum and minimum tooth thickness specications. Dierent measurement
methods are used:

- At pitch circle (chordal),

- Span measurement across several teeth,

- Measurement over pins or balls that are placed in diametrically opposed tooth spaces,

- Check of the centre distance allowance with zero-backlash engagement by using a master gear in a ank
roll tester.

In the following you get some information on the widely used measurement methods:

- Span measurement Wk
- Measurement by diameter over balls or pins, the measurement by using balls and pins

Span Measurement across Several Teeth

Span measurement Wk is the measurement of the distance across several teeth in a normal plane. As long as
the measuring device has parallel measuring surfaces that contact on an unmodied portion of the involute,
the measurement will be along a line tangent to the base cylinder. It is a widely used method for gauging the
tooth thickness by using the span measurement. The tooth thickness of spur or helical gears is often measured
with calipers. An advantage is that the dimensions can be inuenced during the manufacturing.

Figure 7.48: Span measurement

The calculation program determines the number of teeth for the span measurement (number of teeth across
the span measurement has to be gauged). By using the `Lock' button you are able to activate the input eld
and you can enter your own input value. If you click the button again, the previous input value appears.

Figure 7.49: Number of teeth for the span measurement

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Tooth Thickness Measurement by Diameter over Pins or Balls

The tooth thickness is often checked by measurement over pins MdR or balls MdK . The pins or balls are
placed in diametrically opposed tooth spaces (even number of teeth) or nearest to it (odd number of teeth).
Measurement over pins is the measurement of the distance taken over a pin positioned in a tooth space and
a reference surface. The reference surface may be the reference axis of the gear, a datum surface or either
one or two pins positioned in the tooth space or spaces opposite the rst. The measurement over pins is only
used for spur gears and external helical gears. For the measurement values a distinction is made between:

- Measurement over balls MdK

- Measurement over pins MdR
- Measurement over pins for a spur gear

- Measurement over pins for external helical gears with even number of teeth

- Measurement over pins for external helical gears with odd number of teeth

For an external gear the measurement over balls MdK is the largest outer measure. The two balls are placed
in diametrically opposed tooth spaces. The balls have to be in the same plane perpendicular to a gear axis.
For an internal gear (see gure: `Internal spur gear with odd number of teeth') the measurement over balls is
the smallest inner measure between the balls. DM is the diameter of ball or pin. The internal gear is generally
checked for tooth thickness with measuring pins, like the external gear. However, the measurement is made
between the pins instead of over pins.

Measurement over balls: External spur gear with even num-

ber of teeth

Measurement over balls: External spur gear with odd num-

ber of teeth

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 235

Measurement over balls: Internal spur gear with odd num-

ber of teeth

The eAssistant software already species the diameter of ball or pin for the test dimensions. Enable the input
eld by clicking the `Lock' button. Enter your own input value for the diameter. If you click on the button
once again, the previous input value appears.

Figure 7.50: Diameter of ball or pin

Please Note: In the calculation report you can nd all results for the span measurement or measurement
over balls and pins in section `Test dimensions'.

7.4.6 Tolerance Field for Centre Distance

The general purpose of backlash is to prevent gears from jamming and making contact on both sides of their
teeth simultaneously. The center distance and the gear ts have an important inuence on the backlash.
The gear t selection denes the tolerances of the centre distance with the backlash. The gear t selection
provides only one tolerance eld. The allowances are indicated for the `JS' eld. These conform to the ISO
basic tolerances. The backlash is dependent upon the tooth thickness allowances, the tooth space allowances
and the centre distance. Hence, if you change the centre distance, then the backlash is changed, too.

Figure 7.51: Tolerance eld for the centre distance

Select the option `user dened input' from the listbox. Now you are able to enter your own centre distance
allowances. Conrm your entries with the Enter key. The backlashes are automatically determined.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 236

7.4.7 Centre Distance Allowance

The centre distance allowance Aa is the allowed deviation of the centre distance from the nominal centre
distance. The allowances are indicated with ± to get no improper major allowances from the nominal centre
distances with gears having several axes.

Figure 7.52: Centre distance allowance

7.4.8 Backlash Normal Plane

A gear t has to be determined, so that two gears can be meshed. For that, a proper backlash must be provided
for the mesh to avoid jamming of the gears. The eAssistant software oers three dierent backlashes: the
backlash normal plane, the backlash pitch diameter and the radial backlash.

Figure 7.53: Backlash normal plane

Besides errors in manufacturing and assembling, the variation in backlash will depend considerably on the
tooth thickness tolerances and centre distance of the gears. The DIN system represents a standard centre
distance and provides the backlash by changing the tooth thickness. The backlash between the meshing teeth
adjusts the deviations of the tooth thicknesses, centre distance and tooth form using the tooth thickness
Asni and tooth space allowances Asne . The lowest tooth thickness allowance Asni indicates the maximum

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 237

backlash, the upper tooth thickness allowance indicates the minimum backlash Asne . In addition to the tooth
thickness allowance and centre distance allowance, errors in prole and pitch are also factors to consider in
the specication of the amount of backlash.

Please note: The backlash depends also on thermal expansions, deformation of elementes and displacement
of casing. These impacts must be considered for the determination of the tooth thickness.

7.4.9 Backlash Pitch Diameter

The backlash pitch diameter jt refers to the backlash at the pitch circle. The backlash pitch diameter may be
the length of the pitch circle arc in which the gear rotate against its mating gear.

Figure 7.54: Backlash pitch diameterl

7.4.10 Radial Backlash

The radial backlash is the dierence of the centre distance between the working condition and zero-backlash
engagement. The radial backlash jr matters especially for very small modules (m < 0.6 mm).

Figure 7.55: Radial backlash

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7.5 Representation of Gear Tooth Form

A special highlight of this calculation module is the presentation of the accurate gear tooth form with an
animation and simulation of the tooth mesh. For the presentation you can select the lower, upper and mean
allowances for the tooth thickness, tip diameter and centre distance. When you dene the geometry for the
gear pair, then you can have a look at the tooth form at any time. Click on the `Tooth form' button and you
get a general or detailed view of the tooth form. By clicking the `Geometry' or `Tool' button, you can open
the main input masks of the calculation module again.

Figure 7.56: Tooth form

Please Note: Please keep in mind that all values are later taken over to the DXF output and CAD generation.
In case you change the tooth thickness allowance or the centre distance allowance in the tooth form mask, then
the last modication is taken over to the DXF output. The section 7.15 contains some helpful information on
this function.

Figure 7.57: DXF output

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7.5.1 Rotating Angle

Enter an rotating angle for the rotation of gear pair.

Figure 7.58: Rotating angle

Rotation of the driving gear counter-clockwise

Rotation of the driving gear clockwise

7.5.2 Rotation
When you click on one of the two arrows, a continuous rotation of the spur gears occurs.

Figure 7.59: Rotation

Continuous rotation of the driving gear counter-clockwise

Continuous rotation of the driving gear clockwise

The rotation is stopped.

7.5.3 Tooth Thickness Allowance

Click on the `Detail view' button and the tooth mesh is represented in detail. Now you can change the tooth
thickness allowance, that is already given in the main mask for the `Allowances', within the tolerance limit.
All changes are displayed immediately. For the representation of the tooth mesh, select the lower, upper and
mean tooth thickness allowances for pinion and gear rack.

Figure 7.60: Tooth thickness allowance in the main mask `Allowance'

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 240

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower tooth thickness allowance. The right arrow
shows the representation for the upper tooth thickness allowance. The middle button displays the mean tooth
thickness allowance. At the rst start of the tooth form, you will get the mean tooth thickness allowance as
a standard feature. The tooth thickness allowances can be dened between the lower and upper allowance.

Figure 7.61: Tooth thickness allowance

Please Note: In case you have specied the lower and upper tooth thickness allowance for pinion and gear
rack in the input mask `Allowances' by using the `Calculator' button, then the manually dened values appear
here as lower and upper tooth thickness allowance.

7.5.4 Tip Diameter Allowance

Click the `Detail view' button and the tooth mesh is represented in detail. Now you can change the tip
diameter allowance for pinion and gear rack, that is already given in the main mask for the `Geometry', within
the tolerance limit. All changes are displayed immediately. For the representation of the tooth mesh, select
the lower, upper and mean tip diameter allowances for pinion and gear rack.

Figure 7.62: Tip diameter allowance in the main mask `Geometry'

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower tip diameter allowance. The right arrow shows
the representation for the upper tip diameter allowance. The middle button displays the mean tip diameter
allowance. At the rst start of the tooth form, you will get the mean tip diameter allowance as a standard
feature.

Figure 7.63: Tip diameter allowance

Please Note: In case you have specied the lower and upper tip diameter allowance for pinion and gear rack
in the input mask `Geometry' by using the `Lock' button, then the manually dened values appear here as
lower and upper tip diameter allowance.

7.5.5 Centre Distance Allowance

Click on the `Detail view' button and the tooth mesh is represented in detail. Now you can change the centre
distance allowance, that is already given in the main mask for the `Allowances', within the tolerance limit. All
changes are displayed immediately. You can check the operation of the gears by using various centre distance
settings.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 241

For the representation of the tooth mesh, select the lower, upper and mean centre distance allowances for
pinion and gear rack.

Figure 7.64: Centre distance allowance in the main mask `Allowances'

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower centre distance allowance. The right arrow
shows the representation for the upper centre distance allowance. The middle button displays the mean centre
distance allowance. At the rst start of the tooth form, you will get the mean centre distance allowance as a
standard feature.

Figure 7.65: Centre distance allowance

Please Note: In case you have specied the lower and upper centre distance allowance in the input mask
`Allowances' by using the `User dened input' option, then the manually dened values appear here as lower
and upper centre distance allowance.

7.6 Calculation of Gear Load Capacity

Gears fail by tooth breakage, pitting as well as by scung. The strength is determined by the loads, the
geometry of gearing as well as selected materials. The calculation of the load capacity is about the proof of
the following strength factors that result from the above-mentioned forms of damage:

- Load capacity of the tooth root (safety against failure of the toothing due tooth breakage)

- Load capacity of the tooth ank (safety against failure of the toothing due to pitting)

- Scung load capacity (safety against failure of the toothing due to scung)

Load Capacity of the Tooth Root - Tooth Breakage

Tooth breakage is a fatigue failure. Pitting, scung or wear may weaken the tooth so that it breaks. The slow
progress of the fracture apparently causes the metal to break like brittle material. A tear or grinding notch
may cause a tooth breakage. Gear tooth fractures ordinarily start in the root llet. The tooth breakage can
destroy an entire gearing and leads to a failure of the gearing. Sometimes a new tooth will break as a result
of severe overload or a serious defect in the tooth structure. According to DIN 3990, an operation with a
reduced load is possible after a tooth breakage, if just a small portion of a tooth broke o and the other parts
of the gearing are intact.

For a high load capacity of the tooth root, the following methods are advantageous: positive prole shift (for
small number of teeth), usage of hardened and tempered or case-hardened materials with larger load capacity
of the tooth root, larger root llet, larger module

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Load Capacity of the Tooth Flank - Pitting of Gear Teeth

Pitting is a fatigue failure and is characterized by little bits of metal breaking out of the surface and thereby
leaving small holes or pits, so that oil seeps into the pits. This is caused by high tooth loads leading to
excessive surface stress, a high local temperature due to high rubbing speeds or inadequate lubrication. The
cracking of the surface develops, spreads and ultimately results in small bits breaking out of the tooth surface.
But it is often possible to get some years of service out of gears that have pitted rather extensively.

For a high load capacity of the tooth ank, the following methods are advantageous: large number of teeth,
positive prole shift (for small number of teeth), higher pressure angle, large hardness of tooth ank, nitriding,
more viscous oil

Figure 7.66: Load capacity

Scung Load Capacity

Scung is a surface destruction and it can be caused by a lubrication failure. Tears and scratches appear on
the rubbing surface of the teeth. This form of damage is called `scung'. The terms of `scung' and `scoring'
are used interchangeably. Scung is an important form of damage leading to component replacements in
lubricated mechanical systems. Compared with tooth breakage and pitting, it is not a fatigue failure, it can
come very quickly. A short overload can lead to scung and the gearing fails. Scung is apt to occur when
the gears are rst put into operation because the teeth have not sucient operating time to develop smooth
surfaces. Due to the scung, the temperature, the forces and the noise increase, the gear teeth nally break
o. The following factors may inuence the occurrence of scung:

- Gear material

- Lubrication

- Surface condition of tooth anks

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 243

- Sliding velocity

- Load

- Impurities in a lubricant

After the occurrence of scung, high-speed gears apt to additional dynamic forces that cause usually pitting or
tooth breakage. The high surface temperature may cause a breakdown of the lubricating lm. The following
factors support scung:

- High loads

- Kind of lubrication: Non-alloy oil protects less against scung than E.P. oil (extreme pressure)

- High oil temperature

- Rough oil surface

- Low gear quality: Larger contact ratio and tooth alignment errors may cause local stresses by impacts
and unbalanced carrying.

For a high scung load capacity, the following methods are advantageous: E.P. oils (oil that contains chemical
additives), a careful running-in period of the gearing, low sliding velocity due to tip relief and a smaller module

Please note: There are two dierent types of scung - cold and hot scung. Both types describe a damage
on the ank. The scung problem is not limited to high-speed gears. Scung can also occur on slow-speed
gears. The slow-speed scung is called cold scung and the high-speed hot scung. Cold scung is not
often observed. Hence, all further comments and information refer to hot scung.

7.6.1 Activate Load Capacity

The calculation of load capacity of cylindrical gears is standardized according to DIN 3990, ISO 6336 and
ANSI/AGMA 2101-D04. The standards give dierent methods to calculate the load capacity in DIN 3990,
ISO 6336 or ANSI/AGMA 2101-D04. The eAssistant software provides all calculations according to DIN 3990
Method B, ISO 6336 Method B and ANSI/AGMA 2101-D04. Hence, you can check the load capacity of tooth
root and tooth ank as well as the scung fast and easily. The scung safeties are determined according to
the integral and ash temperature method. The material properties, the endurance, face load factor, applica-
tion factor as well as the kind of lubrication and the selected lubrication are taken into consideration for the
calculation. There are extended input options to inuence the number of load changes or the roughness. A
grinding notch can be integrated into the calculation and the mode of operation can be selected.

Click on the `Load capacity' button to get to the calculation mask. You will notice that all input elds or
listboxes are disabled. When you select the entry `DIN 3990 Method B', `ISO 6336 Method B' or `ANSI/AGMA
2101-D04' from the listbox `Calculation method', all input elds are enabled. In case you do not need the
calculation for load capacity, the calculation can be disabled. Thus, the size of the calculation report becomes
smaller.

Figure 7.67: Activate load capacity

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 244

7.6.2 Inputs for Load Capacity According to DIN 3990 Method B

Comment
You can add a description or a short comment to pinion and gear rack. The notes will appear later in the
calculation report.

Figure 7.68: Add a comment

Material Selection
Select an appropriate material directly from the listbox or click on the button `Material' to open the material
database.

Figure 7.69: Listbox `Material'

The material database provides some detailed information on the several kinds of material. If the listbox is
active, the two arrow keys `Up' and `Down' of your keyboard allows you to search through the database, so
you can compare the dierent values with each other.

Figure 7.70: Material database

In order for gears to achieve their intended performance, life and reliability, the selection of a suitable material
is very important. Steel is the most common material that is used for gears. There are a number of steels

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 245

used for gears, ranging from plain carbon steels through the highly alloyed steels from low to high carbon
contents. The choice will depend upon a number of factors, including size, service and design. For pinion
and gear, the same hardened and tempered steel may be used. It has to be kept in mind that unhardened
gears with equal hardness should not be meshed with each other because scung is apt to occur. A hardened
or nidrided gear HRC > 50 smoothes the tooth anks of the hardened and tempered mating gear, reduces
the form deviations and increases the load capacity of the tooth ank. For a mating of hardened gears, no
hardness dierence is necessary. The nal selection of the material should be based upon an understanding of
the material properties and application requirements.

Hardening and tempering diers from hardening by annealing at high temperatures. The temperature range
for hardening and tempering ranges from 400◦ to 700◦ C while after hardening, parts are annealed at a low
temperature. On the other hand, a distinction is made between the material. For hardening, steel contains
more than 0.6 to 0.7% of carbon, for hardening and tempering less than 0.6% of carbon. However, there is
no well-dened limit between hardening and tempering and hardening.

Kind of Material
Steel casting: Steel casting belongs to the ferrous metals that include carbon (up to max. 2%) and are poured
into sand molds to produce several components. Due to a higher melting temperature, steel casting is more
dicult to cast than cast iron. Steel casting is cheaper than ground or forged gears.

Steel: Steel is the most common material and is used for medium and high-loaded gears.

Nidrided steel: Nitriding is adding nitrogen to solid iron-base alloys by heating the steel in contact with am-
monia gas or other suitable nitrogenous material. This process is used to harden the surface of gears.

Case-hardened steel: Case-hardened steel is a quality and high-grade steel with low carbon content. Case-
hardened steel is usually formed by diusing carbon (carburization), nitrogen (nitriding) into the outer layer
of the steel at high temperature and then heat treating the surface layer to the desired hardness. When the
steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard while the
core remains soft and tough.

Blackheart malleable cast iron (pearlitic structure): Malleable cast iron is a heat-treated iron carbon alloy.
Two groups of malleable cast iron are specied, whiteheart and blackheart cast iron. Blackheart malleable cast
iron is used for parts with a complex shape, in which a high durability, shock resistance and good machining
are important. Malleable cast iron is used for smaller dimensions and has got a higher strength and toughness
than steel castings.

Cast iron with spheroidal graphite (pearlitic structure, bainitic structure, ferritic structure): Cast iron usually
refers to gray cast iron but identies a large group of ferrous alloys that contain more than 2% of carbon. It
is extremely rare that the maximum carbon content is higher than 4.5%. Cast iron is a low-priced material.
However, cast iron has less toughness and ductility than steel. Cast iron with spheroidal graphite can be used
for parts with higher vibration stress.

Heat-treated steel: Hardening and tempering is a heat-treating technique for steels by quenching from the
hardness temperature and annealing at a high temperature so that the toughness is increased signicantly. At
the same time, a higher elastic limit is reached. Annealing temperatures and times dier for dierent materials
and with properties desired, steel is usually held for several hours at about 400◦ C to 700◦ C. Some steels have
to be cooled very quickly (Annealing: in order to achieve the intended properties of work pieces (e.g., desired
strength or toughness), reheating of the work pieces to certain temperatures is necessary.).

Gray cast iron: Gray cast iron is used for complex shapes and oers low cost and an easy machinability. It
provides excellent damping properties but it is a disadvantage that the load capacity is very low.

Please Note: In case there is no material that will fulll the design requirements, then simply dene your
individual material. Select the option `User dened input' and all inputs and options are enabled and you can
specify your individual material very easily. Your inputs will be saved to the calculation le.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 246

Please be advised that changing the material will delete your dened inputs and you have to enter the inputs
again.

Figure 7.71: Own input of a material

Ovako´s Clean Steels

Ovako´s clean steels 159X and 159Q can be selected from the listbox. Both steels are based on the case-
hardening steel 18CrNiMo7-6. Due to signicantly lower levels of contamination, these steels have modied
Woehler curves. Within the static strength, both steels are comparable to 18CrNiMo7-6. However, in the
fatigue strength range the IQ-Steel 159Q (Isotropic Quality ultra clean steel) is designed to increase eciency
by 30 percent for the ank load capacity and 60 percent for the tooth root load capacity. The fatigue strength
values are based on Ovako´s in-house investigations and external verications at WZL of RWTH Aachen
University and at the Gear Research Centre (FZG) of Technical University of Munich.

Figure 7.72: Selection of clean steels from the material database

The BQ-Steel 159X (Bearing Quality clean steel) delivers slightly smaller performance gains compared to
18CrNiMo7-6 and can be taken to improve existing designs. The potential of the 159Q can be used particularly
in new designs. It can be advantageous to focus on optimized scung load capacity. This can be achieved by
increasing the number of teeth and simultaneously reducing the module. This generally results in better gear
eciency and lower power losses. These Ovako steels open up completely new design possibilities for gears
and have a high potential for further increasing the performance of gears and gear components.

Figure 7.73: 159Q with the material properties in the material database

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 247

Load Spectrum
The calculation of load spectra is in accordance with ISO 6336, Part 6. The determination is based on the
Palmgren-Miner rule and the load-dependent K-factors are calculated for each torque class. The safeties
are determined by way of iteration until the sum of damage parts is obtained. This method, demanded by
the wind energy industry, is very accurate. The linear damage accumulation model, which is also known as
Palmgren-Miner's rule, denes damage as the ratio of the number of cycles of operation to the number of
cycles to failure at any given stress level.

