STD-AGMA BOOL-D47-ENGL 1497 MM@ Ob87575 OOOSHe4 cat mm ANSI/AGMA 6001-D97 (Revision of ANSVAGMA 6001-C88) AMERICAN NATIONAL STANDARD rr Design and Selection of Components Sor Enclosed Gear Drives ANSI/AGMA 6001-D97STD-AGMA BUUL-DY¢~ENGL LIT¢ mm UbOrS;> UUUasCS suo i Design and Selection of Components for Enclosed Gear Drives American ‘ANSI/AGMA 6001-D97 National [Revision of ANS/AGMA 6001-C88} Standard Approval ofan American National Standard requires verification by ANS! that the require- ‘ments for due process, consensus, and other criteria for approval have been met by the standards developer. ‘Consensus is established when, in the judgment of the ANS! Board of Standards Review, ‘substantial agreement has been reached by directly and materially affected interests. ‘Substantial agreement means much more than a simple majority, but not necessarily una- rimity. Consensus requires that all views and abjections be considered, and that a concerted effort be made toward their resolution. ‘The use of American National Standardsis completely voluntary; their existence does not in any respect preclude anyone, whether he has approved the standards or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standards. ‘The American National Standards Institute does not develop standards and will in no Circumstances give an interpretation of any American National Standard. Moreaver, no person shall have the right or authority 1 issue an interpretation of an American National ‘Standard inthe name of the American National Standards Institute. Requests for interpre- tation of this standard should be addressed to the American Gear Manufacturers ‘Association. CAUTION NOTICE: AGMA technical publications are subject to constant improvement, revision, or withdrawal as dictated by experiance. Any person who refers to any AGMA ‘Technical Publication should be sure that the publication is the latest available from the ‘Association on the subject matter. [Tables and other selt-supporting sections may be quoted or extracted in their entirety. Credit lines should read: Extracted from AGMA 6001-D87, Design and Selection of Com- ponents for Enclosed Gear Drives, with permission of the publisher, American Gear Manu- facturers Association, 1500 king Street, Suite 201, Alexandria, Virginia, 22314] Approved August 7, 1997 ABSTRACT This standard outlines the basic practices for the design and selection of components, other than gearing, for use in commercial and industrial enclosed gear drives. Published by American Gear Manufacturers Association 1500 King Street, Suite 201, Alexandria, Virginia 22314 Copyright © 1997 by American Gear Manufacturers Association Al rights reserved. 'No part ofthis publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission ofthe publisher. Printed in the United States of America ISBN: 1-85589-683-9 ‘is Donen Pte nepemet orp comes ee @AMERICAN NATIONAL STANDARD ‘ANSVAGMA 6001-D37 Contents Foreword . ‘Scope ...... Definitions and symbols Design conditions Shafts ..... Keys .... Bearings . Housings ....... ‘Threaded fasteners Miscellaneous components Tables 1. Symbols used in equations E 2 Modifying factor for stress concen. - aval or Keyan ‘solid round steel shafts... ©arounrson+ Figures Design criteria, Cyclic loading ... Stress convention showing orbiting element . Surface finish factor, ky. Size factor, Reliability factor, k Notch sensitivity ~ steel, q “Theoretical stress concentration factor in bending for a circular shaft with a ‘square shoulder, K; (nominal stress is calculated at diameter d,) . 2 18 “Theoretical stress concentration factor in bending fora circular shaft with a u-notch, K, (nominal stress is calculated at diameter d,) ........6...0.4. 18 10 Theoratical stress concentration factor in bending for a circular shaft with a radial hole, K; (based on full section without considering hoie) 11 Torsional deformation . : 12 Bending detection intermediate concentrated oad | 13 Bending deflection overhung concentrated load . 14 Bending deflection intermediate concentrated moment 15. Bending deflection overhung concentrated moment 16 Axial deformation... a 17 Average shaft and hub radius 2... 18. Variation of coefficient of friction versus the bearing par @Vonrsen+ © Annexes Allowable stresses for typical key and keyway materials Allowable stresses for typical threaded fasteners Interference fit torque capacity Previous method ~ shaft design . ‘Sample problems ~ transmission shaft design . ‘Sample problems - deflection References. . o7mo0m> Somers tnwecewtescs Se AGMA bODL-DI2-ENGL (rowveneste ssw creteANSVAGMA 6001-D97 AMERICAN NATIONAL STANDARD Foreword [The foreword, footnotes, and annexes, if any, in this document are provided for informational purposes only and are not to be construed as a part of ANS/AGMA Standard © 6001-97, Design and Selection of Components for Enclosed Gear Drives.) ‘AGMA 260.02 was approved by the AGMA membership on February 1, 1873, andissuedin vanuary