Figure 7.74: Load spectrum

Click the button `Load spectrum'. Once the option `Use load spectrum' has been activated, add any number
of load spectra with time ratio, torque and speed. The load spectra can be entered manually or imported from
les. The load spectra can be saved and loaded. To do this, use the two buttons `Open' and `Save'.

Figure 7.75: Dene load spectrum

Application Factor KA
The application factor KA evaluates the external dynamic forces that aect the gearing. These additional
forces are largely dependent on the characteristics of the driving and driven machines as well as the masses
and stiness of the system, including shafts and couplings used in service. Because scung is not a fatigue
failure, the application factor shall consider the stronger inuence of several load peaks during the calculation

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 248

of the scung load capacity. Several load peaks aect directly only the ank temperature. Because of that,
the same application factor KA can be used for the calculation of the scung load capacity as well as of
the load capacity of the tooth root and tooth ank. The application factor is determined by experience. An
application factor of `1.0' is best thought of a perfectly smooth operation. The following table gives some
values according to DIN 3990.

Application Factors KA According to DIN 3990-1: 1987-125

Working Characteristics Working Characteristics of the Driven Machine

of the Driving Machine

Uniform Light shocks Moderate shocks Heavy shocks

Uniform 1.0 1.25 1.5 1.75

Light shocks 1.1 1.35 1.6 1.85

Moderate shocks 1.25 1.5 1.75 2.0

Heavy shocks 1.5 1.75 2.0 2.25 or higher

5 from: DIN 3990 Part 1, December 1987, p. 55, table: A1

Working Characteristics of the Driving Machine

- Uniform: e.g., electric motor, steam or gas turbine (small, rarely occurring starting torques)

- Light shocks: e.g., electric motor, steam or gas turbine (large, frequently occurring starting torques)

- Moderate shocks: e.g., multiple cylinder internal combustion engines

- Heavy shocks: e.g., single cylinder internal combustion engines

Working Characteristics of the Driven Machines

- Uniform: e.g., steady load current generator, uniformly loaded conveyor belt or platform conveyor, worm
conveyor, light lifts, packing machinery, feed drives for machine tools, ventilators, centrifuges, centrifugal
pumps, agitators and mixers for light liquids or uniform density materials, shears, presses ...

- Light shocks: e.g., heavy lifts, crane slewing gear, industrial and mine ventilator, centrifugal pumps,
agitators and mixers for viscous liquids or substances of non-uniform density, multi-cylinder piston pumps
...

- Moderate shocks: e.g., rubber extruders, continuously mixers for rubber and plastics, wood-working
machine, lifting gear, single cylinder piston pumps ...

- Heavy shocks: e.g., excavators (bucket wheel drives), rubber kneaders, foundry machines, brick presses,
peeling machines, rotary drills ...

Please Note: You will nd a `Question mark' button next to the input eld. Click on this button and
the above-mentioned table opens. The `Question mark' button is an additional feature and provides further
information. You will nd this button next to several input elds.

Figure 7.76: The question mark button

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 249

Face Load Factor KHβ

The face load factor takes into account the eects of the non-uniform distribution of load over the gear
facewidth on the surface stress KHβ , on the tooth root stress KF β and on the scung KBβ . The face load
factor is determined according to DIN 3990, Part 1 Method B.

Figure 7.77: Face load factor for the surface pressure

When you start the calculation module, the value `1.25' is entered into the input eld. In case you already
use a dened face load factor, you can save the certain factor to a template le. Then the calculation module
starts with the individual face load factor. When you click on the `Calculator' symbol, the input mask for the
face load factor opens. In the top input eld `Face coe.' you can nd the default value `1.25'. You will
notice that the lower input elds and listboxes are disabled. By using the `OK' button you can take over the
default value to the main mask. There is a listbox next to the input eld for the face load factor. When you
open the listbox, the entry `DIN 3990 T1 Method B' appears.

Figure 7.78: Listbox with the selection of DIN

As soon as you select this entry from the listbox, the remaining input elds and listboxes are enabled. The
face load factor is determined automatically but you still cannot take over the value to the main mask. In
order to take over the calculated value, you have to add further inputs from the input mask for the face load
factor. When the button `OK' is activated, then the determined face load factor can be conrmed with the
button `OK'.

Please Note: However, there is the possibility to take over the value, determined according to DIN, to the
main mask without changing the extensive settings. When you click on the `Calculator' button next to the face
load factor, the above-mentioned input mask opens. The face load factor KHβ is displayed in the input eld.
Open the adjacent listbox and select the entry `DIN 3990 T1 method B'. The face load factor is calculated
but the button `OK' is still disabled.

Figure 7.79: Face load factor

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 250

Open the listbox again and select the entry `User dened'. Now the `OK` button is enabled and you can take
over the face load factor.

Figure 7.80: Take over of the face load factor

Mesh Misalignment Fβx

The path of teeth is marked by the path of tooth traces. The tooth trace is the section of a tooth ank with
the reference surface. The mesh misalignment Fβx considers all inuences of manufacturing, assembly and
deformation that may intensify and compensate each other.

Figure 7.81: Tooth trace

The mesh misalignment is determined according to DIN 3990, part 1 method C. Using this method, portions
of the mesh misalignment are considered caused by a deformation of pinion and pinion shaft as well as
manufacturing inaccuracies. Fβx consists of fsh and fma . fsh is the mesh misalignment due to bending
and torsion of the pinion and pinion shaft, therefore it is a mesh misalignment due to deformation. The
mesh misalignment fma is a misalignment due to manufacturing inaccuracies and is dependent upon the gear
accuracy and the facewidth of the gear.

Figure 7.82: Mesh misalignment

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 251

Please Note: Select the entry DIN 3990 method B from the listbox for the face load factor, then the factor
is determined according to DIN. The selection and input elds are enabled. User-dened inputs for the mesh
misalignment are also possible.

Figure 7.83: User-dened selection

Position of Tooth Contact Pattern

The tooth contact pattern gives some insight into the required geometry and accuracy of gears. While rolling
o each other, a tooth ank will not come into contact with every point of its mating ank. A tooth contact
pattern is a representation of contact surfaces of two engaged tooth anks of gear pair. Under operating
conditions, an even load distribution over the facewidth and tooth depth is to be accomplished. For a contact
pattern, a thin layer of a marking compound is applied to the anks. After that, the gear pair is rotated as
long as the tooth contact pattern appears. Then the gears are visually inspected to check the tooth contact
pattern which is indicated by a light wear pattern on the mating tooth surfaces. The optimization of the
contact pattern plays an important role for improving smoothness and quietness of operation. Click on the
`Question mark' button and you will get a representation of the contact pattern according to DIN 3990, Part
1.

Figure 7.84: Open contact pattern

Figure 7.85: Contact pattern according to DIN Figure 7.86: Contact pattern according to DIN
3990, Part 1, 1987 3990, Part 1, 1987

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Pinion Corrections
Errors in manufacturing and elastic deformations that may inuence the load capacity can be adjusted by
using intentional deviations from the involute (modication of the tooth depth) and theoretical tooth trace
(modication of the facewidth). Lead crowning and end relief are the most important pinion corrections and
are advantageous for a good load distribution over the facewidth of a gear. Due to lead crowning or end
relief, a non-uniform load distribution can be reduced. The calculation program allows you to select one of
the above-mentioned pinion corrections from the listbox.

Figure 7.87: Selection of the pinion correction

Lead Crowning
Lead crowning is a common modication that results in the ank of each gear tooth having a slight outward
bulge in its center area. A crowned tooth becomes gradually thinner towards the end of the teeth. The purpose
of lead crowning is to ensure that manufacturing inaccuracies and deformations are adjusted under load and
that the tooth ends are relieved. In general, lead crowning Cc is carried out symmetrically to the centre of the
facewidth.

Figure 7.88: Lead crowning

End Relief
Due to mesh misalignments, an overloading of the tooth ends occurs. Therefore, this kind of pinion correction
is used to protect the tooth ends against overloading. Generally, the size of the relief at both sides of the
tooth ank is equal. If crown shaving and crown grinding are not possible, then end relief is recommended.

Figure 7.89: End relief

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Pinion Arrangement - Stiening Eect

When d1 /dsh ≥ 1, 15, then stiening is assumed; when d1 /dsh < 1.15, there is no stiening; furthermore,
scarcely any or no stiening at all is to be expected when a pinion slides on a shaft and feather key or a similar
tting, nor when normally shrink tted (DIN 3990, part 1, edition December 1987, Beuth Verlag GmbH Berlin,
gure 6.8, p. 33).

Figure 7.90: Pinion arrangement

Transmitted Power - Power Distribution for the Dimensioning of the Face Load Factor kHβ
The transmitted power k is the percentage of the power which will be transmitted through the pinion tooth
mesh, in the ratio of the full power which is transmitted through the pinion shaft. For example: The power
input on a shaft is 10 kW. 60% is transmitted through the tooth mesh and the remaining 40% is transmitted
to the end of the shaft. Now you have to dene 6 kW for the pinion to dimension the gearing. To determine
the face load factor, you have to enter 60% of the transmitted power because the stronger deformation of the
shaft due to the full torque transmission (10 kW) is taken into consideration.

Figure 7.91: Transmitted power

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Reference Gear
The inputs for the power, speed and torque apply for the appropriate gear that is selected in the listbox. For
the other gear, speed and torque are determined from the reference gear.

Power and Torque

The power, torque and speed are dependent upon each other. Click on the adjacent button `T/P' to switch
between the input for the torque and the input for the power. If you click on the `TP' button, then you can
enter either the torque or the power. The values are converted. The description of the input eld changes
accordingly into `Torque' or `Power'.

Kind of Lubrication and Lubricant Selection

Lubrication serves several purposes but its basic and most important function is to protect the sliding and
rolling tooth surfaces from seizing, wear and friction. The friction of the tooth ank is responsible for ank
wear, gear heating and gear noise. A reduced ank friction improves the eciency that is dependent on the
tooth load, circumferential velocity, gear quality and the surface condition of the tooth anks. In order that
the gearing should work properly, the selection of a lubricant is an important choice. A liquid lubricant is a
good choice and can be easily introduced between the contacting surfaces. In addition, a lubrication has to
reduce frictional heat and has to protect the surfaces against corrosion. The bearings and clutches in a gearing
require also an appropriate lubricant. Therefore, the lubricant has to be suitable as well. Oil and greases
are the most common lubricants. The compounding of oils provides a combination and generation of various
properties. Oil oers a wider range of operating speeds than greases. They are easier to handle and are most
eective. Special E.P. (extreme pressure) oils have been developed for slow-speed, highly-loaded vehicle gears.
These oils develop chemical compounds on the contacting gear-tooth surfaces. Grease is a combination of
liquid and solids. Grease has the advantage of remaining in place and not spreading as oil. It can provide a
lubricant lm at heavily loads and at low speeds.

Figure 7.92: Open the selection of a lubricant

For the selection of liquid lubricants applies: the smaller circumferential velocity and larger the contact pres-
sure as well as the roughness of tooth anks, the higher the viscosity. A higher viscosity will result in a
higher hydrodynamic load capacity and an increased scung load limit where scratching and scung of the
tooth anks occur (Muhs/Wittel/Jannasch/Vossiek: Rolo/Matek Maschinenelemente, 17th revised edition,
published by Vieweg, Wiesbaden 2005).

Please Note: If the viscosity is too low, the oil lm will not be suciently formed and if the viscosity is too
high, the viscosity resistance will also be high and cause temperature rise. For higher speed, a lower viscosity
oil should be used and for heavy loads, a higher viscosity oil should be used.

Gears that are running primarily in a gearbox are lubricated with oil. A distinction is made between oil splash
lubrication and oil injection lubrication.

Oil splash lubrication: The oil splash lubrication is an easy, reliable and reasonable lubrication system. It is
a type of lubrication used in enclosed gear drives. In splash lubrication, the gear tooth dips into a tray of
lubricant and transfers the lubricant to the meshing gear as it rotates. As a result, oil reaches all of the places
where it is needed. The oil splash lubrication can be used for average speed applications.

Oil injection lubrication: With the oil injection lubrication, the oil can be ltered, cooled and checked and
the oil is directly fed to the bearings. The amount of oil can be controlled according to the heat dissipation
requirements. The gearbox is used as an oil tank reservoir from which several units can be supplied. The oil

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 255

is sprayed directly by a pump injector into the mating surfaces.

Grease lubrication: The selection of the grease is dependent upon the circumferential velocity, the kind of
application and the service temperature. A grease lubrication requires low maintenance and protects against
contamination. Grease lubrication is suitable for any gear system that is opened or enclosed, so long as it runs
at low speed. The grease should have a suitable viscosity with good uidity especially in a enclosed gear unit.
Click on the `Lubricant' button and open database. The extensive database contains the lubricants including
all detailed information about the oils and greases (e.g., density, viscosity, load stage of FZG test). Select
`User dened input' from the listbox to dene your individual lubricant.

Figure 7.93: Lubricant selection

7.6.3 Extended General Input Options

Click the corresponding button in the main screen of the load capacity to open the advanced input options. If
you do not change any entries in the following screen, the calculation continues with the default input values.

Figure 7.94: Selection of extended input options

If you do not change any entries in the following mask, the calculation continues with the default input values.

Figure 7.95: Extended general input options

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 256

Dynamic Coecient KV
The dynamic coecient KV considers additional inner dynamic forces. Inner dynamic forces are caused by
mesh alignments, lead crowning, deformation of teeth, the housing, shafts and gear bodies as well as oscillation
of the wheel masses. As the circumferential velocity of the gear rim increases, the dynamic forces increase. The
forces decrease with an increasing load of the teeth. Click the `Lock' button to change the dynamic coecient.

Transverse Coecient KHα

The transverse coecients account for the eect of the non-uniform distribution of transverse load between
several pairs of simultaneously contacting gear teeth on the surface pressure (KHα ), stress leading to scung
(KBα ) and loading of the tooth root (KF α ). Click the `Lock' button to change the transverse coecient.

Mesh Load Factor Kγ

The mesh load factor takes into account an uneven distribution of the total circumferential force for gearings
with multiple transmission paths or for planetary gear trains with more than three planets. For transmission
paths, the total circumferential force is distributed to several mesh. For gearings without transmission paths,
the value is set at `1.0'.

Carried Width
When the facewidth of pinion and gear is not equal, then a maximum overhang of `1 x m' at each tooth end is
assumed as a carried width. Unhardened portions of surface-hardened gear tooth anks (including transition
zone) consider only 50% as the carried width. However, if it is foreseen that because of crowning or end relief
the contact does not extend to the end of face, then the smaller facewidth shall be used for both pinion and
gear. Click the `Lock' button to change the carried width.

Permit Pitting
In specic cases, the development of pits on the gear ank is allowed. Use this option to permit several pits.
In general, initial pitting is considered normal and is not a cause for concern. In particular, case-hardened and
nitrided gears usually has the tendency to pit near the tooth root and lead eventually to fatigue breakage. Here
an individual assessment is necessary. In some cases (aerospace industry), pits are absolutely not permitted.
For turbo transmissions, pits may lead to oscillations and increased additional dynamic forces.

Figure 7.96: Permit pitting

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 257

7.6.4 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank
The main mask of the load capacity provides the `Tooth root/ank' button, click on that button and the
extended input options appear. If you do not change any inputs in the following mask, then the default input
values are used.

Figure 7.97: Extended input options for tooth root and tooth ank

Roughness
The surface roughness of the tooth anks inuences the load capacity of the tooth anks. The average rough-
ness Rz is the arithemitc average of ve individually measured roughness values. The input of the roughness
occurs for root and ank of pinion and gear. The right choice of the surface roughness is determined by
economical aspects depending upon the intended purpose and manufacturing process. A ne surface can be
very expensive because of the high manufacturing costs. A surface that is too rough may not fulll the required
functionality.

Grinding Notch
A grinding notch may signicantly reduce the fatigue strength and a tooth breakage can occur due to a
grinding notch.

Figure 7.98: Grinding notch

Shot-peening can be used to increase the fatigue strength of gears that are damaged by a grinding notch. A
careful grinding of the notch is basically suitable. Click the question mark button to open the representation
of the grinding notch.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 258

Hardening Depth Root/Flank

The hardening depth is signicantly for the pitting load capacity and is determined by the depth of surface layer
heated to hardening temperature, the hardenability of the material and the eect of the quenching method.
Case-hardening: Steels get their specic features by case-hardening. This combined heat treatment process
consists of the following subprocesses:

- Carburizing, i.e., using carbon for the surface

- Hardening, i.e., heat treatment to achieve a hardened and wear-resistant surface

- Annealing (stress relief )

Figure 7.99: Hardening depth

Please Note: The calculation module determines the optimal hardening depth automatically, but the hard-
ening depth can be dened also individually. If the individual hardening depth is smaller than the optimal
hardening depth, then the fatigue strength is reduced accordingly. The determination of the optimal hard-
ening depth and reduction of fatigue strength with reduced hardening depth is based on: `Tobie, Thomas:
Zur Gruebchen- und Zahnfusstragfaehigkeit einsatzgehaerteter Zahnraeder, Dissertation Technische Universi-
taet Muenchen (Lehrstuhl fuer Maschinenelemente, Forschungsstelle fuer Zahnraeder und Getriebebau) 2001,
Section. 10.3: Eingliederung der Versuchsergebnisse in das Rechenverfahren nach DIN 3990'.

Technology Factor YT
The technology factor YT considers the change of the strength of the tooth root by machining process.

σF lim = σF lim0 YT

σF lim0 Fatigue strength of the tooth root from material data

σF lim Fatigue strength of the tooth root with inuence of the technology factor

YT Technology factor (see following table)

Technology Factor YT According to Linke6

Kind of Manufacturing of the Tooth Root Technology Factor YT
Shot peening: 1.2 to 1.4

Applies for case-hardened or carbonitrided gears; not ground

in the hardened layer

Rolling: 1.3 to 1.5

Applies for ame and induction hardened gears; not ground in

the hardened layer

Grinding: General: 0.7

Applies for case-hardened or carbonitrided gears for CBN grinding wheel: 1

Shape cutting: 1

Does not apply for ground gears

6 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Verlag

Muenchen Wien, 1996, p. 320, table 6.5/6

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 259

Click the `Question mark' button to open the tables for the technology factor and mode of operation factor.

Figure 7.100: Open the tables

Mode of Operation Factor YA

The fatigue strength of the tooth root σF lim is corrected with the inuence of the mode of operation.

σF lim = σF lim0 YA

σF lim0 Fatigue strength of the tooth root from material data

σF lim Fatigue strength of the tooth root with inuence of the mode of operation factor

YA Mode of operation factor (see following table)

The following reference values can be used for the mode of operation factor YA . DIN 3990 species identical
values for swelling and alternating load.

Mode of operation factor YA according to Linke7

Mode of Operation Mode of Operation Factor YA Direction of Load

Swelling 1

Alternating 0.7

lgNrev
0.85 - 0.15
6

Oscillating (for 1 ≤ Nrev ≤ 106 )

0.7 (for Nrev > 106 )

Please Note: Nrev = Number of load direction changes during operation time

7 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Verlag

Muenchen Wien, 1996, p. 321, table 6.5/7

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 260

7.6.5 Extended Input Options for Scung Load Capacity

The scung load capacity oers dierent extended input options. Click on the `Scung' button and the
extended input options appear.

Figure 7.101: Extended input options `Scung'

Thermal Contact Coecient BM

The thermal contact coecient BM is required for the determination of the ash factor. The ash factor
considers the inuence of the material properties of gear and pinion on the ash temperature.

Figure 7.102: Thermal contact coecient

Relative Structure Factor XW relT

The relative structure factor XW relT is primarily intended to take into account inuence of the material
properties on the scung load capacity and is determined by:

XW
XW relT =
XW T

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 261

XW The lower table provides the empirically determined relative structure factor.

XW T The relative structure factor for the test gears that are used for the determination of the scung
temperature. XW T = 1.0 for the FZG gear test.

Structure Factor XW 8
Material/Heat Treatment Structure Factor XW
Through-hardened steel 1.00

Phosphated steel 1.25

Copper plated steel 1.50

Bath and gas nitrided steel 1.50

Hardened carburized steel, with austenite content:

- less than average 1.15

- average 1.00

- greater than average 0.85

Austenitic steel (stainless steel) 0.45

8 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl

Hanser Verlag Muenchen Wien, 1996, p. 367, table 6.5/16

Load Stage of Standard FZG Gear Test

Because scung is not a fatigue failure, a standard FZG gear test was developed to determine the scung load
capacity of a lubricant under certain operating conditions. The gear test, known as FZG gear test (Institute for
Machine Elements Gear Research Center, University Munich, Germany), is a standardized method according to
DIN 51354. At the FZG, the dierent inuences on scung are extensively investigated. The test is performed
on a standard FZG test machine using standard test gears. Standardized, case-hardened and ground spur gears
with a large one-side prole shift are used. The load is increased gradually on a FZG gear test rig with dened
technical parameters. There are 12 load stages and the gears are inspected for scung after every load
stage. Finally, the load stage is determined where scung of the gear teeth occurs and where the ank area
is damaged by scratches. The higher the load stages, the better the industrial gear lubricants resistance to
scung.