of 1974. It consolidated with minor revision, information contained in the following Superseded AGMA Standards: ‘AGMA 25.02 (November 1964), Botting (Allowable Tensile Stress) for Gear Drives; ‘AGMA 260.01 (March 1953), Shatng - Allowable Torsional and Bending Stresses; ‘AGMA 260.02 also incorporated allowable stresses for keys; ‘AGMA 265.01 Bearings - Allowable Loads and Speeds. ‘The purpose of AGMA 6001-C88, as a replacement for AGMA 260.02, was to establish a ‘common base for the design and selection of components for the different types of ‘commercial and industrial gear drives. ‘AGMA 6001-C88 was expanded to include a generalized shaft stress equation which included hollow shafting, miscellaneous components, housings, and keyway stress calculations. All design considerations were revised to allow for 200 percent peak load for helical, spiral bevel, spur and herringbone gearing, and 300 percent peak load for wormgearing. The bearing section was updated to include considerationof ie adjustment ‘actors, bearing ives other than 5000 hours and reliabilty levels other than L10. During the preparation of AGMA 6001-C88, a considerable amount of time was spent on the shaft design section in an effortto include the mast recent theories on shaft stresses and ‘material characteristics. The standard included the existing practice for shaft design, and for reference purposes, appendix C included a description of, and excerpts from, ANSVASME B106.1M, Design of Transmission Shafting, published in 1985. AGMA 6001~C88 was approved by the membership in May 1988 and approved as an ‘American National Standard on June 24, 1988. This revision, AGMA 6001-D97, has been expanded to include more recent theories on shaft design and analysis. Also, equations for shatt deformation were added. ‘AGMA 6001-097 was approved by the membership in October 1996 and approved as an ‘American National Standard on August 7, 1997. ‘Suggestions for improvement of this standard will be welcome. They should be sent to the ‘American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria, Virginia 22814. v. AMERICAN NATIONAL STANDARD ANSV/AGMA 6001 - 7 8 TD“AGMA bOOL-Da7-ENGL Labeeieea tears PERSONNEL of the AGMA Component Design Committee ‘Chairman: D. MeCerthy Dorris Company Vice Chaitman: D. Cressman Philadelphia Mixers Corporation ACTIVE MEMBERS R.Errichello ........ GEARTECH J.B. Hagaman . Cone Drive Operations, Inc. R. Holzman . +++. Milwaukee Gear Company, tn. J. Uisiecki «The Fatk Corporation D.R. McVittie «Gear Engineers, Inc. K.Newton ........ . Rockwell Automation/Dodge WE. Schierenbeck . += Xtek, Inc. RG. Smith +++ Philadelphia Gear Corporation R. Tameja . Peerless-Winsmith, Inc. F.C. Uherek Flender Corporation vid. Vielhauer ‘The Cincinnati Gear Company ASSOCIATE MEMBERS D. Behike ‘Twain Dise, Inc. RE.Brown . « Caterpillar, Inc. RZ. Johnston . «University of Maine S.Miller .... The Cincinnati Gear Company C. Mischke coseescseeeses+ + lowa State University AE. PhIllpS coe eee ee eee csesseses + Plockwell Automation/Dodge Williston... - - Dorris Company cy trent ‘st me oy oppANSUAGMA 6001-097 AMERICAN NATIONAL STANDARD : (This page is intentionally blank) vi STD-AGMA BODL-D97-ENGL 19 'atindmmnbtytemmersccasce | Bo Ill‘AMERICAN NATIONAL STANDARD American National Standard — Design and Selection of Components for Enclosed Gear Drives 1 Scope This standard provides an acceptable practice for the design and selection of components for enclosed ‘gear drives. Fundamental equations provide for the proper sizing of shafts, keys, and fastenersbasedon Stated allowable stresses. Other components are discussed in a manner to provide an awareness of their function or specific requirements. This stan- ‘dard applies to the following types of commerciatand industrial enclosed gear drives, individually or in combination: spur, helical, herringbone, bevel and worm. 1.1 Exceptions. ‘The equations in this standard are not applicable ‘when gear drives are subjected to vibratory condi- tions where there may be unpredictable fatigue failure. ‘The procedure for design or selection of the spectfic ‘gear components is varied and complex and is ‘beyond the scope of this standard. Designers must refer to the specific rating or enclosed drive standards for this aspect of drive design. 1.2 Intended use ‘The equations and values presented provide a general approach to design. Deviations from the ‘methods and values stated in this standard may be made when justified by experience, testing, or more specific analysis. ft is intended for use by ‘experienced gear designers capable of selecting Teasonable values based on their knowledge of the performance of similar designs and the effect of such items as lubrication, deflection, manufacturing toler- SFOTAGHA bOO-D97-ENGL 199 ten eee ake een pe ‘ANSVAGMA 6001-D97 ances, metallurgy, residual stresses, and system dynamics. It is not intended for use by the engineering pubiic at large. 