Figure 7.103: Selection of load stage

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 262

Type of Prole Modication

For high-duty gearings, it is possible to change the theoretical involute. Using the listbox to dene the type
of prole modication. You can select the following options:

- without prole modication

- for high-duty gearing

- for uniform mesh

Figure 7.104: Prole modication

The force distribution factor XΓ evaluates the inuence of the force distribution over several pairs of meshing
teeth. A polygon-like shape over the line of action represents the progress of the force distribution factor. The
values of the points A and E depend upon the type of prole modication. According to DIN 3990 (see Part
4, p. 17), the force distribution factor is as follows:

Force Distribution Factor Without Prole Modication and With Prole Modication for High-Duty
Gears

Figure 7.105: Without prole modication Figure 7.106: For high-duty gears (the pinion
drives)

Force Distribution Factor With Prole Modication for High-Duty Gears and for Uniform Mesh

Figure 7.107: For high duty gears (the gear Figure 7.108: For uniform mesh
drives)

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 263

Contact Temperature Along the Path of Contact

The contact temperature varies along the path of contact due to the progress of the ash temperature.

Contact Temperature Without Prole Modication

Figure 7.109: Contact temperature without prole modication

Contact Temperature With Prole Modication

Figure 7.110: Contact temperature with prole modication

Contact Temperature for Uniform Mesh

Figure 7.111: Create calculation report

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 264

Flash Temperature Method and Integral Temperature Method

High surface temperatures due to high loads and slidings speeds can cause a lubricant lm breakdown. Because
of that, there are two calculation methods in ISO/TR 13989 that are based on dierent criteria for the
development of a damage. The eAssistant software provides both the integral temperature method and ash
temperature method:

- Flash temperature method denes a variable contact temperature along the path of contact.

- Integral temperature method denes a weighted average of the surface temperature along the path of
contact.

Flash Temperature Method

The ash temperature is the temperature at which a gear-tooth surface is calculated to be hot enough to
destroy the oil lm and allow instantaneous welding at the contact point. The contact temperature ϑB in any
point of contact Y results from the sum of the bulk temperature ϑM and the ash temperature ϑf la :

ϑB = ϑM + ϑf la

According to the ash temperature method, there is no scung as long as the contact temperature ϑB (as the
sum of bulk temperature ϑM and ash temperature ϑf la ) does not exceed the scung contact temperature
in all points of contact. The scung temperature ϑS to be a characteristic value for the material-lubricant-
material system of a gear pair, to be determined by gear tests with the same material-lubricant-material
system.

Figure 7.112: Progress of contact temperature along the path of contact

Please note: Points A to E mark the important points from the beginning to the end of the mesh.

The safety against scung SB is determined according to the ash temperature method:

ϑS − ϑoil
SB = ≥ SBmin
ϑBmax − ϑoil

ϑBmax Maximum contact temperature along the path of contact

ϑoil Oil temperature before reaching the mesh

ϑS Scung temperature

The safety factor SBmin is dependent on whether the gearing is put into operation after a good running-in
period. With a careful running-in period, there is no scung damage up to SBmin ≈ 1. Without a running-in
period, there is no scung up to SBmin ≈ 3 (according to Linke).

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 265

Integral Temperature Method

According to the integral temperature method, scung occurs when the integral temperature exceeds the
scung integral temperature. The scung integral temperature is assumed as a characteristic value for
the material-lubricant-material system of a gear pair and is determined from gear tests. The scung safety
according the integral temperature method SintS is calculated as follows:

ϑintS
SintS = ≥ SSmin
ϑint

ϑintS Scung integral temperature

ϑint Integral temperature

As uncertainties and inaccuracies in the assumptions cannot be excluded, it is necessary to introduce a safety
factor. According to Linke, the following reference values can be used:

SintS < 1.0 In all probability, scung damages are expected to occur.

1.0 ≤ SintS ≤ 2.0 For a careful running-in period of the gearing, good contact pattern and real assumed
loads, there are no scung damages to be expected.

SintS > 2.0 There is no risk of scung.

7.6.6 Input Options for Load Capacity According to ISO 6336 Method B
In addition to DIN 3990 Method B, it is possible to calculate the load capacity of tooth root and tooth ank
according to ISO 6336 (2008) Method B. Select the ISO 6336 Method B from the listbox and the input elds
are enabled.

Figure 7.113: Activate load capacity according to ISO 6336 Method B

There is a strong similarity between the DIN 3990 standard and the ISO 6336 standard and most parts of the
load capacity calculation according to ISO 6336 correspond to DIN 3990. In fact, the ISO 6336 evolved from
the DIN 3990 standard. There are factors that inuence the tooth root stress and tooth ank strength, but
the dierences are minor and the inuence on the safety of root, ank and scung is very low. One large
dierence is the calculation of the helix angle factor Zβ as well as the calculation of the long life factors (ZN T
and YN T ) for the tooth root stress. Another dierence between DIN 3990 and ISO 6336 is the critical stress
point on the root llet. ISO 6336 uses the tangency point of a 60◦ angle as the most critically stressed point
on the root llet for internal gears. The DIN 3990 standard uses the tangency point of a 30◦ angle as the
critical stress point on the root llet for external and internal gears as the basis for the calculation of the
load capacity.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 266

Life Factors ZN T and YN T

The long life factor YN T accounts the higher tooth root stress and the long life factor ZN T accounts the
higher contact stress including static stress, which may be tolerable for a limited life (number of load cycles).
The factors mainly depend on the quality of the material, heat treatment, number of load cycles as well as
notch sensitivity, surface conditions and gear dimensions. The life factors YN T and ZN T can be read from the
following graph for the static and reference stress as a function of material and heat treatment.

Figure 7.114: DIN 3990 and ISO 6336: Life factors

Long life factor YN T :

With optimum lubrication, material and manufacturing YN T = 1.0 may be used for the number of load cycles
NL = 3 · 106 . For static stresses NL ≤ 103 , the long life factor is 2.5.

Long life factor ZN T :

With optimum lubrication, material and manufacturing ZN T = 1.0 may be used for the number of load cycles
NL = 5 · 107 . For static stresses NL ≤ 105 , the long life factor is 1.6.

Figure 7.115: Input of life factors

There are signicant dierences in the calculation of the life factors YN T and ZN T when comparing DIN 3990
and ISO 6336. Values appropriate to the relevant number of load cycles, NL , are indicated by the S-N curve
(also known as a Woehler curve). The S-N approach is dierent. The long life factor for the load capacity
of the tooth root approaches 1.0 for the range of long life (depending on the material, usually at 3 · 106 load
cycles). In DIN 3990, the life factor remains 1.0 for higher number of load cycles. According to ISO 6336, the
factor for materials decreases from 1.0 to 0.85 at 1010 load cycles. Only after that, the factor remains 0.85 at
10
10 load cycles. For gears in the long life range, the calculations according to ISO 6336 result in signicantly
smaller safeties (15% lower) for tooth root and tooth ank. This also applies for the long life factor for anks.
Use the `Lock' button to modify the long life factors YN T and ZN T . The input elds are enabled and you can
dene your own value for the factors. Please remember to keep the modied input eld open or the default
values will be used again.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 267

Face Load Factor KHβ

Another dierence between ISO and DIN is the determination of the mesh stiness cγ . The mesh stiness is
needed for the calculation of the face load factor KHβ . The factor KHβ takes into account uneven distribu-
tion of load over the facewidth due to mesh misalignment caused by inaccuracies in manufacture and elastic
deformations. For the calculation of the face load factor, ISO 6336 uses a mesh stiness cγ that is reduced by
15% in comparison to the mean stiness the DIN 3990 use for the calculation of KHβ . This results in slightly
lower face load factors.

Rim Thickness Factor

If the rim thickness is too thin and not sucient to provide full support for the tooth root (e.g., for planetary
gear trains or internal gears), then this can be accounted for by the rim thickness factor YB . YB is expressed
as a function of the tooth depth for external gears and as a function of the normal module for internal gears.
The load capacity decreases with a gear rim thickness sR < 1.2 · ht for external gears or 2.8 · mn , for internal
gears sR < 3.5 · mn (ISO 6336 Edition 2006 - Was ist neu?: Dr.-Ing. R. Hess, Dipl.-Ing. B. Kisters, A. Friedr.
Flender AG, Bocholt, Tagungsbeitrag Dresdener Maschinenelemente Kolloquium 2009).

Helix Angle Factor Zβ

Another dierence is the determination of the helix angle factor Zβ . Independent of the inuence of the helix
angle on the length of path of contact, this factor accounts for the inuence of the helix angle on the load
capacity of the tooth anks, allowing for such variables as the distribution of load along the lines of contact.
Zβ is dependent only on the helix angle, β. The given formulae for the determination of the helix angle factor
are dierent in DIN 3990 and ISO 6336. DIN 3990 gives the following formular to calculate the helix angle
factor (β is the helix angle at reference circle):

p
Zβ = cos β

In ISO 6336, the helix angle factor is dened as follows:

1
Zβ = √
cos β

Figure 7.116: Comparison of helix angle factor in DIN and ISO

Work Hardening Factor ZW

The work hardening factor ZW has been revised in ISO 6336. This factor is used to take into consideration the
Hertzian pressure which serves as a basis for the calculation of the load capacity of the tooth anks. The work
hardening factor accounts for the increase in surface durability due to meshing a steel gear with a hardened
or substantially harder pinion with smooth tooth anks. In DIN 3990 and the previous version of ISO 6336,

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 268

the work hardening factor was dependent solely on the ank hardness of the softer gear.

Surface Roughness
The increase in the surface durability of the soft gear depends not only on any work hardening of this gear, but
also on other inuences such as ank surface roughness. In addition, the inuence of the surface roughness
is addressed in ISO 6336. Tooth ank curvature, pitch line velocity and lubricant viscosity are taken into
account in the calculation. The work hardening factor is reduced for gears with hard, rough surface. Gear
teeth with rough surfaces may wear a softer mating teeth. Wear of the surface is not covered by ISO 6336.
Especially for rough pinion surfaces, values of ZW < 1 may be evaluated. As in this range eects of wear can
limit the surface durability, ZW is xed at ZW = 1.0 (ISO 6336 Edition 2006 - Was ist neu?: Dr.-Ing. R.
Hess, Dipl.-Ing. B. Kisters, A. Friedr. Flender AG, Bocholt, Tagungsbeitrag Dresdener Maschinenelemente
Kolloquium 2009).

7.6.7 Scung Load Capacity According to ISO/TR 13989

ISO 6336 does not provide a calculation method for scung. For the safety against scung, the Technical
Report ISO/TR 13989 shall be preferably used. ISO/TR 13989 is a Technical Report (March 2000). This
document is not to be regarded as an `International Standard'. It is proposed for provisional application so
that information and experience of its use in practice may be gathered. The scung load capacity is calculated
according to ISO/TR 13989 Part 1 (Flash temperature method) and Part 2 (Integral temperature method) as
soon as you select `ISO 6336 Method B'.

Figure 7.117: Scung load capacity according to ISO/TR 13989

Thermal Contact Coecient BM

The thermal contact coecient BM is required for the determination of the ash factor. The ash factor
considers the inuence of the material properties of gear and pinion on the ash temperature.

Lubricant Factor XL
The lubricant factor XL depends on the the type of lubricant. You can select the following types:

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 269

- Mineral oils XL = 1.0

- Water soluble polyglycols XL = 0.6

- Non-water soluble polyglycols XL = 0.7

- Polyalfaolens XL = 0.8

- Phosphate esters XL = 1.3

- Traction uids XL = 1.5

Figure 7.118: Type of lubricant

Relative Structure Factor XW relT

The relative structure factor XW relT is primarily intended to take into account inuence of the material
properties on the scung load capacity and is determined by:

XW
XW relT =
XW T

XW The lower table provides the empirically determined relative structure factor.

XW T The relative structure factor of test gears that are used for the determination of the scung
temperature. XW T = 1.0 for the FZG gear test.

Structural Factor XW 9
Material/Heat Treatment Structural Factor XW
Through-hardened steel 1.00

Phosphated steel 1.25

Copper plated steel 1.50

Bath and gas nitrided steel 1.50

Hardened carburized steel, with austenite content:

- less than average 1.15

- average (10% to 20%) 1.00

- greater than average 0.85

Austenitic steel (stainless steel) 0.45

9 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag Muenchen Wien, 1996, p. 367, table 6.5/16

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 270

Load Stage of Standard FZG Gear Test

Because scung is not a fatigue failure, a standard FZG gear test was developed to determine the scung load
capacity of a lubricant under certain operating conditions. The gear test, known as FZG gear test (Institute for
Machine Elements Gear Research Center, University Munich, Germany), is a standardized method according to
DIN 51354. At the FZG, the dierent inuences on scung are extensively investigated. The test is performed
on a standard FZG test machine using standard test gears. Standardized, case-hardened and ground gears
with a large one-side prole shift are used. The load is increased gradually on a FZG gear test rig with
dened technical parameters. There are 12 load stages and the gears are inspected for scung after every
load stage. Finally, the load stage is determined where scung of the gear teeth occurs and where the ank
area is damaged by scratches. The higher the load stages, the better the industrial gear lubricants resistance
to scung. Click the `Lock' button in order to select a load stage.

Figure 7.119: Selection of load stage

Flash Temperature Method and Integral Temperature Method

High surface temperatures due to high loads and slidings speeds can cause a lubricant lm breakdown. Because
of that, there are two calculation methods in ISO/TR 13989 that are based on dierent criteria for the
development of a damage. The eAssistant software provides both the integral temperature method and ash
temperature method:

- Flash temperature method denes a variable contact temperature along the path of contact.

- Integral temperature method denes a weighted average of the surface temperature along the path of
contact.

Flash Temperature Method

The ash temperature is the temperature at which a gear-tooth surface is calculated to be hot enough to
destroy the oil lm and allow instantaneous welding at the contact point. The contact temperature ϑB in any
point of contact Y results from the sum of the bulk temperature ϑM and the ash temperature ϑf la :

ϑB = ϑM + ϑf la

According to the ash temperature method, there is no scung as long as the contact temperature ϑB (as the
sum of bulk temperature ϑM and ash temperature ϑf la ) does not exceed the scung contact temperature
in all points of contact. The scung temperature ϑS to be a characteristic value for the material-lubricant-
material system of a gear pair, to be determined by gear tests with the same material-lubricant-material
system.

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 271

Please note: Points A to E mark the important points from the beginning to the end of the mesh.

Figure 7.120: Progress of contact temperature along the path of contact

The safety against scung SB is determined according to the ash temperature method:

ϑS − ϑoil
SB = ≥ SBmin
ϑBmax − ϑoil

ϑBmax Maximum contact temperature along the path of contact

ϑoil Oil temperature before reaching the mesh

ϑS Scung temperature

The safety factor SBmin is dependent on whether the gearing is put into operation after a good running-in
period. With a careful running-in period, there is no scung damage up to SBmin ≈ 1. Without a running-in
period, there is no scung up to SBmin ≈ 3 (according to Linke).

Integral Temperature Method

According to the integral temperature method, scung occurs when the integral temperature exceeds the
scung integral temperature. The scung integral temperature is assumed as a characteristic value for
the material-lubricant-material system of a gear pair and is determined from gear tests. The scung safety
according the integral temperature method SintS is calculated as follows:

ϑintS
SintS = ≥ SSmin
ϑint

ϑintS Scung integral temperature

ϑint Integral temperature

As uncertainties and inaccuracies in the assumptions cannot be excluded, it is necessary to introduce a safety
factor. According to Linke, the following reference values can be used:

SintS < 1.0 In all probability, scung damages are expected to occur.

1.0 ≤ SintS ≤ 2.0 For a careful running-in period of the gearing, good contact pattern and real assumed
loads, there are no scung damages to be expected.

SintS > 2.0 There is no risk of scung.

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7.6.8 Input Options for Load Capacity According to ANSI/AGMA 2101-D04

The standard provides the calculation of safeties for the root and ank. Further the calculation of risk of
scung is also available. Additional to the DIN 3990 and ISO 6336 standard, the ANSI/AGMA 2101-D04
provides also the calculation of wear. The eAssistant software calculates the wear as failure probability. Select
ANSI/AGMA 2101-D04 from the listbox and the input elds are enabled. The following explains some factors
from the standard.

Figure 7.121: Activate load capacity according to ANSI/AGMA 2101-D04

Overload Factor KO
With the new edition of the ANSI/AGMA 2101-D04 (ANSI/AGMA 2001-D04 imperial unit edition, the ap-
plication factor from ANSI/AGMA 2101-C95 was replaced by overload factor KO .

Figure 7.122: Overload factor

The overload factor is intended to make allowance for all externally applied loads in excess of the nominal
tangential load, Ft , for a particular application. Overload factors can only be established after considerable
eld experience is gained in a particular application.

For an overload factor of unity, this rating method includes the capacity to sustain a limited number of up to
200 % momentary overload cycles (typically less than four starts in 8 hours, with a peak not exceeding one
second duration). Higher or more frequent momentary overloads shall be considered separately.

In determining the overload factor KO , consideration should be given to the fact that many prime movers and
driven equipment, individually or in combination, develop momentary peak torques appreciably greater than
those determined by the nominal ratings of either the prime mover or the driven equipment. There are many
possible sources of overload which should be considered. Some of these are: system vibrations, acceleration
torques, overspeeds, variations in system operation, split path load sharing among multiple primemovers, and
changes in process load conditions.

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Stress Cycle Factors ZN and YN

The stress cycle factors, ZN and YN , adjust the allowable stress numbers for the required number of cycles
of operation. For the purpose of this standard, nL , the number of stress cycles is dened as the number of
mesh contacts, under load, of the gear tooth being analyzed.

AGMA allowable stress numbers are established for 107 unidirectional tooth load cycles at 99 % reliability. The
stress cycle factor adjusts the allowable stress numbers for design lives other than 107 cycles. The stress cycle
factor accounts for the S-N characteristics of the gear material as well as for the gradual increased tooth stress
which may occur from tooth wear, resulting in increased dynamic eects and from shifting load distributions
which may occur during the design life of the gearing.

Surface Condition Factor ZR

Standard surface condition factor ZR for gear teeth have not yet been established for cases where there
is a detrimental surface nish eect. In such cases, some surface nish factor greater than unity should be
used. The surface condition factor can be taken as unity provided the appropriate surface condition is achieved.

Size Factor ZR
The size factor KS reects non-uniformity of material properties. It depends primarily on: tooth size, diameter
of parts, ratio of tooth size to diameter of part, facewidth, area of stress pattern, ratio of case depth to tooth
size, hardenability and heat treatment of materials Standard size factors for gear teeth have not yet been
established for cases where there is a detrimental size eect. In such cases, some size factor greater than unity
should be used. The size factor may be taken as unity for most gears, provided a proper choice of steel is
made for the size of the part and its heat treatment and hardening process.

Temperature Factor Yϑ
The temperature factor Yϑ is generally taken as unity when gears operate with temperatures of oil or gear
blank not exceeding 120°C. When operating temperatures result in gear blank temperatures below 0°C, special
care must be given. When operating at oil or gear blank temperature above 120°C, Yϑ is given a value greater
than 1.0 to allow for the eect of temperature on oil lm and material properties. Consideration must be
given to the loss of hardness and strength of some materials due to the tempering eect of temperatures over
150°C.

Figure 7.123: Additional options for calculation of load capacity

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Reliability Factor YZ
The reliability factors YZ account for the eect of the normal statistical distribution of failures found in
materials testing. The allowable stress numbers given in ANSI/AGMA (tables 3 through 6) are based upon a
statistical probability of one failure in 100 at 107 cycles. The following table contains reliability factors which
may be used to modify these allowable stresses to change that probability. These numbers are based upon
data developed for bending and pitting failure by the U.S. Navy. Other values may be used if specic data is
available.

Reliability Factor YZ 110

Requirements of Application YZ
Fewer than one failure in 10 000 1.50

Fewer than one failure in 1000 1.25

Fewer than one failure in 100 1.00

Fewer than one failure in 10 0.85

2

Fewer than one failure in 2 0.70

23

Notes: 1) Tooth breakage is sometimes considered a greater hazard than pitting.

In such cases a greater value of YZ is selected for bending. 2) At this value plastic
ow might occur rather than pitting. 3) From test data extrapolation.