2 Definitions and symbols ‘The symbols and definitions used in this standard ‘may differ from those in other AGMA standards. The User should not assume that familiar symbols can be used without @ careful study of the applicable section(s) and equation(s). 21 Definitions The terms used, wherever applicable, conformtothe following standards: AGMA 904~C96, Metric Usage ANSI Y10.3-1968, Letter Symbols for Quantities Used in Mechanies of Solids ANSVAGMA _1012-F90, Gear Nomenclature, Definitions of Terms with Symbols 2.2 Symbols ‘The symbols used in this standard are shown intable 1 ‘SI units of measure are shown in parentheses in ‘table 1 and in the text. Where equations require a ifferent format or constant for use with SI units, a ‘second expression is shown after the first, indented, in smallertype, and with “M" included in the equation ‘number. Example: We Fo ores (0 - WF 0785(D ~ 0.9382)" ‘The second expression uses SI units. Se = (70M) 3 Design conditions This standard should be used in conjunction with appropriate current AGMA standards. When theANSYAGMA 6001-D97 ‘operating conditions are known, each component of the drive shall be designed to meet those conditions. ‘When operating conditions are not known, all load carrying components of the drive shall be designed ‘to support the stated mechanical rating of the drive for continuous duty based on a unity service factor (1.0). External loads mustbe consideredas acting in AMERICAN NATIONAL STANDARD irections and rotations producing the most unfavor- able stresses unless more specific information is available. Due allowances must be made for peak loads. For enclosed drives designed to operate under ‘specific conditions such as load, speed, duty cycle and life, components may be selected accordingly. Table 1 - Symbols used in equations First Symbol Term Units _| referenced x Coaticient = ig Ac Compressive area of key in keyway in? (mm?) | Eq 68. As ‘Shear area in? (mm?) | Eq Acs ‘Cross sectional area ‘in? (mm?) | Eq @ Distance from support to concentrated load in(mm) | Eq 46 B Coefficient - Fig 4 e Coefficient - Eq37 D Fastener nominal diameter in(mm) —|Eq70 4 Shaft diameter adjacent to section being analyzed in(mm) | Fig 4 Shaft inside diameter in(mm) | Eq6 4 Shaft outside diameter in(mm) |Eq6 jE Modulus of elasticity bfin? (Nimm?) | Eq 46 F Concentrated load Ibis) J Eq4e. Fy Peak load factor - Eqs Fy Fatigue safety factor - Eqt Fsy Peak load safety factor - Eq2 Fra [Allowable stress to yield strength factor - Eq5 6 Modulus of rigiaity lyin? (Ny?) | Eq 44 Hy Brinell hardness number HB {Eq30 h Radial step in(mm) | Figs ir ‘Second area moment of cross section int (mms) | Eq 46 J ‘Second polar moment of area int (mms) |Eq at Jn ‘Second polar moment of area of th section of shaft int (mm) | Eq 44 K (Constant - Eq8 Ke ‘Theoretical stress concentration factor in bending - Eq 38 Ke Fastener torque coefficient - Eq71 ‘ Fatigue strength modification factor - Eqo4 ke Surface finish factor - Eq 35 rs Size factor - Eq 35 ke Reliability factor - Eq 35, ke ‘Temperature factor - E935 ke Life factor - Eq 35 iy ‘Modifying factor for stress concentration - Eq 35 Ig ‘Miscellaneous effects factor - Eq35 IL Length of shaft in(mm) | Eqat in Length of the nth section of shaft in(mm | Eq44 Me Bending moment tbin(vm) |Eq7 m Coefficient - Eq37 IN Number of stress cycles = Eq37 (continued) 2 STD-AGMA bOOL-D97-ENGL 2:AMERICAN NATIONAL STANDARD ANSUAGMA 6001-D97 Table 1 (continued) : First ‘Symbol Term Units | referenced Np Termissible number of momentary peak load Cycles : Eq35 n Fastener threads per inch it |Eq70 P Fastener thread pitch (mm) | Eq 70M Pe Axial force Ibi) [Eq 10 @ Notch sensitivity - Eq 38 R Reliability (survival rate) - Eq 96 Re Surface finish xin (um) | Fig 4 r Notch radius, filet radius, hole radius ingmm) | Fig7 te ‘Average radius along the key length in(mm) | Eq69 Tee Average radius at compressive load area in(mm) — |Eqes Sea Allowable compressive stress lbyin? (N/mm?) | Eq 66 & Sat 108 stress cycles Abyin® (N/mm2) | Eq 37 5 Modified fatigue strength (endurance limit) Ibfin? (Nim?) | Eqs Se Basic fatigue strength (endurance limit) of polished, unnotched | bin? (Nimm2) | Eq 32 test specimen in reverse bending Sp Fastener proof load stress {b/in? (N/mm?) | Eq 72 Sa Allowable shear stress Ijin? (N/mm?) | Eq 67 Si. Ultimate tensile strength lyin? (Nem?) | Eq 30 S) Tensile yield strength byin? (Nimm2) | Eq 3 se Calculated compressive stress lovin? (Nimm2) | Eq 68 Su Calculated key shear stress Ijin? (Nimm2) | Eq 69 se Calculated tensile stress in fastener Ijin? (Nim?) | Eq 70 Tr Torque tin (Nm) JEq6 Ty Fastener torque tin (Wm) Eq 71 é v Transverse shear force bw) |Eq8 - wy ‘Applied tensile load on fastener b(N) Eq 70 Wp Fastener tensile preload wy) fea7t x Distance from support to crass section in(mm). | Eq 46 y Deffection of shaft in(mm) | Eq 46 8 Elongation in(mm) | Eq63 6 ‘Angular position of shaft element radians |Fig 4 Shaft slope radians |Eq 47 6. Critical stress angle radians | Eq 28 8 Angle of twist radians |Eq.41 fy Poisson's ratio - qo % ‘Atteriating component of stress Aovin® (Nymm2) | Eq 12 Ox Atternating axial normal stress Abyin? (N/mm?) | Eq 13 Guy ‘Alternating radial normal stress tbvin? (N/mm2) | Eq 13 Gz ‘Alternating tangential normal stress Whfin? (N/mm?) | Eq 13 ° ‘Axial normal stress due to bending lin? (Nimm2) | Eq 7 On Mean component of stress lyin? (Némm2) | Eq 11 Gmax | Maximum stress lovin? (Nim?) | Fig 2 Spin | Minimum stress Ijin? (Nimm2) | Fig 2 One ‘Mean axial normal stress tbvin® (N/mm2) | Eq 14 ny Mean radial normal stress Ibfin? (Nem?) | Eq 14 Onz Mean tangential normal stress Ijin? (N/mm?) | Eq 14 oF ‘Axial normal stress due to tension or compression Aoyin? (N/mm?) | Ea 10 ¢ (continued) 3 STD-AGMA bOOL-DI7-ENGL 199 ?sstoommanayiimgeetinp toes SS alANSVAGMA 6001-D97 AMERICAN NATIONAL STANDARD Table 1 (concluded) First | Symbol Term Units | referenced Ox Total axial normal stress | ane (Nima Eq 15 Gy ‘Total radial normal stress Ibfin? (Nimm?) | Eq 15 & ‘Total tangential normal stress lyin? (Nim?) | Eq 15 & Von Mises altemating stress lovin? (Nimm2) | Eq’ Sn ‘Von Mises mean stress Abin? (N/mm?) | Eq 3 & Equivalent uniaxial stress under peak loading lbjin? (N/mm?) | Eq 39 Grout __| Von Mises total stress Ibfin? (N/mm?) | Eq 5 tar ‘Alternating torsional shear stress Ibfin? (N/mm)? | Eq 20 xy Alternating radial shear stress Ibfin? (N/mm?) | Eq 13 kaye ‘Atternating axial shear stress lbjin? (N/mm?) | Eq 13 ase ‘Atternating tangential shear stress lovin? (N/mm?) | Eq 13 Tuy Mean radial shear stress Iofin? (Nim?) | Eq 14 ‘mz | Mean axial shear stress Abin? (N/mm?) | Eq 14 Sct Mean tangential shear stress loin? (Nim?) | Eq 14 % max Maximum torsional shear stress Iofin? (Nim?) | Eq 19 % min | Minimum torsional shear stress lovin? (N/mm?) | Eq 19 ne Mean torsional shear stress Afi? (Némm?) | Eq 19 Tay ‘Total radial shear stress lyin? (N/mm?) | Eq 15 ye ‘Total axial shear stress lovin? (N/mm?) | Eq 15 Tex ‘Total tangential shear stress Ibfin? (N/mm?) | Eq 15 © Torsional shear stress Ijin? (N/mm?) | Eq 6 iw ‘Shear stress due to shear force Ibfir? (Nimm2) | Eq 8 Test Test shear stress to find @. lin? (Nim?) | Eq 27 ‘3.1 Load spectrum analysis It Is recommended that the cumulative fatigue ‘damage criteria proposed by Miner (Miner's Rule) be employed to evaluate the effects of variable loading ‘on the life of components. 3.2 Momentary peak loads This standard is based on an allowable momentary ‘mechanical peak load rating of 200 percent (2.0 x ‘mechanical rating) for spur, helical, herringbone, ‘and bevel gear drives and an allowable momentary ‘mechanical peak load rating of 300 percent (3.0 x mechanical rating) for worm gear drives, Frequency ‘and duration of peak ioads must be considered when designing and selecting components. If the fre- uency of duration of peak loading becomes signifi- ‘cant (greater than 100 cycles during the design ite), the designer should consider a cumulative fatigue ‘analysis such as Miner's File. 4 STD-AGMA bOOL-D97-ENGL 1997 Mm 3.3 System analysis ‘This standard assumes that within the operating ‘speed range, the system of connected rotating parts is compatible and free from critical speeds and torsional or other types of vibrations, no matter how induced. ‘The gear drive designer or manufacturer is not responsible for the system analysis unless this provision is clearly identified by contractual agreement. 4 Shafts ‘This section covers a stress analysis procedure applicable to cylindrical stee! shafts used in conjunc- tion with and as apart of enclosed gear drives. This analysis may or may not be applicable to other materials. ‘Shaft stress is but one consideration in the design of shafting. A shaft must have proper radial, axial, and €AMERICAN NATIONAL STANDARD torsional stifiness to limit deflections to acceptable levels and to avoid unwanted vibratory motion. 4.1. Design criteria Shafts must pass two stress analysis tests to be considered adequately designed. First, they must be designed to resist fatigue fallure due to cyclic loading over their intended life. All operating loads, including momentary peak loads, must be consid- ered, and 2 Miner's Rule analysis (see ISO TR 10495) may be required to properly account for the different stress states. See 4.6.8. F210 ott) where Fsy_ is fatigue safety factor. ‘Second, they must be designed to withstand mo- ‘mentary peak loads without distress or permanent deformation. Foy = 1.0 2) where Fsp_ is peak load safety factor. The requirement for both of these criteria is to ‘compare the stress condition for the given shaft geometry and loading to properties of the shaft material. Each stress condition applied to the shaft ‘must be checked with equation 1 and equation 2 such that Fsy2 1.0and Fsp 2 1.0. Seefigure 1. Where ‘nominal or estimated material properties are used, a factor of safety, Fyy, greater than 1.0 is recom- mended. 