10 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl

Hanser Verlag Muenchen Wien, 1996, p. 367, table 6.5/16

Service Factor CSF

The service factor CSF has been used in previous AGMA standards to include the combined eects of overload,
reliability, life and other application related factors. This standard provides a means to account for: variations
in load (with overload factor), statistical variations in S-N data (with reliability factor), and the number of
design stress cycles (with stress cycle factor).

The AGMA service factor as traditionally used in gear applications depends on experience acquired in each
specic application. Product application standards can be a good source for the appropriate value of service
factor. Equations 28 and 29 of AGMA 2101-D04 are used to establish power ratings for unity service factor
to which established service factors may be applied using equation 30. When this is done, the stress cycle
factor is calculated using the number of cycles equivalent to a specic number of hours at a specic speed, to
establish power rating for unity service factors.

Where specic experience and satisfactory performance has been demonstrated by successful use of established
service factors, values of ZN and YN of 1.0 may be appropriate.

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7.7 Input of Gear Tooth Prole and Gear Flank Modications

Manufacturing errors, misalignment in the assembly of the gears as well as displacement of the gears under
load lead to non-uniform load carrying across the facewidth and move a signicant concentration of load to
the tooth edges. Intentional deviations from the involute prole (prole modication) and from the theoretical
tooth trace (ank modication) are used to minimize the manufacturing inaccuracies and elastic deformations,
to improve the running behavior and to reduce the noise of the gear pair.

Figure 7.124: Input of prole and ank modications

There are dierent types of tooth corrections. Short and long linear or short and long circular tip and root relief
are typical tooth prole modications. Lead crowning and end relief are common ank modications. These
corrections tend to give better load distribution over the facewidth and can reduce the eects of misalignment.
Using prole or ank modication requires an appropriate degree of gear accuracy. The minimum required
gear manufacturing accuracy is DIN quality 7 or better. Design details should be based on a careful estimate
of the deformations and manufacturing deviations of the gearing.

7.7.1 Gear Tooth Prole Modication

In case of gear tooth prole modication, parts of the involute prole are changed to reduce the load in that
area. Prole modications help gears to run more quietly and to regulate transmission errors.

Figure 7.125: Gear tooth prole modication

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Tip Relief and Root Relief

Tip relief is a modication whereby material is removed at the tips of the gear tooth. In case of root relief, a
small amount of material is removed near the root of the gear tooth. The modied tooth prole merges as
continuously as possible into the theoretical tooth prole. Prole crowning can be seen as a combination of
tip and root relief.

Figure 7.126: Tip and root relief

There are dierent types that can be chosen for the prole modication. A simple type of prole modication
is the linear tip relief on pinion and gear. However, it is also possible to execute only one gear with a tip and
root relief instead of both gears. The listbox allows to select linear and circular prole modication. The linear
relief results in the greatest material removal and thus the greatest relief in the eective ank area.

When determining the lengths of the prole correction, a distinction is made between short and long prole
modication. In case of long tip and root relief, the entire double contact area is corrected, while in the case
of short execution, only half of the double contact area is removed. Either long or short reliefs are used on a
gearing. The long prole modication is usually suitable for a quiet operation, while the short prole correction
has better load behavior. As long as the overlap ratio is sucient, a long prole correction is more suitable
for helical gearing.

Figure 7.127: Selection of tip relief

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Linear and Circular Tip and Root Relief

Figure 7.128: Linear tip relief Figure 7.129: Linear root relief

Figure 7.130: Circular tip relief Figure 7.131: Circular root relief

The linear tip and root relief is executed in the eAssistant with a transition rounding from the modied to the
unmodied area. You can enter the start and end of the transition rounding in the corresponding input elds.
For circular relief, the input of the transition start and transition end is not required.

Figure 7.132: Selection of linear tip relief

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 278

Linear Relief with Transition Radius

Figure 7.133: Linear relief with transition radius

In case you know the relief length, you can simply enter this value into the input eld. In case the length
is unknown, select `short' or `long' from the listbox. The eAssistant software determines the relief length
automatically. If a diameter is given on the drawing, it is possible to dene the diameter. Click the `d/l'
button on the right side to switch between the input for diameter or length.

Figure 7.134: Diameter and length

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 279

When you enable the checkbox `Use theoretical length of path of contact', then the theoretical path of contact
of a gear with a rack is used.

Figure 7.135: Use theoretical length of path of contact

Prole Crowning
Prole crowning can be seen as a combination of tip relief and root relief. Material is removed from the tip
and from the root of the tooth.

Figure 7.136: Prole modication

You can select symmetric prole crowning from the listbox and add a value for Cha to the input eld.

Figure 7.137: Symmetric modication

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7.7.2 Gear Flank Modications

Gear ank modications are intentional deviations from the theoretical tooth trace. Lead crowning and
end relief are typical gear ank modications and are advantageous for a better load distribution across the
facewidth of the gear. Both can compensate for misalignment so that the stresses do not rise at the tooth
ends.

Figure 7.138: Flank modication

End Relief
Due to mesh misalignments, an overloading of the tooth ends occurs. Therefore, end relief is used to protect
the tooth ends from overloading. Usually, the relief applied is the same at both ends of the teeth. In case
crown shaving and crown grinding are not possible, then end relief is recommended.

Figure 7.139: End relief (double-sided)

End relief can be applied to both tooth ends or to the left or right end of the tooth.

Figure 7.140: Selection of end relief

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 281

End relief: Double-sided, Left and Right Side

Figure 7.141: End relief (left side)

Figure 7.142: End relief (right side)

Figure 7.143: End relief (double-sided)

According to DIN 3990 Part 1, the height of end relief is calculated as follows:

For through-hardened gears: Ce ≈ Fβxcv plus a manufacturing tolerance of 5 to 10 µm. Thus, by analogy
with Fβxcv (initial equivalent misalignment) in DIN 3990, Ce should be approximately:

Ce = fsh + 1, 5 · fHβ

For surface hardened and nitrided gears: Ce ≈ 0, 5 · Fβxcv plus a manufacturing tolerance of 5 to 10 µm.
Ce should be approximately:

Ce = 0, 5 · (fsh + 1, 5 · fHβ )

When the gears are of such sti construction that fsh can for all practical purposes be neglected or when the
helices have been modied to compensate deformation, the following is appropriate:

Ce = fHβ

60% to 70% of the above values is appropriate for very accurate and reliable gears with high tangential
velocities.

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According to DIN 3990 Part 1, the width (or length) of end relief can be determined as follows:

Figure 7.144: End relief

For approximately constant loading and higher tangential velocities:

le = kleinerer Wert von 0, 1 · b oder 1·m

The following is appropriate for variable loading, low and average speeds:

bred = (0, 5 to 0, 7) · b

Lead Crowning
Lead crowning is a common way of crowning is the so-called lead crowning. This type is employed in order
to compensate for manufacturing deviations and load-induced deformations of the gears and in particular to
relieve the tooth-endloading.

Figure 7.145: Lead crowning

Gears are usually crowned symmetrically about the mid-facewidth and the tooth center is slightly thicker than
the tooth edges. The tooth anks of the gear have a slight outward bulge in its center area. It is possible to
select symmetrical and asymmetrical lead crowning from the listbox.

Figure 7.146: Symmetrical crowning Figure 7.147: Asymmetrical crowning

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 283

According to DIN 3990 Part 1, the height of lead crowning can be determined as follows:

Cb = 0, 5 · (fsh + 1, 5 · fHβ )

When the gears are of such sti construction that fsh can for all practical purposes be neglected or when
the helices have been modied to compensate for deformation at mid-face width, the following value can be
substituted:

Cb = fHβ

Subject to the restriction 10 ≤ Cb ≤ 25 µm plus a manufacturing tolerance of about 5 µm, 60% to 70% of
the above values are adequate for extremely accurate and reliable high speed gears.

Figure 7.148: Height of lead crowning

7.8 Meshing Interferences for External Gears

If parts of the ank of gear and mating gear mesh outside of the path of contact or if the contact ratio is
γ < 1, then meshing interferences may occur. A large prole shift as well as a very small tip clearance may
cause meshing interferences. Interference takes place between the tip of the tooth of the gear and root llet
area of the mating tooth. In some cases, the interference may be eliminated by decreasing the addendum of
only one gear teeth. Due to meshing interferences, operating noise, gear failure (e.g., tooth breakage) and an
increased wear can occur. In case of a basic rack prole, meshing interferences can be manipulated or removed
by the following:

- Tip diameter modication,

- Addendum chamfer,

- Changing of prole shift,

- Other manufacturing tools

7.8.1 Meshing Interferences Due to Low Contact Ratio

To assure smooth continuous tooth action, a pair of teeth must already have come into engagement. Especially
for spur gear pairs a low contact ratio can appear:

- the prole shift is too large and a small number of teeth,

- the tip diameter modication is too large,

- an undercut occurs due to insucient prole shift and small number of teeth.

The condition for a smooth and continuous tooth action is:

γ = α + β > 1

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The result panel displays the total contact ratio. In case the condition γ = α + β > 1 is not fullled, the
total contact ratio will be marked in red. Furthermore, you will get an appropriate warning in the message
window.

Figure 7.149: Total contact ratio

7.9 Message Window

The calculation module provides a message window. This message window displays detailed information,
helpful hints or warnings about problems. One of the main benets of the program is that the software
provides suggestions for correcting errors during the data input. If you check the message window carefully
for any errors or warnings and follow the hints, you are able to nd a solution to quickly resolve calculation
problems.

Figure 7.150: Message window

7.10 Quick Info: Tooltip

The quick info tooltip provides additional information about all input elds and buttons. Move the mouse
pointer over the input eld or button, then you will get the additional information. This information will be
displayed in the quick info line.

Figure 7.151: Quick info line

7.11 Calculation Results

All results will be calculated during every input and will be displayed in the result panel. A recalculation
occurs after every data input. Any changes that are made to the user interface take eect immediately. In

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case a minimum safety is not fullled, the result will be marked red. Press the Enter key or move to the
next input eld to complete the input. Alternatively, use the Tab key to jump from eld to eld or click
the `Calculate' button after every input. Your entries will be also conrmed and the calculation results will
displayed automatically.

Figure 7.152: Calculation results

7.12 Dokumentation: Protokoll

After the completion of your calculation, you can create a calculation report. Click on the `Report' button.

Figure 7.153: Button `Report'

The calculation report contains a table of contents. You can navigate through the report via the table of
contents that provides links to the input values, results and gures.

Figure 7.154: Calculation report

The report is available in HTML and PDF format. Calculation reports, saved in HTML format, can be opened
in a web browser or in Word for Windows. You may also print or save the calculation report:

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 286

- To save the report in the HTML format, please select `File' ⇒ `Save as' from your browser menu bar.
Select the le type `Webpage complete', then just click on the `Save' button.

- If you click on the symbol `Print', then you can print the report very easily.

- If you click on the symbol `PDF', then the report appears in the PDF format. If you right-click on the
PDF symbol, you should see the `Save Target As' option. Click on that option and you will see the
Windows save dialog.

7.13 How to Save the Calculation

When the calculation is nished, it is easy to save the calculation. You can save your calculation either to the
eAssistant server or to your computer. Click on the button `Save'.

Figure 7.155: Button Speichern

Before you can save the calculation to your computer, you need to activate the checkbox `Local' in the
calculation module. A standard Windows dialog for saving les will appear. Now you will be able to save the
calculation to your computer.

Figure 7.156: Windows dialog for saving the le

In case you do not activate the option in order to save your les locally, then a new window is opened and
you can save the calculation to the eAssistant server. Please enter a name into the input eld `Filename' and
click on the button `Save'.

Figure 7.157: Save the calculation

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7.14 The Button `Redo' and `Undo'

The `Undo' button allows you to reset your inputs to an older state. The `Redo' button reverses the undo.

Figure 7.158: The button `Redo' and `Undo'

7.15 The Button `CAD'

The top menu bar of the eAssistant software provides the button `CAD'.

Figure 7.159: Button `CAD'

The eAssistant plugin for various CAD systems (e.g., SOLIDWORKS, Solid Edge or Autodesk Inventor) en-
ables you to combine calculation and design very easily. On the basis of the eAssistant calculation, you can
generate spur gears in a 2D DXF format or create as a 3D part within seconds.

7.15.1 DXF Output for the Accurate Tooth Form

Click on the menu item `CAD ⇒ DXF Output'. Now you are able to create the accurate tooth form of any
involute gearing in the 2D DXF format. Use the various settings for the DXF output.

Figure 7.160: DXF output

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7. Rack/Pinion Pairings According to DIN 3990, ISO 6336 and Other Standards 288

For the DXF output the following options are possible:

- DXF output of pinion or gear rack

- Output in normal section or transverse section (both options will be active when an helix angle is entered)

- DXF output with points, lines, polylines, arcs

- Number of teeth

- Minimum point distance

- Input of a required layer name where the contour should be placed

- Save the DXF le including the header

Figure 7.161: Settings for the DXF output

When you have dened all settings, then click on the button `OK'. A standard Windows dialog is opened to
save the le.

Figure 7.162: Saving the DXF le

Now you can save the DXF le to your computer. Enter a name for the le and click on the button `Save'. It
is not necessary to specify the le extension. The le is identied automatically.

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7.15.2 GDE Format

With the integration of the standardised GDE format into the modules for gears and involute splines, eAssistant
takes a step closer to a seamless data workow. GDE stands for Gear Data Exchange. This format, which is
dened in VDI/VDE guideline 2610, is already supported by many measuring machine manufacturers. With
the GDE format, geometries of cylindrical gears and involute splines can be loaded directly from the software
into the measuring machine. It only takes a few clicks to create a measuring program. This avoids transmission
errors and allows to work with standard measuring instructions.

Figure 7.163: GDE format

7.15.3 eAssistant CAD Plugin

The eAssistant plugin for various CAD systems (e.g., SOLIDWORKS, Solid Edge, Autodesk Inventor) enables
you to combine calculation and design very easily and fast. Based on your eAssistant calculation, you can
generate external and internal spur and helical gears as a 3D part within seconds. A single menu pick in the
eAssistant software transfers the eAssistant calculation data to the CAD system. Based on these parameters,
the automatic creation of a 3D parametric model starts in the CAD system. Allowances, addendum chamfer,
prole shift and prole modications (tip and root relief ) are taken into consideration.

Figure 7.164: CAD plugin

The CAD model stores all features and dimensions as design parameters. The eAssistant calculation is linked
and associated to the part and can be opened at any time throughout the entire design phase. This is also
possible if one part contains dierent calculations. Click the button `CAD' and select the CAD plugin. Open
the CAD system and start the generation by clicking the integrated button `eAssistant'.

Please note: First you need to download and install the right CAD plugin for your CAD system. The plugin
is available on our web site www.eAssistant.eu. After installation, an integrated button called `eAssistant'
appears in the CAD system.

With just one click, the design table with all manufacturing details can be placed on the sheet. The appearance
and size of that table is individually congurable. There is no need to manually add all design table parameters
to the drawing. For further information, please visit our web site www.eAssistant.eu or read the manual.

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7.15.4 Manufaturing Data

The button `CAD ⇒ Manufacturing data' allows to save the manufacturing data to a text le.

Figure 7.165: Output of manufacturing data

7.15.5 Coordinate Table

The gear tooth form geometry of a tooth space can be exported as a coordinate text le in transverse section
as well as in normal section.

Figure 7.166: Coordinate table

7.16 The Button `Options'

Click on the button `Options' in the top menu bar of the eAssistant software.

Figure 7.167: Button `Options'

This option allows you to change some general settings:

- Unit switch between the metric system and the U.S. customary unit system, the unit can also be changed
directly for each individual input value. Simply click on the label of the corresponding input eld and

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select the unit from the context menu. You will see the change of the unit of measurement immediately
in the label of the input eld. The current eld value will be converted to the corresponding unit.

- Driving gear

- Minimum safety tooth root/tooth ank

- Minimum safety scung (integral)/scung (ash)

- Factor for minimal gear ring thickness: the factor can be specied by the user. This factor controls
the value for the largest possible bore diameter (inner diameter) for external gears and the smallest
possible outer diameter for internal gears. The default value 2.0 refers to forged gears (see main mask
`Geometry'), recommendations according to Schlecht (Maschinenelemente 2, 2010): gear ring thickness
for extreme lightweight constructions < 2 · m, cast constructions 5...8 · m, for welded constructions
3...5 · m.

- Chord of tooth root thickness analog FVA: this option has only eect on the calculation with protuberance
tools

- Complete calculation report

- Calculation report without load spectrum

Figure 7.168: Settings

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Chapter 8

Cylindrical Gears According to DIN

3990 and Other Standards

8.1 Start the Calculation Module

Please login with your username and your password. To start the calculation module for cylindrical gears,
please click the menu item `Gear calculation' on the left side and then select `Cylindrical gear pair'.

Figure 8.1: General overview

The eAssistant module allows an easy and fast calculation of the geometry of cylindrical gears according to
DIN 3960, DIN 3961, DIN 3964, DIN 3967, DIN 3977 and DIN 868. The load capacity according to DIN
3990, ISO 6336, ANSI/AGMA 2101-D04, ISO/TR 13989 (scung) and the load capacity for plastic gears
according to VDI 2736 is considered as well. You can calculate external and internal spur and helical gears.
The prole shift, the addendum chamfer and allowances are also integrated into the calculation.

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8.2 Input of Geometry Data

All important calculation results will be calculated during every input and will be displayed in the result panel.
A recalculation occurs after every data input. Any changes that are made to the user interface take eect
immediately. Press the Enter key or move to the next input eld to complete the input. Alternatively, use
the Tab key to jump from eld to eld or click the `Calculate' button after every input. Your entries will be
also conrmed and the calculation results will displayed automatically. If the result exceeds certain values, the
result will be marked red.

8.2.1 Normal Module

The normal module mn is one of the basic parameters in the gear geometry and describes the size of a gear.
The module is dened as the ratio of the pitch diameter to the number of teeth of a gear. Note that the
larger the module the larger the teeth. The value of the module is dened in millimeters. In order to limit the
number of the gears, the module has been standardised in preferred series 1 and 2 (see following tables). The
calculation with the eAssistant software is possible with any modules including several decimal places.

Series of Modules in mm According to DIN 780 Series 1 (Part 1)

0.05 0.06 0.08 0.10 0.12 0.16 0.20 0.25

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Series of Modules in mm According to DIN 780 Series 1 (Part 2)

1.25 1.5 2 2.5 3 4 5 6 8

10 12 16 20 25 32 40 50 60

Series of Modules in mm According to DIN 780 Series 2 (Part 1)

0,055 0.07 0.09 0.11 0.14 0.18 0.22 0.28 0.35

0.45 0.55 0.65 0.75 0.85 0.95 1,125 1,375 1.75

Series of Modules in mm According to DIN 780 Series 2 (Part 2)

2.25 2.75 3.5 4.5 5.5 7 9 11

14 18 22 28 36 45 55 70

8.2.2 Pressure Angle

The pressure angle is the angle between the line-of-action and the common tangent to the pitch circles. With
an increasing distance from the base circle, the prole angles αy increase too. The most common pressure
angle αn (on reference circle) now in use for spur gears is 20◦ . This pressure angle is usually preferred due
◦
to its stronger tooth shape and reduced undercutting. The 25 pressure angle has the highest load-carrying
ability, but is more sensitive to center-distance variation and hence runs less quietly. The choice is dependent
on the application. The default startup setting for the pressure angle is set to 20◦ .

8.2.3 Helix Angle

For spur gears the helix angle is β = 0◦ , for helical gears the angle β is up to 45◦ due to the fact that the
◦
teeth for a helical gear are inclined by the angle. 45 is also the maximum value that you can enter into the
input eld for the helix angle. For an external gearing a right-hand teeth and a left-hand teeth can only mesh
correctly. For internal gearings pinion and gear must have the same direction.

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Helical Gears
Helical gears are used to transmit power or motion between parallel shafts. Helical gears dier from spur gears
in that they have teeth that are cut in the form of a helix on their pitch cylinders instead of parallel to the
axis of rotation. As two teeth on the gear engage, it starts a contact on one end of the tooth which gradually
spreads with the gear rotation, until the time when both the tooth are fully engaged. Finally, it recedes until
the teeth break contact at a single point on the opposite side of the wheel. Thus force is taken up and released
gradually. Helical gears oer a renement over spur gears. The angled teeth engage more gradually than do
spur gear teeth. This causes helical gears to run smoother than spur gears. Helical gears are used in areas
requiring high speeds, large power transmission or where noise prevention is important.

8.2.4 Standard Centre Distance

The centre distance is the distance between the centre of the shaft of one gear to the centre of the shaft of
the other gear. If you change the number of teeth, the standard centre distance ad is modied automatically.
The standard centre distance is an operand. If the sum of the prole shift coecients = 0, ad corresponds to
the working centre distance a.