1h selecting a value for safety factor, the conse- ANSV/AGMA 6001-D37 considerably greater than unity shall be used. Ifthe consequence of failure is minimal, a safety factor closer to unity may be used. 4.2 Fatigue safety factor The elliptic equation has been selected for analysis, of the fatigue failure mode. itis found in references {3}, [10] and [15]* This equation is: ee) % is Von Mises altemating stress, tbjin? (Nimm?); is modified fatigue strength, Ib/in? (N/mm?); {is Von Mises mean stress, tb/in? (Nimm2); is tensile yield strength, ib/in? (N/mm?); Fy is fatigue safety factor. ‘This equation can be rewritten to solve for the fatigue safety factor. = 1 Y Plo (e-@y) 8) For the design to be considered acceptable for fatigue condition, the resutting fatigue safety factor, sj, must be equal to or greater than 1.0. 43 Peak load safety factor ‘The following peak load analysis equation is used to solve for the peak load safety factor: uence of failure shall be considered. if the p= Fes a consequence of failure is high, a safety factor 9 * FO Stress curve associated with equation 5 ‘Stress curve associated with equation 4 Alternating stress © ° ‘Mean stress s Figure 1 - Design criteria ‘Numbers in Brackets throughout the text, [], refer to publications listed in annex G. STD-AGMA bOOL-DI7-ENGL 1997 1 i aeANSYAGMA 6001-D57 where Fsp_ is peak load safety factor, Fya_is allowable stress to yield strength factor, 5, _ istensile yield strength, Ibfin? (Nimm?); Fp _ is peak load factor, Gratis Von Mises total stress, Ib/in? (Nimm?).. CAUTION: Equation 5 is based on a ductile material For purposes of this standard, a material is considered ‘ductile ifthe tensile elongation of the core material is at least 10%. For nonductle materials, the effects of sess concentration should be considered. See4.5.1. Sota includes stresses which are not a function of load, such as stress resulting from the weight of ‘components or stress resutting from shrink fit of ‘components, Fs, may be conservative. Consider- ations may be given to only applying F, to those stresses Of Oioig that are load related, For the design to be considered acceptable for peak ‘oad condition, the resutting peak load safety factor, Fp, must be equal to or greater than 1.0. ‘The safety factors are to be chosen based on ‘experience and engineering judgement. 43.1 Allowable stress to yield strength factor, Fra The allowable stress to yield strength factor is to provide conservatism over the stress resulting from ‘expected peak load conditions and variations in the tensile yield strength. Values between 0.66 and0.80 have traditionally been employed for this variable. Unless otherwise agreed upon, a value of 0.75 is recommended, 4.3.2 Peak load factor, F, ‘The peak load factor accounts for momentary peak loads over the unity service factor load. In the absence of other known conditions, the following values for the peak load factor are to be used: For spur, helical, herringbone, and bevel gear drives, Fy 20. For wormgear drives, F,= 3.0. 4.4 Calculated stresses ‘There are four major types of loading applied to sshafting that constitute the simplified case. These result in torque (7), bending moments (H), shear forces (¥), and axial tension or compression (P,). ‘The equations converting these forces to stresses are given in equations 6 to 10. Positive forces and stresses are in tension and negative forces and stresses are in compression. Allforces and stresses 6 STD+AGMA bODL-D57-ENGL LAT7shdem tr omnometiya reat ae ES AMERICAN NATIONAL STANDARD ‘Must be those which would be present when the rive is loaded to its unity (1.0) service factor rating. For torque: Satare "xe = a) » @ cee, x(a - #) ww (6M) % __istorsional shear stress, Ib/in? (N/mm?); is torus, bin (i; d, __ is Shaft outside diameter, in (mm); d; is Shaftinside diameter, in (mm). For bending mame May (8 - 4) a) 200M x(¢- 4) (7M) where % Is axial normal stress due to bending, Ibjin? (Nimm?);, Mis bending moment, ib in (Nm). For shear force: y= — KK _ aa = * where is shear stress due to shez (Nim? V __ istransverse shear force, tb (N). and eet a(a + 2.2542) + we +) force, Ibfin? where isthe materia's Poisson's ratio. Fora solid steel shaft, where v= 0.3, K= 1.23 andor a thin walled hollow steel shaft, K approaches 2.0. For axial tension or compression: 4P °° 51é - 8) (10) where % is axial normal stress due to tension or compression, Ib/in? (N/mm?); @AMERICAN NATIONAL STANDARD P, is axial force, lb (N). Allof these stresses can have alternating and mean Components. See figure 2. Therefore: Gn = 05 (Omax + Gnin) = Mean Component of stress oft) 1 = 0.5 (Cmax ~ Omia) = alternating component of stress. (12) (Equations 11 and 12 are generalized for a normal stress, but also apply to shear stresses.) The case of completely reversed stress, where = Gmax ANS Gy =0, occurs for the axial normal bending stress, o,, and the shear stress, x, (due to transverse shear force) when the shaft is rotating ands subjected to a constant direction load. This is ‘a common loading condition. ‘The location of the maximum and minimum stress intensities due to these loads varies as the stress ‘element being analyzed orbits with the rotating shat. See figure 3. In this figure, the loads are fixed and only the shaft element under analysisis rotating with ANSVAGMA 6001-D97 the shaft. f all loads are treated as positive values and are therefore additive, the crtical locations to be ‘examined are at positions A (0 = 0) and B (0 = n/2) ‘and at positions 6 between them. Depending on the relationships between the four stresses, any position of @ between 0 and x/2 may be the location of maximum stress. Tension w Compression Figure 2 - Cyclic loading Element at % position B Figure 3 - Stress convention showing orbiting element STD-AGMA bDDL-DI7-ENGL L897 Siismrennoiimgemteeascae TL ialANSYAGMA 6001-D87 Where stress is not uniformly distributed around the Periphery of the shaft, the stress intensity of an element orbiting between A and B will vary ‘approximately in a sine or cosine pattem as appropriate. Most shaft stress analyses are concemed only with position A, as the bending stress, op, is typically much larger than the transverse shear stress, t), ‘which produces the bending. Stress at position B or @, between A and B, can become important ina short shaft section with a high shear force as may be found adjacent to a bearing. 4.4.1 The general case For a complete 3-dimensional fatigue analysis, the Von Mises stresses will be used. Refer again to figure. These are givenin equations 13 through 15, where the total or maximum stress is the sum of the alternating and mean stresses (0,; = Og: + Omr + ---)- Von Mises altemating stress: Ge = {0.5{(Cax ~ Gay)? + (ay ~ Gaz)? 4 (Ges ~Oax)?} + Altay? + Roe? + Ter?) (18) where % is Von Mises altemating stress, tbvin? (Nimm?); ux is altemating axial normal stress, Ib/in? (Nim); xy is altemating radial normal stress, Ib/in? (Nim); Sz is attemating tangential normal stress, b/in? (Nim); Tey is alternating radial shear stress, tb/in? (Nimm?); Ye: (8 alternating axial shear stress, lovin? (Nimm?); ‘uz is altemating tangential shear stress, Ibjin? (Nimm?). Von Mises mean stress: Gm = {0.51(Gnx ~ Ony)?+ (ny ~ Oz)? + (Gz ~ Gms?) + 3l my? + tape” + ax"]}°5 (14) where Gp _ is Von Mises mean stress, lbjin2 (N/mm?); Gre iS mean axial normal stress, Ib/in? (N/mm?); ny 1s mean radial normal stress, Ib/in? (Nimm2);, 8 STD-AGMA bODL-D97-ENGL 1997 AMERICAN NATIONAL STANDARD mz iS mean tangential normal stress, Ibjin? (Nimm*); ‘my iS mean radial shear stress, lb/in? (Nimm?); wz ‘is mean axial shear stress, Ibyin? (Nimm?); ‘mx iS mesn tangential shear stress, Ib/in? (Nim?) ‘Von Mises total stress: Gra = {0-5( Cex ~ Cy + (Ory ~ 2)? + (Or ~ G)?] + 3ltay? + ye? + te} (15) where Gyouai Is Von Mises total stress, Ib/in? (N/mm?); Gx is total axial normal stress, Ibyin? (N/mm2); Gy is total radial normal stress, Ib/in? (N/mm?); %z is total tangential normal stress, Ib/in? (Nimm?); “oy is total radial shear stress, tb/in? (Nimm?); ‘yz is total axial shear stress, tb/in? (Nimm2); ‘cx {8 total tangential shear stress, bin? (umm?) ‘All unused terms in the above equations are set equaltozero. The results of equations 13 through 15 are used in equations 3 through 5. 42 The simplified case ‘There are stresses which are not included in these ‘simplified case formulas but to which, nonetheless, the designer must be alert and appropriately ad- dress if they are encountered. These include, but are not limited to, hoop stresses due to press fitted Parts, pressure on hollow shatts, thermal stresses, ‘tresses due to unbalance and centrifugal forces, and residual stresses, any of which can become significant. For the simplified case, all stresses on the free (outer) surface of the element are zero (Le., no interference fitted elements), as are shear stress in the radial direction and the tangential stress. However, experience has shown that the effect of the interference fit can be modeled using the simplified ‘case and the modifying factor for stress concentra- tion, i, a8 discussed in 4.6.6. Keeping in mind sign ‘convention: At position @: = Op 608 8 +.g, (16) eat sin +4 “17) GeG=ty 520 (18) ‘After determining the forces and stresses on the shattat the critical sections, determine the amount of each stress that s alternating and the amount that is mean, per equations 11 and 12. For many cases oy a &AMERICAN NATIONAL STANDARD and + are completely altemating, whereas 9, is ‘entirely mean, The torsional shear stress, x, often has both a mean (jp,) and an altemating component i). ur = 0.5 (% max +% min) (19) Ter = 05 (% max ~% min) «(20) if such is the case, at position 8, Mean stresses: Sux = co) ou = Tot (22) Alternating stresses: Ou = 0) 6088 (max at®=0) (23) Tes WsinOtty (macatO=%) (24) ‘The mean components of stress have m as the first subscript (Gmc, tux) while the altemating ‘components have a as the first subsoript (dgz, Tx). For standard catalogued gear drives that are not subjected to torque reversals, alternating torques in the range of 25% to 50% are suggested. If no data exists, a worst case 50% alternating torque (that is between zero and the maximum torque, where Tw =e) Should be used. A value lower than 25% may be used if experience shows that reduced torque fluctuations exist Hf frequent torque reversals are present, consider setting tw = Tmax AND tq = 0 (100% altemating torque) ‘Von Mises alternating stress for the simplified case: G = [un? + Btacx?