8.2.5 Working Centre Distance

The working centre distance a is the distance between the axes. In case of changing the normal module mn ,
the working centre distance is determined automatically. If the prole shift is too large, the working centre
distance can be modied manually at any time. If the standard centre distance and the working centre distance
are equal, the prole shift coecients will be set to the value `0' automatically.

Figure 8.2: Standard centre distance and the working centre distance

Enter the value `13' for the number of teeth for gear 1 and the number of teeth `63' for the gear 2, a `5'
normal module and a helix angle of β = 15◦ . The standard centre distance and the working centre distance
are determined automatically.

Figure 8.3: Inputs

Enter the value `0' for the working centre distance into the input eld and conrm with Enter key or click on
the `Calculate' button.

Figure 8.4: Input `0'

The standard centre distance and the working distance are equal.

Figure 8.5: Centre distance

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8.2.6 Direction of Helix Angle

Enter a value for the direction of the helix angle. When the gear is placed on a at surface, the teeth of a
left-hand gear lean to the left and the teeth of a right-hand gear lean to the right. It should be noted that a
pair of helical gears on parallel shafts must have the same helix angle β. However, the helix directions must be
opposite, i.e., a left-hand mates with a right-hand helix. For an external gear pair the engaged gearings have
dierent directions, internal gears have the same direction with the same helix angle. Find further information
in the section 8.10.1 `Direction of Helix Angle'.

Figure 8.6: Left and right-hand teeth

Select the option `left' for gear 1. That means: Gear 1 is left-handed, gear 2 is right-handed (for external
gears).

Figure 8.7: Option

Select the option `left' for gear 2. That means: Gear 2 is left-handed, gear 1 is right-handed (for external
gears).

Figure 8.8: Option

8.2.7 Number of Teeth

The number of teeth of a gear describes the number of the teeth on the full rim. The number of teeth is
positive for external gears and negative for internal gears. Please note that the smaller the number of teeth
the larger the inuence of the prole shift. Find more information about the prole shift coecient in section
8.2.9 `Prole Shift Coecient'. In section `Internal gearings' you will get more information about the number
of teeth for internal gearings.

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8.2.8 Facewidth
The facewidth b is the length of the gear teeth as measured along a line parallel to the gear axis.

Figure 8.9: Facewidth

Enter a value for the facewidth. The following table shows some additional information about the facewidth
b as well as minimum number of teeth z.

Figure 8.10: Enter the facewidth

Standard Values for the Facewidth b and Minimum Number of Teeth z 1

Gears on rigid shafts, that run in roller or excellent plain bearings,
b ≤ 30 . . . 40 · m
Teeth, machine-cut rigid substructure

Gears in usual gear boxes, roller or plain bearings b ≤ 25 · m

Gears on steel constructions, beams and suchlike b ≤ 15 · m
Gears with excellent bearing in high duty gearings b ≤ 2 · d1
Teeth, cast roughly Overhung gears b ≤ 10 · m
Gears with high circumferential velocity(υ > 4 m/s) and considerable z1 ≥ 16
power, when εα > 1.5
Gears with mean circumferential velocity(υ = 0.8 . . . 4 m/s) z1 ≥ 12
Gears with low circumferential velocity(υ < 0.8 m/s) or for low power for subor-
z1 ≥ 10
dinated purposes

Basically external gearings z1 + z2 ≥ 24

Basically internal gearings z2 ≥ z1 + 10
1 from: Karl-Heinz Decker: Maschinenelemente: Gestaltung und Berechnung, 1992, p. 506, table 23.2

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8.2.9 Prole Shift

Prole shift can make spur gears or helical gears run more quietly and carry more load. If spacing errors
of some magnitude are present, proper prole shift will give the teeth a little clearance at the rst point of
contact. If a pair of teeth are spaced too close together, there is a bump as the tooth comes into mesh. With
the modication there is a little relief at the rst point of contact. The prole shift aects the tooth form
because the tool is shifted by the value xm towards or away from the tip circle. The calculation of the tip
diameter da and root diameter df includes the prole shift coecient x. According to DIN 3960 the prole
shift is

- positive if the prole reference line is shifted from the reference circle towards the tip circle,

- negative if the prole reference line is shifted from the reference circle towards the root circle.

You can select the prole shift coecients x1 and x2 . Please note that no meshing interferences occur. In
case meshing interferences occur, you will get an appropriate message in the message window.

Figure 8.11: Change the tooth form with the prole shift: number of teeth z = 10; tooth 1: x = 0.5; tooth
2: x = 0; tooth 3: x = -0.5

Characteristics of the Prole Shift

- A positive prole shift increases the tooth thickness, a negative prole shift decreases the tooth thickness.

- With an increasing positive prole shift, the tooth tip thickness and the root llet become smaller, the
axle load and the load capacity increase. This advantage occurs especially for a smaller number of teeth.

- The minimum permitted tooth tip thickness determines the limit for a very large prole shift, in particular
for very small number of teeth.

- The prole shift aects the operating pressure angle as well as the load capacity.

- For a small number of teeth and with a negative prole shift, an undercut becomes a problem (see above
gure). The undercut weakens the tooth root and a part of the tooth ank is cut o.

Here you get the possibility to dimension and optimize the prole shift coecient. To optimize the prole
shift coecient, click on the `Calculator' button.

Figure 8.12: Prole shift coecient

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8. Cylindrical Gears According to DIN 3990 and Other Standards 298

Enter either your own value for the prole shift coecients into the input eld or activate the option `Balanced
specic sliding'. The coecients will be modied. Enter either your own values for the prole shift coecients
or activate the option `Balanced specic sliding'. The factors are modied so that the specic sliding is
balanced. The tooth anks slide and roll on each other. The measure for the sliding velocity and the rubbing
wear of the tooth anks presents the relative sliding, the so-called specic sliding. The specic sliding is the
ratio of the sliding velocity and radial velocity. The specic sliding shows which of the two gears could be
damaged by the rubbing wear. In general, the value for the specic sliding should not exceed `3'.

Figure 8.13: Balanced specic sliding

Please Note: Activate the `Lock' button next to Σx and click the `OK' button. You will get to the geometry
mask and you will see that the input eld for the working centre distance is disabled. Enter the prole shift
coecients x1 and x2 and click the Enter key and the working centre distance is automatically determined
from x1 andx2 . Disable the `Lock' button again, then the input eld changes and you can add your value for
the working centre distance.

Figure 8.14: Enable `Lock' button

Further options are available for the distribution of the prole shift coecients: `Fixed working center distance
(recalculation)', `Minimum sliding speed', `Geometric minimum gear 1', `Geometric maximum gear 1', `Max-
imum root safety', `Maximum ank safety' and `Maximum scung load capacity (integral)'. The last three
options are only available for selection when the load capacity is activated.

Figure 8.15: Options for the distribution of the prole shift coecients

The calculation module provides the function Fixed working center distance (recalculation) for disconnecting
the prole shift sum and the center distance. With this function, the prole shift coecients can be can be
specied independently of the center distance. This enables, for example, the calculation of existing gear pairs
that are to be installed in the housing with the `wrong' centre distance. Transverse contact ratio, backlash
and load capacity are also calculated correctly in this case. This function can also be used for the calculation

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8. Cylindrical Gears According to DIN 3990 and Other Standards 299

of small-module gears.

8.2.10 Tip Diameter

The tip diameter da depends on the module and will be determined by the program automatically. If you
change the prole shift, the tip diameter will change, too. There is the possibility to enable the tip circle
using the `Lock' button. Now you can add and modify the tip diameter very easily. Please note that the tip
diameter has an inuence on the modication of the tip diameter. Click on the button again to disable the
input eld. The value is determined again according to DIN. In case you use a special tool, the tip diameter can
be changed by a tool customization. Find out more about the tool data in the section `The input of tool data'.

8.2.11 Tip Diameter Allowance

The tip diameter allowance is determined according to DIN. Click on the `Lock' button to enable the input
eld and enter your own value. If your values are out of range of the DIN, you will get an information in
the message window. Click on the `Lock' button and the input eld is disabled again. The allowances are
determined according to DIN.

Figure 8.16: Enable the input eld

8.2.12 Modication of Tip Diameter

The modication of the tip diameter k is automatically determined by the program that a sucient tip
clearance is available. For external gears the modication of the tip diameter is k ≤ 0, for internal gears,
the value is often set to k=0 in order to avoid meshing interferences. Click on the `Lock' button to enable
the input eld and enter your own value. Such a modication of the tip diameter has an eect on the tip
diameter.

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8.2.13 Tip Clearance

Clearance c is the distance between the root circle of a gear and the addendum circle of its mate. A certain
clearance between the gears is necessary for a smooth operation without jamming.

Figure 8.17: Tip clearance c

A distinction is made between two dierent kind of clearances. There is the tip clearance c and the backlash j .
Standard gears have got a basic rack prole with a addendum coecient ha = m or a tool basic rack prole
with hf p = m. The dedendum coecient hf of the basic rack prole or the addendum coecient hap of the
tool basic rack prole has to be larger due to ensure that tip and root circle of the gears are not in contact.

Backlash j
If the gears are of standard tooth proportion design and operate on standard center distance, they would
function ideally with neither backlash nor jamming. The general purpose of backlash is to prevent gears from
jamming and making contact on both sides of their teeth simultaneously. Any error in machining which tends
to increase the possibility of jamming makes it necessary to increase the amount of backlash. Consequently,
the smaller the amount of backlash, the more accurate must be the machining of the gears. Runout of both
gears, errors in prole, pitch, tooth thickness, helix angle and centre distance - all are factors to consider in
the specication of the amount of backlash. In order to obtain the amount of backlash desired, it is necessary
to change the tooth thickness or tooth space allowances (please see also section 8.4.8 `Backlash Normal Plane').

8.2.14 Root Diameter

The root diameter df depends upon the module, the prole shift and addendum coecient of the basic rack
prole. The root diameter is determined by the program. Therefore, the root diameter occurs as a result of
the calculation.

8.2.15 Allowances of Root

The allowances of root result from your calculation and will be determined automatically. The allowances
depend upon the tooth thickness allowances. For instance, if you enter the value `0' for a gear, then the
allowances of root become `0' for this gear as well.

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8.2.16 Inner and Outer Diameter

Here you can enter an inner diameter (for external gears) and outer diameter (for internal gears). It should
be kept in mind that the inner diameter has to be smaller than the root diameter df .

Figure 8.18: Inner diameter

In case the inner diameter is larger than df , then the program automatically corrects the value and enters the
maximum value for the inner diameter. An appropriate message appears in the message window.

8.2.17 Web Width

The web width can be considered here. The web width is shown in the gure next to the input eld. There
is the possibility to modify the web width by using the `Lock' button.

Figure 8.19: Input eld for the web width

The `Lock' button is still disabled. Enter the values for the inner or outer diameter into the input eld. Then
the `Lock' button is enabled and the web width gets the same value as the facewidth. In case the web width
is smaller than the facewidth, then the gear body stiness is aected due to the gear body coecient CR .
The tooth spring stiness changes which aects again the load capacity.

Figure 8.20: Web width

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8. Cylindrical Gears According to DIN 3990 and Other Standards 302

8.2.18 Chamfer
The chamfer can be considered. This reduces the calculated facewidth for the calculation of the load capacity
of the tooth root and tooth ank.

Figure 8.21: Chamfer

8.2.19 Addendum Chamfer

The tooth ends of a gear are often rounded or chamfered. A chamfer is a small angled surface added on
the end of a shaft along an edge. For the calculation you can consider the addendum chamfer. Meshing
interferences can be removed by the addendum chamfer.

Figure 8.22: Addendum chamfer

Please Note: If you dene the geometry of the gear pair, you are able to look at the tooth form. Click on
the button `Tooth form' and select `Total view' or `Detail view' (nd more information on the tooth form and
its functions in section 8.5 `Representation of Tooth Form'). Click the button `Geometry' and you get to the
geometry input again.

As an alternative to the addendum chamfer, a tip corner radius can be specied. This can be dened either
as a radial amount or directly as a radius. The selection is marked by the colored arrow. The radius is entered
directly for the tip radius, the radial amount is entered for the tip radius (Rad.).

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8. Cylindrical Gears According to DIN 3990 and Other Standards 303

If you enter the tip radius directly as a value, you will receive the corresponding radial amount in the calculation
report.

Figure 8.23: Switch between input of addendum chamfer, tip corner radius (radial amount and radius)

In the case of tip corner radius or addendum chamfer, the tip form diameter is smaller than the tip circle
diameter by twice the radial amount hK .

Figure 8.24: Spur gear with addendum chamfer, hK = Radial amount of the tip corner radius, dF a = Tip form
diameter

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8. Cylindrical Gears According to DIN 3990 and Other Standards 304

8.3 Input of Tool Data

For the selection of the manufacturing process you have to consider the material, size of the gear, quantity, gear
type (external or internal gears) and accuracy. The many methods of making gear teeth must be considered
as well. The calculation program distinguishes between gear-tooth cutting and gear hobbing.

Figure 8.25: Input mask for tool data

Please note: If you want to add some own notes, comments or a description, then use the comment line.

8.3.1 Tool
The most important manufacturing processes are gear hobbing and gear shaping. Select either the tool `Hob' or
`Gear shaper cutter' by clicking the listbox. A `Constructed involute' is also available. Basically, the selection
of the tool depends on the gear type (external or internal gears). The external gears can be produced by
cutting wherein the gear cutting tool is a hob. For internal gears a gear shaper cutter is used (see section 8.11
`Manufacturing Process for Internal Gears').

Figure 8.26: Selection of tool

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8. Cylindrical Gears According to DIN 3990 and Other Standards 305

Gear Hobbing
The hobbing is the most widely used method of cutting gear teeth. The hobbing process is quite advantageous
in cutting gears with very wide facewidth. A very high degree of tooth-spacing accuracy can be obtained with
hobbing. With regard to accuracy, hobbing is superior to the other cutting processes. A wide variety of sizes
and kinds of hobbing machines are used. The rotating hob has a series of rack teeth arranged in a spiral
around the outside of a cylinder, so it cuts several gear teeth at one time. To generate the full width of the
gear, the hob slowly traverses the face of the gear as it rotates. Thus, the hob has a basic rotary motion and
an unidirectional traverse at right angles. Both movements are relatively simple to eect, resulting in a very
accurate process.

Field of Application of the Hob:

- Recommended for gears with very wide facewidth

- Recommended for external spur and helical gears up to module `40' (Please keep in mind: it is an
expensive tool for large modules)

- Recommended for all basic rack proles

- The helix angle is arbitrary.

Figure 8.27: Hob and gear shaper cutter

Gear Shaping
The shaping process is a gear-cutting method in which the cutting tool is shaped like a pinion. If a gear is
provided with cutting clearance and is hardened, it may be used as a generating tool in a gear shaper. The
cutter reciprocates while it and the gear blank are rotated together at the angular-velocity ratio corresponding
to the number of teeth on the cutter and the gear. The teeth on the gear cutter are appropriately relieved
to form cutting edges on one face. Although the shaping process is not suitable for the direct cutting of
ultra-precision gears and generally is not as highly rated as hobbing, it can produce precision quality gears.
Usually it is a more rapid process than hobbing. Two outstanding features of shaping involve shouldered and
internal gears. For internal gears, the shaping process is the only basic method of tooth generation.

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8. Cylindrical Gears According to DIN 3990 and Other Standards 306

Field of Application of the Gear Shaper Cutter:

- Recommended for internal and external spur and helical gears

- Racks

- Special gearings, e.g., splined shaft connections, face or chain gears

Constructed Involute
In addition to the hob and the gear shaper cutter, you can also select the entry `Constructed involute' as a
tool. In case internal gears cannot be shaped with a gear shaper cutter, the tooth form calculation is still
possible by using the constructed involute. This specically applies for applications in the precision mechanics.
This method allows a generation of the tooth form with a constant root llet radius.

Figure 8.28: Constructed involute

Representation of Hob and Gear Shaper Cutter

The representation shows either the hob basic rack prole or the gear shaper cutter tooth prole. The radio
buttons enable you to choose one of the graphical representation.

Figure 8.29: Tool

8.3.2 Standard Basic Rack Tooth Prole

To mesh two gears with each other, the parameters have to be coordinated. The standard basic rack tooth
prole is standardized in DIN 867. A gear with an innite number of teeth will have straight lines for both

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8. Cylindrical Gears According to DIN 3990 and Other Standards 307

the pitch and the base circles. The involute prole will be a straight line. The rack can be used to determine
the basic parameters. Racks can be both spur and helical. A rack will mesh with all gears of the same pitch.
The pressure angle and the gears pitch radius remain constant regardless of changes in the relative position of
the gear and rack. The tool standard basic rack prole is the counter prole of the standard basic rack tooth
prole. The following standard basic rack proles are available for your calculation. Choose your prole from
the listbox.

Figure 8.30: Listbox for the basic rack prole

- ISO 53 Prole A: is recommended for gears transmitting high torques

- ISO 53 Prole B: is recommended for normal service

- ISO 53 Prole C: is recommended for normal service, type C may be applied for manufacturing with
some standard hobs.

- ISO 53 Prole D: is recommended for high-precision gears transmitting high torques and consequently
with tooth anks nished by grinding or shaving. Care should be taken to avoid creating notches in the
llet during nishing which could create stress concentrations.

- DIN 3972 Prole I

- DIN 3972 Prole II

- Prole 1 DIN 867 (Numerical example from DIN 867)

- Prole 2 DIN 867 (Numerical example from DIN 867)

- Prole 3 DIN 867 (Numerical example from DIN 867)

- Prole 4 DIN 867 (Numerical example from DIN 867)

- AGMA PT (for plastic gears)

- AGMA XPT-2 (for plastic gears)

- AGMA XPT-3 (for plastic gears)

- AGMA XPT-4 (for plastic gears)

In addition to the standard basic rack proles, you can also select a protuberance tool. When part of the
involute prole of a gear tooth is cut away near its base, the tooth is said to be undercut. By using a
protuberance tool an undercut near the root can be generated. Grinding notches at the tooth ank can
be avoided during the grinding. That provides relief for subsequent nishing operations (see section 8.3.6
`Protuberance').

Figure 8.31: Selection of the protuberance tools

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8. Cylindrical Gears According to DIN 3990 and Other Standards 308

You can select the following proles:

◦
- Prot 1.4-6 /0,085

◦
- Prot 1.5-6 0.02

◦
- Prot 1.6-6 /0.02

◦
- Prot 1.4-8 /0.04

◦
- Prot 1.4-8 /0,066

◦
- Prot 1.4-10 /0.05

◦
- Prot 1.5-10 /0.02

◦
- Prot 1.6-10 /0.02

◦
- Prot 1.25-14 /0,024

◦
- Prot 1.4-6

◦
- Prot 1.4-10 (Fette) (Protuberance tool with shifted prole reference line with the data of the tool
manufacturer LMT Fette)

◦
- TBK Prot 10 (Protuberance tool with shifted prole reference line with data analog TBK V22)

Please Note: If you select `user dened input', then the input elds for the edge radius, the addendum
coecient and the dedendum coecient are activated. Now you can modify the basic rack prole.

Figure 8.32: Own input

Determination of the Basic Rack Prole

In case you use special tools, the eAssistant software oers an easy and comfortable solution. The basic rack
prole can be determined by clicking the `Calculator' button.

Figure 8.33: Tool dimensioning

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8. Cylindrical Gears According to DIN 3990 and Other Standards 309

Here you can change the tip circle and the root diameter for gear 1 and gear 2. Conrm your entries with the
button `OK'. The listbox for the basic rack proles displays then `user dened input'. The modication of the
tip diameter is set to '0'.

8.3.3 Tip Form

For the tip form you can choose between `Full radius' and `Radius with straight line'. Normally `Radius with
straight line' is used.

Figure 8.34: Listbox for tip form

8.3.4 Addendum Coecient

eAssistant provides a functionality for tools with a shifted prole reference line. Additionally to the addendum
coecient h∗aM P 0 of the shifted prole, the dedendum coecienth∗f M P 0 is displayed and visible in the
∗
calculation report. The dedendum coecient hf M P 0 can also be dened by clicking the `Lock' button so that
∗
the dedendum coecient hf P 0 of the converted, non-shifted basic rack prole is always 1.0 according to DIN
867.

Figure 8.35: Input of the addendum coecient for tool with shifted prole reference line

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8. Cylindrical Gears According to DIN 3990 and Other Standards 310

Shifted Prole Reference Line

Figure 8.36: Prole reference line according to DIN and shifted prole reference line

8.3.5 Semi Topping Flank and Topping

With the denition of the semi topping ank, corresponding hobs can then be specied. These generate an
addendum chamfer during the cutting process. The option `Topping' allows to dene the tip diameter directly
with the dedendum coecient of the tool, making it impossible to subsequently modiying the tip diameter.
The result, at the same time, will be tip diameter allowances analogous to the root diameter allowances directly
from the tooth thickness allowances. The eAssistant 3D CAD plugins for various CAD systems support the
function and the semi topping ank can be considered in the 3D CAD model.