}> = (25) Von Mises mean stress for the simplified case: B= 10m? + Hyun} (28) Calculate equations 23 through 25 for @. depending ON Tes ANG Ty? o} - 30 ten = Be (7) Her < es 6. = sin-! (=) (2B) Iftar = tes O¢ = Z radians 2 where & isthe critical stress angle, deg. and use the components os, and tux for the maximum value of G, to calculate Von Mises total stress for the simpified case: Groxal = [(Gmz + Oar)? + 3tmex + Tecr)*}5 (28) STD-AGMA GODR-D97-ENGL 1997 ANSVAGMA 6001-D97 This represents the maximum value of stress at any Point of the shaft surface at that location for the general case. The results of equations 25, 26 and 29 are used in equations 8 through 5. 4.5 Mechanical properties of stee! Mechanical property values, determined from test, of the specified grade of steel in its processed and hheat treated condition should be used whenever available. 45.1 Estimated properties of ste! It is important to note that the estimated material properties may deviate significantly from actual test values. Thus, an appropriate factor of safety should be used. In the absence of test data, the following properties Of forged or rolled steel shatting material may be used. For through hardened steel shafts, the timate tensile strength can be based on the Brinell hardness of the shaft, near the outer surface, at the diameter under consideration. For stee! shafts that are case hardened by processes such as carburizing and nitriding, the uttimate tensile strength is based ‘on the Brinell hardness of the shaft underneath the hardened case uniess a detailed analysis or experi- ‘ence indicates that a diferent tensile strength should be used. See sampie problem S in annex E, The yield strength and modified fatigue strength can be calculated based on the ultimate tensile strength. ‘The following equations have been developed by curve fiting representative test results from references [3}, [18] and [18]. Utimate tensile strength: 5, = 500 Hy (30) S.=3.45 Hy (30M) where 5S, _iSultimate tensile strength, tbyin? (N/mm2); Hg is Brineli hardness number, HB. NOTE: The value of 500 in equation 30 is a typical value. In reference [15], 450 is mentioned as a ‘minimum value. Tensile yield strength: S$ =094 5, 12 500 (31) $,=0945, 86.2 (81M) where ‘5, _ istensile yield strength, Ibyin? (N/mm). Basic fatigue strength: Se= 05S, ify = 200.000 Ibfin® (32) Se=05S, ifS,=1380Nmm? (32M) NOTE: The value of 0.5 in equation 32 is an average value. The values can range trom 0.4 100.6 depending, ‘upon heat treatment. See{15] for detailed information,ANSVAGMA 6001-97 ‘See = 100 000 Ibfin? if S, > 200 000 tbvin? (33) Se =690.Nimm? tS, > 1380.Nimm? (83M) where Seis basic fatigue strength of polished, un- notched test specimen in reverse bending, bjin? (N/mm?). 4.6 Modified fatigue strength Since the fatigue strength is largely influenced by physical conditions, environmental conditions, and application conditions as well as material conditions, ‘he basic fatique strength must be modified. $= kSe (34) where 54 _ is modified fatigue strength, ibyin? (Nimm?); Is fatigue strength modification factor. ‘The fatigue strength modification factor, x, is the [product of the fatigue factors (k, through fy). The fatigue safety factor, Fry, is greatly by the fatigue strength modification factor. Therefore, care should be exercised in determining the values of the fatigue factors [3]. Te = hy eet hey by (85) 1.0 09 08 07 06 os 04 03 02 ‘Surface finish factor, 01 00 bbbSSLBS| eo 80100120140 AMERICAN NATIONAL STANDARD 4.6.1 Surtace finish factor, k, ‘The surface finish factor accounts forthe diference between the actual shaft and a highly polished test specimen. Valves for k, are given in figure 4. 462 Size factor, ky ‘The size factor accounts for the increased likelihood of encounteringa fatigue initiating defect as the shaft diameter increases. Values for k, are given in figure 6. 4.63 Reliability tactor, i ‘The reliability factor accounts for variation or scatter in fatigue test data for samples of a given material. ‘The reliablity factor is determined by the desired level of reliabilty and the dispersion of he test data. Unless otherwise agreed upon, a value of k. = 0.817 (for 89% reliabilty) should be used. ‘The formulas and data in figure 6 are for a normal distribution where the standard deviationis 8% of the mean. NOTE: For hich loveis of reliability (greater than 0.99) the reliabilty factor is very sensitive to the failure Gistribution assumed. The equation shown in figure 6 may only provide an approximation of the actual reliability factor for these levels. ‘Surlace fish, Re in ur) 380.4) 22 So. x 250 800 10, Fit raed 2 160180 200220240 1000 Ibyin? 