8.3.6 Protuberance
Undercut may be deliberately introduced to facilitate nishing operations. Undercut is the loss of prole in
the vicinity of involute start at the base circle due to tool cutter action in generating teeth with low numbers
of teeth. The protuberance cuts an undercut at the root of the gear tooth. The protuberance design is also
used in some cases to permit the sides of gear teeth to be ground without having to grind the root llet.

Determination of the Amount of the Protuberance from the Height of the Protuberance Flank
The following equation determines the amount of the protuberance. In case the height of the protuberance
ank is given and not the amount of the protuberance, the amount of the protuberance may be calculated by
this equation.

(h∗prP 0 − ρ∗aP 0 · (1 − sin(αp ))) · sin(αn − αp )

prP∗ 0 = + ρ∗aP 0 · (1 − cos(αn − αp ))
cos(αp )

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8. Cylindrical Gears According to DIN 3990 and Other Standards 311

The following gure shows a representation:

Figure 8.37: Height of the protuberance ank

To avoid grinding steps, a deviation in the tooth root area of the prole is a common and allowed method.
Because of a grinding stock allowance, an undercut must be allowed. Hence, a larger tooth root thickness is
necessary. The following table shows some determination of the undercut dependent upon the module.

Undercut spr for Ground Gears Dependent upon Module2

Module Allowance Size of Protuberance Addendum Edge Radius

m q Undercut spr prP∗ 0 h∗aP 0 ρ∗aP 0

2 0,160 0,100 0,260 2,900 0,500

2,5 0,170 0,110 0,280 3,625 0,625

3 0,180 0,120 0,300 4,350 0,750

4 0,200 0,140 0,340 5,800 1,000

5 0,220 0,160 0,380 7,250 1,250

6 0,240 0,180 0,420 8,700 1,500

7 0,260 0,200 0,460 10,150 1,7500

2 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag, Muenchen, Wien, 2nd ed. 2010, p. 68, table 2.1/2

8.3.7 Machining Allowance

You can consider an allowance for the tooth ank. The tool provides an allowance q on the ank and/or root
for the pre-cutting tool. The allowance is the smallest distance between the involutes and the pre-machining
having the same root diameter. In case you select the tool basic rack prole with protuberance, the allowance
refers to the tooth ank.

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8. Cylindrical Gears According to DIN 3990 and Other Standards 312

If the allowance of the tool basic rack prole is selected without protuberance, then tooth ank and tooth
root get the allowance.

Figure 8.38: The eAssistant software provides the following allowances for the grinding of a gear: a) Constant
allowance with bottom of the tooth space, b) Protuberance: Cutter tooth prole is built up on the tip to
provide an undercut near the root of the gear being generated.

Figure 8.39: Input of machining allowance

Maximum Machining Allowances3

Allowance per Tooth Flank Manufacturing Process

< 0.05 (0.10) mm Finishing operation by cold rolling, gear shaving, hon-
ing, lapping

0.05 to 0.5 (1.5) mm Grinding, prole grinding, (honing)

> 0.5 mm, pre-cutting Primary shaping, forming, cutting with geometrically
determined edges except shaving, grinding and prole
grinding in special cases

3 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Ver-

lag, Muenchen, Wien, 1996, p. 638

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8. Cylindrical Gears According to DIN 3990 and Other Standards 313

8.4 Input of Data for the Determination of Allowances

A manufacturing of work-pieces with accurate nominal dimensions is impossible. Hence, a deviation from the
nominal size has to be allowed. For a lot of applications the gear and the pinion of a pair must be independently
manufactured and meshed without any modications. That means, the parts have to be separately replaceable.
In addition to DIN 3961 for gear tolerances/gear qualities, DIN 58405 for precision engineering as well as ISO
1328 and ANSI/AGMA 2015 are available.

Figure 8.40: Input of allowances

8.4.1 Gear Quality

The choice of the right toothing quality is determined by economical aspects depending upon the intended
purpose and manufacturing process. In all elds of gearing, the control of gear accuracy is essential. Several
classes or grades of accuracy can be set. 12 grades (12 to 1) are dened according to DIN standards. High
accuracy grades can be set for a long-life, high speed gears. Lower accuracy grades will cover medium or
slow-speed grades. Accuracy grade `1' describes the highest possible accuracy, `12' a very low accuracy. The
gear accuracy `1 to 4' is mainly used for master gears, quality `5 to 12' is used for gear wheels (gure from:
Niemann, G.: Maschinenelemente, Vol. 2, Getriebe allgemein, Zahnradgetriebe-Grundlagen, Stirnradgetriebe,
1989, p. 73, gure 21.4/1).

Figure 8.41: Tolerances according to the manufacturing process

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8. Cylindrical Gears According to DIN 3990 and Other Standards 314

Select the appropriate quality between 1 and 12 by using the following listbox.

Figure 8.42: Listbox for the selection of quality

The following table provides some reference values for the selection of the quality, tolerances for gearings made
of metal and plastics:

Toothing Made of Metal4

ν Machining Quality Tolerance Sequence
to m/s of Tooth Flanks (Accuracy) DIN 3967
0.8 Cast, raw 12 2x30

0.8 Rough-machined 11 or 10 29 or 28

2 Finish milled 9 27

4 Finish milled 8 26

8 Fine nished 7 25

12 Shaved or ground 6 24

20 Precision-ground 5 23

40 Precision-machined 4 or 3 22

60 Precision-machined 3 22 or 21

Toothing Made of Injection Molding Plastics

Application d Quality Tolerance Sequence
in mm (Accuracy) DIN 3967
Gearings with high requirements to 10 9 27

Gearings with high requirements 10 to 50 10 28

Gearings with normal requirements 10 to 50 11 29

Gearings with low requirements to 280 12 2 x 30

Toothing made of plastic manufactured by cutting

Gearings with high requirements to 10 8 25 to 27

Gearings with high requirements 10 to 50 9 26 to 28

Gearings with normal requirements to 50 10 27, 28

Gearings with normal requirements 50 to 125 11 27, 28

Gearings with low requirements to 280 12 28

4 from: Karl-Heinz Decker: Maschinenelemente: Gestaltung und Berechnung, 1992, p.

512, table 23.3

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8. Cylindrical Gears According to DIN 3990 and Other Standards 315

For the gear tolerances/gear qualities, DIN 58405 for precision engineering as well as ISO 1328 and ANSI/AGMA
2015 are also available. For ISO 1328 and ANSI/AGMA 2015, two qualities can be selected in each case. The
rst quality is comparable with the tolerances permitted according to DIN 3961, the second value inuences
the radial composite deviation as well as the roll deviations.

8.4.2 Backlash Allowance and Tolerance Sequence

The system for gearings is very similar to the DIN system of ts and tolerances. For the system of ts for
gear transmissions letters are used to indicate the deviation from basic (nominal) size, a number denes the
width. There are clearance ts for gearings, therefore, lower case characters `h' to `a' appear. If you select
the entry `user dened input', the input eld for the tooth thickness allowances is enabled and you can dene
your individual values.

Figure 8.43: Own input

8.4.3 Tooth Thickness Allowance

One of the most important criteria of gear quality is the specication and control of tooth thickness. The
magnitude of tooth thickness and its tolerance is a direct measure of backlash when the gear is assembled
with its mate. Dimensional changes, due to thermal expansion, do not allow a zero-backlash assembly. The
tooth thickness allowance has to be determined that no jamming occurs. To prevent that jamming of gears
during the operation, it is necessary to decrease tooth thickness by a minimum amount (Asne and Asn ).

Figure 8.44: Lower and upper tooth thickness allowances for gear 1 and gear 2

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8. Cylindrical Gears According to DIN 3990 and Other Standards 316

The tooth thickness allowances for teeth of external and internal gearings have to be negative. Then a backlash
occurs (nd more information on the backlash in section 8.4.8 `Backlash Normal Plane').

The eAssistant software oers the possibility to specify the tooth thickness allowances based on measured
data or given test dimensions. Click on the `Calculator' button.

Figure 8.45: `Calculator' button

A new window is opened.

Figure 8.46: Calculation of tooth thickness allowances

Activate gear 1 and gear 2 and enter the input values. Conrm with the button `OK'. The `Lock' button next
to the input eld for the tooth space allowances is enabled. Now you can change the tooth space allowances.

8.4.4 Tooth Space Allowance

The tooth space allowance AW is the dierence between the actual dimension and the nominal dimension of
the span measurement W k. The actual measurement of the span measurement gets smaller for external gears
by negative allowances for a zero-backlash assembly. The upper and lower tooth space allowance are displayed
as well. For an own input of the tooth thickness allowances, the tooth space allowances can be dened as
well. The `Lock' button next to the input eld of the tooth space allowances is enabled. Therefore, you can
change the tooth space allowances.

Figure 8.47: Tooth space allowance for gear 1 and gear 2

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8. Cylindrical Gears According to DIN 3990 and Other Standards 317

8.4.5 Measurement of Tooth Thickness

The tooth thickness of a gear may be measured directly with calipers or it may be determined indirectly by
diameter pins. The sizing of gears may be controlled by double-ank composite checks and centre distance
settings corresponding to maximum and minimum tooth thickness specications. Dierent measurement
methods are used:

- At pitch circle (chordal),

- Span measurement across several teeth,

- Measurement over pins or balls that are placed in diametrically opposed tooth spaces,

- Check of the centre distance allowance with zero-backlash engagement by using a master gear in a ank
roll tester.

In the following you get some information on the widely used measurement methods:

- Span measurement Wk
- Measurement by diameter over balls or pins, the measurement by using balls and pins

Span Measurement across Several Teeth

Span measurement Wk is the measurement of the distance across several teeth in a normal plane. As long as
the measuring device has parallel measuring surfaces that contact on an unmodied portion of the involute,
the measurement will be along a line tangent to the base cylinder. It is a widely used method for gauging the
tooth thickness by using the span measurement. The tooth thickness of spur or helical gears is often measured
with calipers. An advantage is that the dimensions can be inuenced during the manufacturing.

Figure 8.48: Span measurement

The calculation program determines the number of teeth for the span measurement (number of teeth across
the span measurement has to be gauged). By using the `Lock' button you are able to activate the input eld
and you can enter your own input value. If you click the button again, the previous input value appears.

Figure 8.49: Number of teeth for the span measurement

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8. Cylindrical Gears According to DIN 3990 and Other Standards 318

Tooth Thickness Measurement by Diameter over Pins or Balls

The tooth thickness is often checked by measurement over pins MdR or balls MdK . The pins or balls are
placed in diametrically opposed tooth spaces (even number of teeth) or nearest to it (odd number of teeth).
Measurement over pins is the measurement of the distance taken over a pin positioned in a tooth space and
a reference surface. The reference surface may be the reference axis of the gear, a datum surface or either
one or two pins positioned in the tooth space or spaces opposite the rst. The measurement over pins is only
used for spur gears and external helical gears. For the measurement values a distinction is made between:

- Measurement over balls MdK

- Measurement over pins MdR

- Measurement over pins for a spur gear

- Measurement over pins for external helical gears with even number of teeth

- Measurement over pins for external helical gears with odd number of teeth

For an external gear the measurement over balls MdK is the largest outer measure. The two balls are placed
in diametrically opposed tooth spaces. The balls have to be in the same plane perpendicular to a gear axis.
For an internal gear (see gure: `Internal spur gear with odd number of teeth') the measurement over balls is
the smallest inner measure between the balls. DM is the diameter of ball or pin. The internal gear is generally
checked for tooth thickness with measuring pins, like the external gear. However, the measurement is made
between the pins instead of over pins.

Measurement over balls: External spur gear with even num-

ber of teeth

Measurement over balls: External spur gear with odd num-

ber of teeth

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8. Cylindrical Gears According to DIN 3990 and Other Standards 319

Measurement over balls: Internal spur gear with odd num-

ber of teeth

The eAssistant software already species the diameter of ball or pin for the test dimensions. Enable the input
eld by clicking the `Lock' button. Enter your own input value for the diameter. If you click on the button
once again, the previous input value appears.

Figure 8.50: Diameter of ball or pin

Please Note: In the calculation report you can nd all results for the span measurement or measurement
over balls and pins in section `Test dimensions'.

8.4.6 Tolerance Field for Centre Distance

The general purpose of backlash is to prevent gears from jamming and making contact on both sides of their
teeth simultaneously. The center distance and the gear ts have an important inuence on the backlash.
The gear t selection denes the tolerances of the centre distance with the backlash. The gear t selection
provides only one tolerance eld. The allowances are indicated for the `JS' eld. These conform to the ISO
basic tolerances. The backlash is dependent upon the tooth thickness allowances, the tooth space allowances
and the centre distance. Hence, if you change the centre distance, then the backlash is changed, too.

Figure 8.51: Tolerance eld for the centre distance

Select the option `user dened input' from the listbox. Now you are able to enter your own centre distance
allowances. Conrm your entries with the Enter key. The backlashes are automatically determined.

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8. Cylindrical Gears According to DIN 3990 and Other Standards 320

8.4.7 Centre Distance Allowance

The centre distance allowance Aa is the allowed deviation of the centre distance from the nominal centre
distance. The allowances are indicated with ± to get no improper major allowances from the nominal centre
distances with gears having several axes.

Figure 8.52: Centre distance allowance

8.4.8 Backlash Normal Plane

A gear t has to be determined, so that two gears can be meshed. For that, a proper backlash must be provided
for the mesh to avoid jamming of the gears. The eAssistant software oers three dierent backlashes: the
backlash normal plane, the backlash pitch diameter and the radial backlash.

Figure 8.53: Backlash normal plane

Besides errors in manufacturing and assembling, the variation in backlash will depend considerably on the
tooth thickness tolerances and centre distance of the gears. The DIN system represents a standard centre
distance and provides the backlash by changing the tooth thickness. The backlash between the meshing teeth
adjusts the deviations of the tooth thicknesses, centre distance and tooth form using the tooth thickness
Asni and tooth space allowances Asne . The lowest tooth thickness allowance Asni indicates the maximum

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8. Cylindrical Gears According to DIN 3990 and Other Standards 321

backlash, the upper tooth thickness allowance indicates the minimum backlash Asne . In addition to the tooth
thickness allowance and centre distance allowance, errors in prole and pitch are also factors to consider in
the specication of the amount of backlash.

Please note: The backlash depends also on thermal expansions, deformation of elementes and displacement
of casing. These impacts must be considered for the determination of the tooth thickness.

8.4.9 Backlash Pitch Diameter

The backlash pitch diameter jt refers to the backlash at the pitch circle. The backlash pitch diameter may be
the length of the pitch circle arc in which the gear rotate against its mating gear.

Figure 8.54: Backlash pitch diameter

8.4.10 Radial Backlash

The radial backlash is the dierence of the centre distance between the working condition and zero-backlash
engagement. The radial backlash jr matters especially for very small modules (m < 0.6 mm).

Figure 8.55: Radial backlash

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8. Cylindrical Gears According to DIN 3990 and Other Standards 322

8.5 Representation of Gear Tooth Form

A special highlight of this calculation module is the presentation of the accurate gear tooth form with an
animation and simulation of the tooth mesh. For the presentation you can select the lower, upper and mean
allowances for the tooth thickness, tip diameter and centre distance. When you dene the geometry for the
gear pair, then you can have a look at the tooth form at any time. Click on the `Tooth form' button and you
get a general or detailed view of the tooth form. By clicking the `Geometry' or `Tool' button, you can open
the main input masks of the calculation module again.

Figure 8.56: Tooth form

Please Note: Please keep in mind that all values are later taken over to the DXF output and CAD generation.
In case you change the tooth thickness allowance or the centre distance allowance in the tooth form mask,
then the last modication is taken over to the DXF output. The section 8.21 `CAD button' contains some
helpful information on this function.

Figure 8.57: DXF output

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8. Cylindrical Gears According to DIN 3990 and Other Standards 323

8.5.1 Representation of Cylindrical Gear Pair

Click on the `Tooth form' button to represent the gear tooth form.

Figure 8.58: Cylindrical gear pair

Please Note: Please keep in mind that you can check the backlash and the mesh ratio only in the presentation
of the mesh. The gear mesh will be discussed in section 8.5.2 `Representation of Mesh'.

8.5.2 Representation of Tooth Mesh

Click on the `Detail view' button. You get a larger representation of the gear tooth form. Now you can see
the detailed tooth mesh. Click on the `Total view' button to obtain an entire view of the cylindrical gear pair.

Figure 8.59: Detail view of the mesh

Please Note: The representation of the tooth mesh allows you to look at the tooth thickness allowances, the
tip diameter and centre distance allowances as well the tooth mesh and to check the inuence of these values.
The tooth form mask provides various functions. Find a short description of these functions in the following
section.

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8. Cylindrical Gears According to DIN 3990 and Other Standards 324

8.5.3 Rotating Angle

Enter an rotating angle for the rotation of the spur gear pair.

Figure 8.60: Rotating angle

Rotation of the driving gear counter-clockwise

Rotation of the driving gear clockwise

8.5.4 Rotation
When you click on one of the two arrows, a continuous rotation of the spur gears occurs.

Figure 8.61: Rotation

Continuous rotation of the driving gear counter-clockwise

Continuous rotation of the driving gear clockwise

The rotation is stopped.

8.5.5 Tooth Thickness Allowance

Click on the `Detail view' button and the tooth mesh is represented in detail. Now you can change the tooth
thickness allowance, that is already given in the main mask for the `Allowances', within the tolerance limit.
All changes are displayed immediately. For the representation of the tooth mesh, select the lower, upper and
mean tooth thickness allowances for gear 1 and gear 2.

Figure 8.62: Tooth thickness allowance in the main mask `Allowance'

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8. Cylindrical Gears According to DIN 3990 and Other Standards 325

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower tooth thickness allowance. The right arrow
shows the representation for the upper tooth thickness allowance. The middle button displays the mean tooth
thickness allowance. At the rst start of the tooth form, you will get the mean tooth thickness allowance as
a standard feature. The tooth thickness allowances can be dened between the lower and upper allowance.

Figure 8.63: Tooth thickness allowance

Please Note: In case you have specied the lower and upper tooth thickness allowance for gear 1 and gear 2
in the input mask `Allowances' by using the `Calculator' button, then the manually dened values appear here
as lower and upper tooth thickness allowance.

8.5.6 Tip Diameter Allowance

Click the `Detail view' button and the tooth mesh is represented in detail. Now you can change the tip
diameter allowance, that is already given in the main mask for the `Geometry', within the tolerance limit. All
changes are displayed immediately. For the representation of the tooth mesh, select the lower, upper and mean
tip diameter allowances for gear 1 and gear 2.

Figure 8.64: Tip diameter allowance in the main mask `Geometry'

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower tip diameter allowance. The right arrow shows
the representation for the upper tip diameter allowance. The middle button displays the mean tip diameter
allowance. At the rst start of the tooth form, you will get the mean tip diameter allowance as a standard
feature.

Figure 8.65: Tip diameter allowance

Please Note: In case you have specied the lower and upper tip diameter allowance for gear 1 and gear 2 in
the input mask `Geometry' by using the `Lock' button, then the manually dened values appear here as lower
and upper tip diameter allowance.

8.5.7 Centre Distance Allowance

Click on the `Detail view' button and the tooth mesh is represented in detail. Now you can change the centre
distance allowance, that is already given in the main mask for the `Allowances', within the tolerance limit.
All changes are displayed immediately. You can check the operation of the gears by using various centre

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8. Cylindrical Gears According to DIN 3990 and Other Standards 326

distance settings. For the representation of the tooth mesh, select the lower, upper and mean centre distance
allowances for gear 1 and gear 2.

Figure 8.66: Centre distance allowance in the main mask `Allowances'

Both arrows indicate the lower and upper allowance. The active input is grayed out and disabled. Click on
the left arrow and you will get the representation for the lower centre distance allowance. The right arrow
shows the representation for the upper centre distance allowance. The middle button displays the mean centre
distance allowance. At the rst start of the tooth form, you will get the mean centre distance allowance as a
standard feature.

Figure 8.67: Centre distance allowances

Please Note: In case you have specied the lower and upper centre distance allowance in the input mask
`Allowances' by using the `User dened input' option, then the manually dened values appear here as lower
and upper centre distance allowance.

8.6 Calculation of Gear Load Capacity

Gears fail by tooth breakage, pitting as well as by scung. The strength is determined by the loads, the
geometry of gearing as well as selected materials. The calculation of the load capacity is about the proof of
the following strength factors that result from the above-mentioned forms of damage:

- Load capacity of the tooth root (safety against failure of the toothing due tooth breakage)

- Load capacity of the tooth ank (safety against failure of the toothing due to pitting)

- Scung load capacity (safety against failure of the toothing due to scung)

Load Capacity of the Tooth Root - Tooth Breakage

Tooth breakage is a fatigue failure. Pitting, scung or wear may weaken the tooth so that it breaks. The slow
progress of the fracture apparently causes the metal to break like brittle material. A tear or grinding notch
may cause a tooth breakage. Gear tooth fractures ordinarily start in the root llet. The tooth breakage can
destroy an entire gearing and leads to a failure of the gearing. Sometimes a new tooth will break as a result
of severe overload or a serious defect in the tooth structure. According to DIN 3990, an operation with a
reduced load is possible after a tooth breakage, if just a small portion of a tooth broke o and the other parts
of the gearing are intact.

For a high load capacity of the tooth root, the following methods are advantageous: positive prole shift (for
small number of teeth), usage of hardened and tempered or case-hardened materials with larger load capacity
of the tooth root, larger root llet, larger module

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Load Capacity of the Tooth Flank - Pitting of Gear Teeth

Pitting is a fatigue failure and is characterized by little bits of metal breaking out of the surface and thereby
leaving small holes or pits, so that oil seeps into the pits. This is caused by high tooth loads leading to
excessive surface stress, a high local temperature due to high rubbing speeds or inadequate lubrication. The
cracking of the surface develops, spreads and ultimately results in small bits breaking out of the tooth surface.
But it is often possible to get some years of service out of gears that have pitted rather extensively.

For a high load capacity of the tooth ank, the following methods are advantageous: large number of teeth,
positive prole shift (for small number of teeth), higher pressure angle, large hardness of tooth ank, nitriding,
more viscous oil

Figure 8.68: Load capacity

Scung Load Capacity

Scung is a surface destruction and it can be caused by a lubrication failure. Tears and scratches appear on
the rubbing surface of the teeth. This form of damage is called `scung'. The terms of `scung' and `scoring'
are used interchangeably. Scung is an important form of damage leading to component replacements in
lubricated mechanical systems. Compared with tooth breakage and pitting, it is not a fatigue failure, it can
come very quickly. A short overload can lead to scung and the gearing fails. Scung is apt to occur when
the gears are rst put into operation because the teeth have not sucient operating time to develop smooth
surfaces. Due to the scung, the temperature, the forces and the noise increase, the gear teeth nally break
o. The following factors may inuence the occurrence of scung:

- Gear material

- Lubrication

- Surface condition of tooth anks

- Sliding velocity

- Load

- Impurities in a lubricant

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8. Cylindrical Gears According to DIN 3990 and Other Standards 328

After the occurrence of scung, high-speed gears apt to additional dynamic forces that cause usually pitting or
tooth breakage. The high surface temperature may cause a breakdown of the lubricating lm. The following
factors support scung:

- High loads

- Kind of lubrication: Non-alloy oil protects less against scung than E.P. oil (extreme pressure)

- High oil temperature

- Rough oil surface

- Low gear quality: Larger contact ratio and tooth alignment errors may cause local stresses by impacts
and unbalanced carrying.

For a high scung load capacity, the following methods are advantageous: E.P. oils (oil that contains chemical
additives), a careful running-in period of the gearing, low sliding velocity due to tip relief and a smaller module

Please note: There are two dierent types of scung - cold and hot scung. Both types describe a damage
on the ank. The scung problem is not limited to high-speed gears. Scung can also occur on slow-speed
gears. The slow-speed scung is called cold scung and the high-speed hot scung. Cold scung is not
often observed. Hence, all further comments and information refer to hot scung.

8.6.1 Activate Load Capacity

The calculation of load capacity of cylindrical gears is standardized according to DIN 3990, ISO 6336,
ANSI/AGMA 2101-D04 as well as VDI 2736 for plastic gears. The standards give dierent methods to
calculate the load capacity in DIN 3990, ISO 6336 and ANSI/AGMA 2101-D04. The eAssistant software
provides all calculations according to DIN 3990 Method B, ISO 6336 Method B (2006, 2019), ANSI/AGMA
2101-D04 and VDI 2736. Hence, you can check the load capacity of tooth root and tooth ank as well as the
scung fast and easily. The scung safeties are determined according to the integral and ash temperature
method. The material properties, the endurance, face load factor, application factor as well as the kind of
lubrication and the selected lubrication are taken into consideration for the calculation. There are extended
input options to inuence the number of load changes or the roughness. A grinding notch can be integrated
into the calculation and the mode of operation can be selected.

Click on the `Load capacity' button to get to the calculation mask. You will notice that all input elds or
listboxes are disabled. When you select the entry `DIN 3990 Method B', `ISO 6336 Method B (2006, 2019)',
`ANSI/AGMA 2101-D04' or `VDI 2736' from the listbox `Calculation method', all input elds are enabled. In
case you do not need the calculation for load capacity, the calculation can be disabled. Thus, the size of the
calculation report becomes smaller.

Figure 8.69: Activate the calculation for load capacity

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8. Cylindrical Gears According to DIN 3990 and Other Standards 329

8.6.2 Input Options for Load Capacity According to DIN 3990 Method B
Comment
You can add a description or a short comment to gear 1 and gear 2. The notes will appear later in the
calculation report.

Figure 8.70: Add a comment

Material Selection
Select an appropriate material directly from the listbox or click on the button `Material' to open the material
database.

Figure 8.71: Listbox `Material'

The material database provides some detailed information on the several kinds of material. If the listbox is
active, the two arrow keys `Up' and `Down' of your keyboard allows you to search through the database, so
you can compare the dierent values with each other.

Figure 8.72: Material database

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8. Cylindrical Gears According to DIN 3990 and Other Standards 330

In order for gears to achieve their intended performance, life and reliability, the selection of a suitable material
is very important. Steel is the most common material that is used for gears. There are a number of steels
used for gears, ranging from plain carbon steels through the highly alloyed steels from low to high carbon
contents. The choice will depend upon a number of factors, including size, service and design. For pinion
and gear, the same hardened and tempered steel may be used. It has to be kept in mind that unhardened
gears with equal hardness should not be meshed with each other because scung is apt to occur. A hardened
or nidrided gear HRC > 50 smoothes the tooth anks of the hardened and tempered mating gear, reduces
the form deviations and increases the load capacity of the tooth ank. For a mating of hardened gears, no
hardness dierence is necessary. The nal selection of the material should be based upon an understanding of
the material properties and application requirements.

Hardening and tempering diers from hardening by annealing at high temperatures. The temperature range
for hardening and tempering ranges from 400◦ to 700◦ C while after hardening, parts are annealed at a low
temperature. On the other hand, a distinction is made between the material. For hardening, steel contains
more than 0.6 to 0.7% of carbon, for hardening and tempering less than 0.6% of carbon. However, there is
no well-dened limit between hardening and tempering and hardening.

Kind of Material
Steel casting: Steel casting belongs to the ferrous metals that include carbon (up to max. 2%) and are poured
into sand molds to produce several components. Due to a higher melting temperature, steel casting is more
dicult to cast than cast iron. Steel casting is cheaper than ground or forged gears.

Steel: Steel is the most common material and is used for medium and high-loaded gears.

Nidrided steel: Nitriding is adding nitrogen to solid iron-base alloys by heating the steel in contact with am-
monia gas or other suitable nitrogenous material. This process is used to harden the surface of gears.

Case-hardened steel: Case-hardened steel is a quality and high-grade steel with low carbon content. Case-
hardened steel is usually formed by diusing carbon (carburization), nitrogen (nitriding) into the outer layer
of the steel at high temperature and then heat treating the surface layer to the desired hardness. When the
steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard while the
core remains soft and tough.

Blackheart malleable cast iron (pearlitic structure): Malleable cast iron is a heat-treated iron carbon alloy.
Two groups of malleable cast iron are specied, whiteheart and blackheart cast iron. Blackheart malleable cast
iron is used for parts with a complex shape, in which a high durability, shock resistance and good machining
are important. Malleable cast iron is used for smaller dimensions and has got a higher strength and toughness
than steel castings.

Cast iron with spheroidal graphite (pearlitic structure, bainitic structure, ferritic structure): Cast iron usually
refers to gray cast iron but identies a large group of ferrous alloys that contain more than 2% of carbon. It
is extremely rare that the maximum carbon content is higher than 4.5%. Cast iron is a low-priced material.
However, cast iron has less toughness and ductility than steel. Cast iron with spheroidal graphite can be used
for parts with higher vibration stress.

Heat-treated steel: Hardening and tempering is a heat-treating technique for steels by quenching from the
hardness temperature and annealing at a high temperature so that the toughness is increased signicantly. At
the same time, a higher elastic limit is reached. Annealing temperatures and times dier for dierent materials
and with properties desired, steel is usually held for several hours at about 400◦ C to 700◦ C. Some steels have
to be cooled very quickly (Annealing: in order to achieve the intended properties of work pieces (e.g., desired
strength or toughness), reheating of the work pieces to certain temperatures is necessary.).

Gray cast iron: Gray cast iron is used for complex shapes and oers low cost and an easy machinability. It
provides excellent damping properties but it is a disadvantage that the load capacity is very low.

Please Note: In case there is no material that will fulll the design requirements, then simply dene your
individual material. Select the option `User dened input' and all inputs and options are enabled and you can

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8. Cylindrical Gears According to DIN 3990 and Other Standards 331

specify your individual material very easily. Your inputs will be saved to the calculation le. Please be advised
that changing the material will delete your dened inputs and you have to enter the inputs again.

Figure 8.73: Own input of a material

Ovako´s Clean Steels

Ovako´s clean steels 159X and 159Q can be selected from the listbox. Both steels are based on the case-
hardening steel 18CrNiMo7-6. Due to signicantly lower levels of contamination, these steels have modied
Woehler curves. Within the static strength, both steels are comparable to 18CrNiMo7-6. However, in the
fatigue strength range the IQ-Steel 159Q (Isotropic Quality ultra clean steel) is designed to increase eciency
by 30 percent for the ank load capacity and 60 percent for the tooth root load capacity. The fatigue strength
values are based on Ovako´s in-house investigations and external verications at WZL of RWTH Aachen
University and at the Gear Research Centre (FZG) of Technical University of Munich.

Figure 8.74: Selection of clean steels from the material database

The BQ-Steel 159X (Bearing Quality clean steel) delivers slightly smaller performance gains compared to
18CrNiMo7-6 and can be taken to improve existing designs. The potential of the 159Q can be used particularly
in new designs. It can be advantageous to focus on optimized scung load capacity. This can be achieved by
increasing the number of teeth and simultaneously reducing the module. This generally results in better gear
eciency and lower power losses. These Ovako steels open up completely new design possibilities for gears
and have a high potential for further increasing the performance of gears and gear components.

Figure 8.75: 159Q with the material properties in the material database

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Load Spectrum
The calculation of load spectra is in accordance with ISO 6336, Part 6. The determination is based on the
Palmgren-Miner rule and the load-dependent K-factors are calculated for each torque class. The safeties
are determined by way of iteration until the sum of damage parts is obtained. This method, demanded by
the wind energy industry, is very accurate. The linear damage accumulation model, which is also known as
Palmgren-Miner's rule, denes damage as the ratio of the number of cycles of operation to the number of
cycles to failure at any given stress level.

Figure 8.76: Load spectrum

Click the button `Load spectrum'. Once the option `Use load spectrum' has been activated, add any number
of load spectra with time ratio, torque, speed and, if required, with KHβ and temperature per load case. The
load spectra can be entered manually or imported from les. The load spectra can be saved and loaded. To
do this, use the two buttons `Open' and `Save'.

Figure 8.77: Dene load spectrum

Application Factor KA
The application factor KA evaluates the external dynamic forces that aect the gearing. These additional
forces are largely dependent on the characteristics of the driving and driven machines as well as the masses

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8. Cylindrical Gears According to DIN 3990 and Other Standards 333

and stiness of the system, including shafts and couplings used in service. Because scung is not a fatigue
failure, the application factor shall consider the stronger inuence of several load peaks during the calculation
of the scung load capacity. Several load peaks aect directly only the ank temperature. Because of that,
the same application factor KA can be used for the calculation of the scung load capacity as well as of
the load capacity of the tooth root and tooth ank. The application factor is determined by experience. An
application factor of `1.0' is best thought of a perfectly smooth operation. The following table gives some
values according to DIN 3990.

Application Factors KA According to DIN 3990-1: 1987-125

Working Characteristics Working Characteristics of the Driven Machine

of the Driving Machine

Uniform Light shocks Moderate shocks Heavy shocks

Uniform 1.0 1.25 1.5 1.75

Light shocks 1.1 1.35 1.6 1.85

Moderate shocks 1.25 1.5 1.75 2.0

Heavy shocks 1.5 1.75 2.0 2.25 or higher

5 from: DIN 3990 Part 1, December 1987, p. 55, table: A1

Working Characteristics of the Driving Machine

- Uniform: e.g., electric motor, steam or gas turbine (small, rarely occurring starting torques)

- Light shocks: e.g., electric motor, steam or gas turbine (large, frequently occurring starting torques)

- Moderate shocks: e.g., multiple cylinder internal combustion engines

- Heavy shocks: e.g., single cylinder internal combustion engines

Working Characteristics of the Driven Machines

- Uniform: e.g., steady load current generator, uniformly loaded conveyor belt or platform conveyor, worm
conveyor, light lifts, packing machinery, feed drives for machine tools, ventilators, centrifuges, centrifugal
pumps, agitators and mixers for light liquids or uniform density materials, shears, presses ...

- Light shocks: e.g., heavy lifts, crane slewing gear, industrial and mine ventilator, centrifugal pumps,
agitators and mixers for viscous liquids or substances of non-uniform density, multi-cylinder piston pumps
...

- Moderate shocks: e.g., rubber extruders, continuously mixers for rubber and plastics, wood-working
machine, lifting gear, single cylinder piston pumps ...

- Heavy shocks: e.g., excavators (bucket wheel drives), rubber kneaders, foundry machines, brick presses,
peeling machines, rotary drills ...

Please Note: You will nd a `Question mark' button next to the input eld. Click on this button and
the above-mentioned table opens. The `Question mark' button is an additional feature and provides further
information. You will nd this button next to several input elds.

Figure 8.78: The question mark button

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8. Cylindrical Gears According to DIN 3990 and Other Standards 334

Face Load Factor KHβ

The face load factor takes into account the eects of the non-uniform distribution of load over the gear
facewidth on the surface stress KHβ , on the tooth root stress KF β and on the scung KBβ . The face load
factor is determined according to DIN 3990, Part 1 Method B.

Figure 8.79: Face load factor for the surface pressure

When you start the calculation module, the value `1.25' is entered into the input eld. In case you already
use a dened face load factor, you can save the certain factor to a template le. Then the calculation module
starts with the individual face load factor. When you click on the `Calculator' symbol, the input mask for the
face load factor opens. In the top input eld `Face coe.' you can nd the default value `1.25'. You will
notice that the lower input elds and listboxes are disabled. By using the `OK' button you can take over the
default value to the main mask. There is a listbox next to the input eld for the face load factor. When you
open the listbox, the entry `DIN 3990 T1 Method B' appears.

Figure 8.80: Listbox with the selection of DIN

As soon as you select this entry from the listbox, the remaining input elds and listboxes are enabled. The
face load factor is determined automatically but you still cannot take over the value to the main mask. In
order to take over the calculated value, you have to add further inputs from the input mask for the face load
factor. When the button `OK' is activated, then the determined face load factor can be conrmed with the
button `OK'.

Please Note: However, there is the possibility to take over the value, determined according to DIN, to the
main mask without changing the extensive settings. When you click on the `Calculator' button next to the face
load factor, the above-mentioned input mask opens. The face load factor KHβ is displayed in the input eld.
Open the adjacent listbox and select the entry `DIN 3990 T1 method B'. The face load factor is calculated
but the button `OK' is still disabled.

Figure 8.81: Face load factor

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8. Cylindrical Gears According to DIN 3990 and Other Standards 335

Open the listbox again and select the entry `User dened'. Now the `OK` button is enabled and you can take
over the face load factor.

Figure 8.82: Take over the face load factor

Mesh Misalignment Fβx

The path of teeth is marked by the path of tooth traces. The tooth trace is the section of a tooth ank with
the reference surface. The mesh misalignment Fβx considers all inuences of manufacturing, assembly and
deformation that may intensify and compensate each other.

Figure 8.83: Tooth trace

The mesh misalignment is determined according to DIN 3990, part 1 method C. Using this method, portions
of the mesh misalignment are considered caused by a deformation of pinion and pinion shaft as well as
manufacturing inaccuracies. Fβx consists of fsh and fma . fsh is the mesh misalignment due to bending
and torsion of the pinion and pinion shaft, therefore it is a mesh misalignment due to deformation. The
mesh misalignment fma is a misalignment due to manufacturing inaccuracies and is dependent upon the gear
accuracy and the facewidth of the gear.

Figure 8.84: Mesh misalignment

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8. Cylindrical Gears According to DIN 3990 and Other Standards 336

Please Note: Select the entry DIN 3990 method B from the listbox for the face load factor, then the factor
is determined according to DIN. The selection and input elds are enabled. User-dened inputs for the mesh
misalignment are also possible.

Figure 8.85: User-dened selection

Position of Tooth Contact Pattern

The tooth contact pattern gives some insight into the required geometry and accuracy of gears. While rolling
o each other, a tooth ank will not come into contact with every point of its mating ank. A tooth contact
pattern is a representation of contact surfaces of two engaged tooth anks of gear pair. Under operating
conditions, an even load distribution over the facewidth and tooth depth is to be accomplished. For a contact
pattern, a thin layer of a marking compound is applied to the anks. After that, the gear pair is rotated as
long as the tooth contact pattern appears. Then the gears are visually inspected to check the tooth contact
pattern which is indicated by a light wear pattern on the mating tooth surfaces. The optimization of the
contact pattern plays an important role for improving smoothness and quietness of operation. Click on the
`Question mark' button and you will get a representation of the contact pattern according to DIN 3990, Part
1.

Figure 8.86: Open contact pattern

Figure 8.87: Contact pattern according to DIN Figure 8.88: Contact pattern according to DIN
3990, Part 1, 1987 3990, Part 1, 1987

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8. Cylindrical Gears According to DIN 3990 and Other Standards 337

Pinion Corrections
Errors in manufacturing and elastic deformations that may inuence the load capacity can be adjusted by
using intentional deviations from the involute (modication of the tooth depth) and theoretical tooth trace
(modication of the facewidth). Lead crowning and end relief are the most important pinion corrections and
are advantageous for a good load distribution over the facewidth of a gear. Due to lead crowning or end
relief, a non-uniform load distribution can be reduced. The calculation program allows you to select one of
the above-mentioned pinion corrections from the listbox.

Figure 8.89: Selection of the pinion correction

Lead Crowning
Lead crowning is a common modication that results in the ank of each gear tooth having a slight outward
bulge in its center area. A crowned tooth becomes gradually thinner towards the end of the teeth. The purpose
of lead crowning is to ensure that manufacturing inaccuracies and deformations are adjusted under load and
that the tooth ends are relieved. In general, lead crowning Cc is carried out symmetrically to the centre of the
facewidth.

Figure 8.90: Lead crowning

End Relief
Due to mesh misalignments, an overloading of the tooth ends occurs. Therefore, this kind of pinion correction
is used to protect the tooth ends against overloading. Generally, the size of the relief at both sides of the
tooth ank is equal. If crown shaving and crown grinding are not possible, then end relief is recommended.

Figure 8.91: End relief

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8. Cylindrical Gears According to DIN 3990 and Other Standards 338

Pinion Arrangement - Stiening Eect

DIN 3990 describes the stiening eect as follows: When d1 /dsh ≥ 1, 15, then stiening is assumed; when
d1 /dsh < 1.15, there is no stiening; furthermore, scarcely any or no stiening at all is to be expected when
a pinion slides on a shaft and feather key or a similar tting, nor when normally shrink tted (DIN 3990, part
1, edition December 1987, Beuth Verlag GmbH Berlin, gure 6.8, p. 33).

Figure 8.92: Pinion arrangement

Transmitted Power - Power Distribution for the Dimensioning of the Face Load Factor kHβ
The transmitted power k is the percentage of the power which will be transmitted through the pinion tooth
mesh, in the ratio of the full power which is transmitted through the pinion shaft. For example: The power
input on a shaft is 10 kW. 60% is transmitted through the tooth mesh and the remaining 40% is transmitted
to the end of the shaft. Now you have to dene 6 kW for the pinion to dimension the gearing. To determine
the face load factor, you have to enter 60% of the transmitted power because the stronger deformation of the
shaft due to the full torque transmission (10 kW) is taken into consideration.

Figure 8.93: Transmitted power

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8. Cylindrical Gears According to DIN 3990 and Other Standards 339

Reference Gear
The inputs for the power, speed and torque apply for the appropriate gear that is selected in the listbox. For
the other gear, speed and torque are determined from the reference gear.

Power and Torque

The power, torque and speed are dependent upon each other. Click on the adjacent button `T/P' to switch
between the input for the torque and the input for the power. If you click on the `TP' button, then you can
enter either the torque or the power. The values are converted. The description of the input eld changes
accordingly into `Torque' or `Power'.

Kind of Lubrication and Lubricant Selection

Lubrication serves several purposes but its basic and most important function is to protect the sliding and
rolling tooth surfaces from seizing, wear and friction. The friction of the tooth ank is responsible for ank
wear, gear heating and gear noise. A reduced ank friction improves the eciency that is dependent on the
tooth load, circumferential velocity, gear quality and the surface condition of the tooth anks. In order that
the gearing should work properly, the selection of a lubricant is an important choice. A liquid lubricant is a
good choice and can be easily introduced between the contacting surfaces. In addition, a lubrication has to
reduce frictional heat and has to protect the surfaces against corrosion. The bearings and clutches in a gearing
require also an appropriate lubricant. Therefore, the lubricant has to be suitable as well. Oil and greases
are the most common lubricants. The compounding of oils provides a combination and generation of various
properties. Oil oers a wider range of operating speeds than greases. They are easier to handle and are most
eective. Special E.P. (extreme pressure) oils have been developed for slow-speed, highly-loaded vehicle gears.
These oils develop chemical compounds on the contacting gear-tooth surfaces. Grease is a combination of
liquid and solids. Grease has the advantage of remaining in place and not spreading as oil. It can provide a
lubricant lm at heavily loads and at low speeds.

Figure 8.94: Open the selection of a lubricant

Liquid lubricants may be characterized in many dierent ways. Viscosity is one very important property of a
lubricant and determines the oils lubricating eciency.

For the selection of liquid lubricants applies: the smaller circumferential velocity and larger the contact pres-
sure as well as the roughness of tooth anks, the higher the viscosity. A higher viscosity will result in a
higher hydrodynamic load capacity and an increased scung load limit where scratching and scung of the
tooth anks occur (Muhs/Wittel/Jannasch/Vossiek: Rolo/Matek Maschinenelemente, 17th revised edition,
published by Vieweg, Wiesbaden 2005).

Please Note: If the viscosity is too low, the oil lm will not be suciently formed and if the viscosity is too
high, the viscosity resistance will also be high and cause temperature rise. For higher speed, a lower viscosity
oil should be used and for heavy loads, a higher viscosity oil should be used.

Gears that are running primarily in a gearbox are lubricated with oil. A distinction is made between oil splash
lubrication and oil injection lubrication.

Oil splash lubrication: The oil splash lubrication is an easy, reliable and reasonable lubrication system. It is
a type of lubrication used in enclosed gear drives. In splash lubrication, the gear tooth dips into a tray of
lubricant and transfers the lubricant to the meshing gear as it rotates. As a result, oil reaches all of the places
where it is needed. The oil splash lubrication can be used for average speed applications.

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8. Cylindrical Gears According to DIN 3990 and Other Standards 340

Oil injection lubrication: With the oil injection lubrication, the oil can be ltered, cooled and checked and
the oil is directly fed to the bearings. The amount of oil can be controlled according to the heat dissipation
requirements. The gearbox is used as an oil tank reservoir from which several units can be supplied. The oil
is sprayed directly by a pump injector into the mating surfaces.

Grease lubrication: The selection of the grease is dependent upon the circumferential velocity, the kind of
application and the service temperature. A grease lubrication requires low maintenance and protects against
contamination. Grease lubrication is suitable for any gear system that is opened or enclosed, so long as it runs
at low speed. The grease should have a suitable viscosity with good uidity especially in a enclosed gear unit.

Click on the `Lubricant' button and open database. The extensive database contains the lubricants including
all detailed information about the oils and greases (e.g., density, viscosity, load stage of FZG test). You can
nd out more about the FZG test in section 8.6.5 `Extended Input Options for Scung Load Capacity'. Select
`User dened input' from the listbox to dene your individual lubricant.

Figure 8.95: Lubricant selection

8.6.3 Extended General Input Options

Click the corresponding button in the main screen of the load capacity to open the advanced input options. If
you do not change any entries in the following screen, the calculation continues with the default input values.

Figure 8.96: Selection of extended input options

If you do not change any entries in the following mask, the calculation continues with the default input values.

Figure 8.97: Extended general input options

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8. Cylindrical Gears According to DIN 3990 and Other Standards 341

Dynamic Coecient KV
The dynamic coecient KV considers additional inner dynamic forces. Inner dynamic forces are caused by
mesh alignments, lead crowning, deformation of teeth, the housing, shafts and gear bodies as well as oscillation
of the wheel masses. As the circumferential velocity of the gear rim increases, the dynamic forces increase. The
forces decrease with an increasing load of the teeth. Click the `Lock' button to change the dynamic coecient.

Transverse Coecient KHα

The transverse coecients account for the eect of the non-uniform distribution of transverse load between
several pairs of simultaneously contacting gear teeth on the surface pressure (KHα ), stress leading to scung
(KBα ) and loading of the tooth root (KF α ). Click the `Lock' button to change the transverse coecient.

Mesh Load Factor Kγ

The mesh load factor takes into account an uneven distribution of the total circumferential force for gearings
with multiple transmission paths or for planetary gear trains with more than three planets. For transmission
paths, the total circumferential force is distributed to several mesh. For gearings without transmission paths,
the value is set at `1.0'.

Carried Width
When the facewidth of pinion and gear is not equal, then a maximum overhang of `1 x m' at each tooth end is
assumed as a carried width. Unhardened portions of surface-hardened gear tooth anks (including transition
zone) consider only 50% as the carried width. However, if it is foreseen that because of crowning or end relief
the contact does not extend to the end of face, then the smaller facewidth shall be used for both pinion and
gear. Click the `Lock' button to change the carried width.

Permit Pitting
In specic cases, the development of pits on the gear ank is allowed. Use this option to permit several pits.
In general, initial pitting is considered normal and is not a cause for concern. In particular, case-hardened and
nitrided gears usually has the tendency to pit near the tooth root and lead eventually to fatigue breakage. Here
an individual assessment is necessary. In some cases (aerospace industry), pits are absolutely not permitted.
For turbo transmissions, pits may lead to oscillations and increased additional dynamic forces.

Figure 8.98: Permit pitting

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8. Cylindrical Gears According to DIN 3990 and Other Standards 342

8.6.4 Extended Input Options for Load Capacity of Tooth Root and Tooth Flank
The main mask of the load capacity provides the `Tooth root/ank' button, click on that button and the
extended input options appear.

Figure 8.99: Extended input options for tooth root and tooth ank

Roughness
The surface roughness of the tooth anks inuences the load capacity of the tooth anks. The average rough-
ness Rz is the arithemitc average of ve individually measured roughness values. The input of the roughness
occurs for root and ank of pinion and gear. The right choice of the surface roughness is determined by
economical aspects depending upon the intended purpose and manufacturing process. A ne surface can be
very expensive because of the high manufacturing costs. A surface that is too rough may not fulll the required
functionality.

Grinding Notch
A grinding notch may signicantly reduce the fatigue strength and a tooth breakage can occur due to a
grinding notch. Shot-peening can be used to increase the fatigue strength of gears that are damaged by a
grinding notch. A careful grinding of the notch is basically suitable.

Figure 8.100: Grinding notch

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8. Cylindrical Gears According to DIN 3990 and Other Standards 343

Hardening Depth Root/Flank

The hardening depth is signicantly for the pitting load capacity and is determined by the depth of surface layer
heated to hardening temperature, the hardenability of the material and the eect of the quenching method.
Case-hardening: Steels get their specic features by case-hardening. This combined heat treatment process
consists of the following subprocesses:

- Carburizing, i.e., using carbon for the surface

- Hardening, i.e., heat treatment to achieve a hardened and wear-resistant surface

- Annealing (stress relief )

Please Note: The calculation module determines the optimal hardening depth automatically, but the hard-
ening depth can be dened also individually. If the individual hardening depth is smaller than the optimal
hardening depth, then the fatigue strength is reduced accordingly. The determination of the optimal hard-
ening depth and reduction of fatigue strength with reduced hardening depth is based on: `Tobie, Thomas:
Zur Gruebchen- und Zahnfusstragfaehigkeit einsatzgehaerteter Zahnraeder, Dissertation Technische Universi-
taet Muenchen (Lehrstuhl fuer Maschinenelemente, Forschungsstelle fuer Zahnraeder und Getriebebau) 2001,
Section. 10.3: Eingliederung der Versuchsergebnisse in das Rechenverfahren nach DIN 3990'.

Figure 8.101: Hardening depth

Technology Factor YT
The technology factor YT considers the change of the strength of the tooth root by machining process.

σF lim = σF lim0 YT

σF lim0 Fatigue strength of the tooth root from material data

σF lim Fatigue strength of the tooth root with inuence of the technology factor

YT Technology factor (see following table)

Technology Factor YT According to Linke6

Kind of Manufacturing of the Tooth Root Technology Factor YT
Shot peening: 1.2 to 1.4

Applies for case-hardened or carbonitrided gears; not ground

in the hardened layer

Rolling: 1.3 to 1.5

Applies for ame and induction hardened gears; not ground in

the hardened layer

Grinding: General: 0.7

Applies for case-hardened or carbonitrided gears for CBN grinding wheel: 1

Shape cutting: 1

Does not apply for ground gears

6 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Verlag

Muenchen Wien, 1996, p. 320, table 6.5/6

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8. Cylindrical Gears According to DIN 3990 and Other Standards 344

Click the `Question mark' button to open the tables for the technology factor and mode of operation factor.

Figure 8.102: Open the tables

Mode of Operation Factor YA

The fatigue strength of the tooth root σF lim is corrected with the inuence of the mode of operation.

σF lim = σF lim0 YA

σF lim0 Fatigue strength of the tooth root from material data

σF lim Fatigue strength of the tooth root with inuence of the mode of operation factor

YA Mode of operation factor (see following table)

The following reference values can be used for the mode of operation factor YA . DIN 3990 species identical
values for swelling and alternating load.

Mode of operation factor YA according to Linke7

Mode of Operation Mode of Operation Factor YA Direction of Load

Swelling 1

Alternating 0.7

lgNrev
0.85 - 0.15
6

Oscillating (for 1 ≤ Nrev ≤ 106 )

0.7 (for Nrev > 106 )

Please Note: Nrev = Number of load direction changes during operation time

7 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl Hanser Verlag

Muenchen Wien, 1996, p. 321, table 6.5/7

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8. Cylindrical Gears According to DIN 3990 and Other Standards 345

8.6.5 Extended Input Options for Scung Load Capacity

The scung load capacity oers dierent extended input options. Click on the `Scung' button and the
extended input options appear.

Figure 8.103: Extended input options `Scung'

Thermal Contact Coecient BM

The thermal contact coecient BM is required for the determination of the ash factor. The ash factor
considers the inuence of the material properties of gear and pinion on the ash temperature.

Figure 8.104: Thermal contact coecient

Relative Structure Factor XW relT

The relative structure factor XW relT is primarily intended to take into account inuence of the material
properties on the scung load capacity and is determined by:

XW
XW relT =
XW T

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8. Cylindrical Gears According to DIN 3990 and Other Standards 346

XW The lower table provides the empirically determined relative structure factor.

XW T The relative structure factor for the test gears that are used for the determination of the scung
temperature. XW T = 1.0 for the FZG gear test.

Structure Factor XW 8
Material/Heat Treatment Structure Factor XW
Through-hardened steel 1.00

Phosphated steel 1.25

Copper plated steel 1.50

Bath and gas nitrided steel 1.50

Hardened carburized steel, with austenite content:

- less than average 1.15

- average 1.00

- greater than average 0.85

Austenitic steel (stainless steel) 0.45

8 from: Linke, H.: Stirnradverzahnung Berechnung Werkstoe Fertigung, Carl

Hanser Verlag Muenchen Wien, 1996, p. 367, table 6.5/16

Load Stage of Standard FZG Gear Test

Because scung is not a fatigue failure, a standard FZG gear test was developed to determine the scung load
capacity of a lubricant under certain operating conditions. The gear test, known as FZG gear test (Institute for
Machine Elements Gear Research Center, University Munich, Germany), is a standardized method according to
DIN 51354. At the FZG, the dierent inuences on scung are extensively investigated. The test is performed
on a standard FZG test machine using standard test gears. Standardized, case-hardened and ground spur gears
with a large one-side prole shift are used. The load is increased gradually on a FZG gear test rig with dened
technical parameters. There are 12 load stages and the gears are inspected for scung after every load
stage. Finally, the load stage is determined where scung of the gear teeth occurs and where the ank area
is damaged by scratches. The higher the load stages, the better the industrial gear lubricants resistance to
scung.

Figure 8.105: Selection of load stage

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8. Cylindrical Gears According to DIN 3990 and Other Standards 347

Type of Prole Modication

For high-duty gearings, it is possible to change the theoretical involute. Using the listbox to dene the type
of prole modication. You can select the following options:

- without prole modication

- for high-duty gearing

- for uniform mesh

Figure 8.106: Prole modication

The force distribution factor XΓ evaluates the inuence of the force distribution over several pairs of meshing
teeth. A polygon-like shape over the line of action represents the progress of the force distribution factor. The
values of the points A and E depend upon the type of prole modication. According to DIN 3990 (see Part
4, p. 17), the force distribution factor is as follows:

Force Distribution Factor Without Prole Modication and With Prole Modication for High-Duty
Gears

Figure 8.107: Without prole modication Figure 8.108: For high-duty gears (the
pinion drives)

Force Distribution Factor With Prole Modication for High-Duty Gears and for Uniform Mesh

Figure 8.109: For high duty gears (the Figure 8.110: For uniform mesh
gear drives)

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8. Cylindrical Gears According to DIN 3990 and Other Standards 348

Contact Temperature Along the Path of Contact

The contact temperature varies along the path of contact due to the progress of the ash temperature.

Contact Temperature Without Prole Modication

Figure 8.111: Contact temperature without prole modication

Contact Temperature With Prole Modication

Figure 8.112: Contact temperature with prole modication

Contact Temperature for Uniform Mesh

Figure 8.113: Contact temperature for uniform mesh

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8. Cylindrical Gears According to DIN 3990 and Other Standards 349

Flash Temperature and Integral Temperature Method

High surface temperatures due to high loads and sliding speeds can cause a lubricant lm breakdown. Because
of that, there are two calculation methods in DIN 3990 that are based on dierent criteria for the development
of a damage. The eAssistant software provides both the integral temperature method and ash temperature
method:

- Flash temperature method denes a variable contact temperature along the path of contact.

- Integral temperature method denes a weighted average of the surface temperature along the path of
contact.

Flash Temperature Method

The ash temperature is the temperature at which a gear-tooth surface is calculated to be hot enough to
destroy the oil lm and allow instantaneous welding at the contact point. The contact temperature ϑB in any
point of contact Y results from the sum of the bulk temperature ϑM and the ash temperature ϑf la :

ϑB = ϑM + ϑf la

According to the ash temperature method, there is no scung as long as the contact temperature ϑB (as the
sum of bulk temperature ϑM and ash temperature ϑf la ) does not exceed the scung contact temperature
in all points of contact. The scung temperature ϑS to be a characteristic value for the material-lubricant-
material system of a gear pair, to be determined by gear tests with the same material-lubricant-material
system.

Figure 8.114: Progress of contact temperature along the path of contact

Please note: Points A to E mark the important points from the beginning to the end of the mesh.

The safety against scung SB is determined according to the ash temperature method:

ϑS − ϑoil
SB = ≥ SBmin
ϑBmax − ϑoil

ϑBmax Maximum contact temperature along the path of contact

ϑoil Oil temperature before reaching the mesh

ϑS Scung temperature

The safety factor SBmin is dependent on whether the gearing is put into operation after a good running-in
period. With a careful running-in period, there is no scung damage up to SBmin ≈ 1. Without a running-in
period, there is no scung up to SBmin ≈ 3 (according to Linke).

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8. Cylindrical Gears According to DIN 3990 and Other Standards 350

Integral Temperature Method

According to the integral temperature method, scung occurs when the integral temperature exceeds the
scung integral temperature. The scung integral temperature is assumed as a characteristic value for
the material-lubricant-material system of a gear pair and is determined from gear tests. The scung safety
according the integral temperature method SintS is calculated as follows:

ϑintS
SintS = ≥ SSmin
ϑint

ϑintS Scung integral temperature

ϑint Integral temperature

As uncertainties and inaccuracies in the assumptions cannot be excluded, it is necessary to introduce a safety
factor. According to Linke, the following reference values can be used:

SintS < 1.0 In all probability, scung damages are expected to occur.

1.0 ≤ SintS ≤ 2.0 For a careful running-in period of the gearing, good contact pattern and real assumed
loads, there are no scung damages to be expected.

SintS > 2.0 There is no risk of scung.

8.6.6 Input Options for Load Capacity According to ISO 6336 Method B
In addition to DIN 3990 Method B, it is possible to calculate the load capacity of tooth root and tooth ank
according to ISO 6336 (2006, 2019) Method B. Select the ISO 6336 Method B from the listbox and the input
elds are enabled.

Figure 8.115: Activate load capacity according to ISO 6336 Method B

There is a strong similarity between the DIN 3990 standard and the ISO 6336 standard and most parts of the
load capacity calculation according to ISO 6336 correspond to DIN 3990. In fact, the ISO 6336 evolved from
the DIN 3990 standard. There are factors that inuence the tooth root stress and tooth ank strength, but
the dierences are minor and the inuence on the safety of root, ank and scung is very low. One large
dierence is the calculation of the helix angle factor Zβ as well as the calculation of the long life factors (ZN T
and YN T ) for the tooth root stress. Another dierence between DIN 3990 and ISO 6336 is the critical stress
point on the root llet. ISO 6336 uses the tangency point of a 60◦ angle as the most critically stressed point
on the root llet for internal gears. The DIN 3990 standard uses the tangency point of a 30◦ angle as the
critical stress point on the root llet for external and internal gears as the basis for the calculation of the
load capacity.

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8. Cylindrical Gears According to DIN 3990 and Other Standards 351

60° Tangent for Internal Gears

The tooth form factor YF is the form factor, which represents the inuence on nominal tooth root stress of
the tooth form with load applied at the outer point of single pair tooth contact. According to DIN 3990, the
form factor for external and internal gears is calculated at the tooth root at the point of the 30◦ tangent.
This method appeared to be inaccurate, especially for internal gears. ISO 6336 uses the tangency point of a
60◦ angle as the most critically stressed point on the root llet for internal gears. This method is more precise
and leads to higher safeties for the tooth root.

Figure 8.116: 60◦ tangent for internal gears

Life Factors YN T and ZN T

The long life factor YN T accounts the higher tooth root stress and the long life factor ZN T accounts the
higher contact stress including static stress, which may be tolerable for a limited life (number of load cycles).
The factors mainly depend on the quality of the material, heat treatment, number of load cycles as well as
notch sensitivity, surface conditions and gear dimensions. The life factors YN T and ZN T can be read from the
following graph for the static and reference stress as a function of material and heat treatment.

Figure 8.117: DIN 3990 and ISO 6336: Life factors

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8. Cylindrical Gears According to DIN 3990 and Other Standards 352

Long life factor YN T :

With optimum lubrication, material and manufacturing YN T = 1.0 may be used for the number of load cycles
NL = 3 · 106 . For static stresses NL ≤ 103 , the long life factor is 2.5.

Long life factor ZN T :

With optimum lubrication, material and manufacturing ZN T = 1.0 may be used for the number of load cycles
NL = 5 · 107 . For static stresses NL ≤ 105 , the long life factor is 1.6.

There are signicant dierences in the calculation of the life factors YN T and ZN T when comparing DIN 3990
and ISO 6336. Values appropriate to the relevant number of load cycles, NL , are indicated by the S-N curve
(also known as a Woehler curve). The S-N approach is dierent. The long life factor for the load capacity
of the tooth root approaches 1.0 for the range of long life (depending on the material, usually at 3 · 106 load
cycles). In DIN 3990, the life factor remains 1.0 for higher number of load cycles. According to ISO 6336, the
factor for materials decreases from 1.0 to 0.85 at 1010 load cycles. Only after that, the factor remains 0.85 at
10
10 load cycles. For gears in the long life range, the calculations according to ISO 6336 result in signicantly
smaller safeties (15% lower) for tooth root and toot