400 500 600 700 800 900 1000 1100 1200 1800 1400 1600 1600 1700 Nimm2 Unimate tensile strenath, S, Figure 4 - Surface finish factor, k, [10] 10 STD-AGMA bOOL-D97-ENGL 14° @AMERICAN NATIONAL STANDARD ANSVAGMA 6001-097 “= eos 0.869(d,)°97 1 hy = 1.19(d 9-27 (MM) @ ana ip = 149d) 07(M)) os 3 me z aa a 0.7- os eae ete eer rr © 50 100 150 200 250 300 350 400 450 500mm Shatt diameter, d, Figure 5 - Size factor, ky [10] Reliabillity, R, is the fraction of a group of apparently limits of steels. However, between normal operating identical parts that exceed a given life. temperatures ranging from about -20°F (-29°C) to " 7 . 250°F (121°C), the fatigue strength characteristics __humber of picoes exceeding a given life_ of most steels are essentially unchanged. For this total number of pieces subjected to loading temperature range, a temperature factor ky = 1.0 (86) maybe used. Temperature factor, ky ‘CAUTION: Consideration must be given to the loss of hardness and srength of some materials due tothe Extreme operating temperatures affect the fatigue tempering efectat high tomporatures, R 1.00 T an? ose] t= ost(g)) ost 0.96 7 oss ose 0.90 oss oes oss oe a0 078 076 0.74 oa 0s 0.99 0.999 Reliability factor, For normal distribution where the standard deviation is 8% of the distribution mean. Figure 6 Reliability factor, k. [3] [10] Ww STD AGHA GOOL-DA7-ENGL 1997 SoeaRauaiANSVAGMA 6001-D37 For applications outside this temperature range, the fatigue properties should be determined by actual tests [3}. 4.6.5 Life factor, ke Life factor, de, is taken as unity (1.0) at 108 stress, cycles. At greater than 10° stress cycles, & should be taken as unity, but in fact may be continually decreasing with increasing number of stress cycles at an unknown (lesser) rate. 4 is greater than unity between 10% and 108 stress cycles and in this range may be calculated es follows: (87) m is Yylogro 085,15, 6 islogi0 (0.8 52.) S. is Syat 108 stress cycles (where ke = 1.0); N aaa mee iee emer 1 Below 10° stress cycles, the value of k obtained at 10° cycles should be used. 4.8.6 Modifying factor for stress concentration, y Experience has shown that a shaft fatigue failure almost always ocours at a notch, hole, keyway, AMERICAN NATIONAL STANDARD shoulder, or other discontinuity where the effective stresses have been amplified. The effect of stress. ‘concentration on the fatigue strength of the shaft is represented by the modifying factor for stress ‘concentration, &. 1 ,-— (88) T° T+ 4 (K-71) ® where @ _ isnotch sensitivity: K, _is theoretical stress concentration factor in bending. A single fatigue stress concentration factor, that in bending (X;) is utilized as representative of any stress condition. For many applications, only a small error will result from this assumption because the other stress concentration factors are very close to that in bending. However, if a diferent stress Concentration fector (ather than bending) is required and itis signficantly different than K,, a modification to this analysis may be necessary. Notch sensitivity, g, accounts for the phenomenon that low strength steels are less sensitive to fatigue atnoiches than are high strength steels. Values for ‘are shown in figure 7 for ductile (Le., elongation > 10%) through hardened steel shafts. The theoretical stress concentration factor in bend- ing, K,, a8 shown in figures 8 through 10 are taken from reference 13. These values for K; represent ‘some of the more common cases. 10 = }— J z nme 2 = [oS eee : a= [seit] forseinw/ £06 s, 1" 300r-0386) 4 3 le a [Rag] eseinn/om? 2 Os (r= shaft radius 20.16 (44 mn maximum) = ninches (n mm) 04 6 80 100 120 140 160 180 200 220 240 260 1000 byin? 400 500 600 700 800 900 1000 1100 1200 1900 1400 1500 1600 1700 1800. N/mm? Utimate tensile strength, 5, Figure 7 ~ Notch sensitivity - steel, q [10] 12 STD-AGMA LOOL-D97-ENGL 19) {cots namoetekrongmnor ease Se iy[AMERICAN NATIONAL STANDARD ‘ANSV/AGMA 6001-D57 2m so 7 = 5, +6 (2) +0(2) +x(2) To for 025 < wr <20 4 for20 = h/r's 200 & 45 | Ki | 0.927 + 1.149 fhjr—0.086h/r | 1.225 + 0.831 Jhfr— 0.0104/r z ts S| s~san dir « a | amo + ans raze S209 |Ks| 0847 + 1.716 /hfr—0.s06n/r | 7374-4834 Jh/r + 0.862h/r 40 K, | -0.790 + 0.417 Vh/r—0.246h/r | -3.809 + 3.046 Jh/r—0595h/r as 230 — 25 ie So pa] PE — 20 FSS —— = se —= 1950 01 og oa os ds Figure 8 - Theoretical stress concentration factor in bending for a circular shaft with a square ‘shoulder, K; (nominal stress is calculated at diameter d,){13] = 28) 4 1,(22) + x (24), ( oe son (2) +n(2) +22) for 0.25 = h/r = 2.0 for 2.0 s h/r = 50.0 50 iki] 0.455 + 3356 /a/r — 0.760h/r] 0935 + 1922 Jhjr + O004n/r |X| 0.891 ~ 12.721 Ji/r + 4.593h/r |-0.552-5.327 Jijr + 0.086h/r oe Ks) 0.286 + 15.481 /h/r—6.392h/r | 0.754 + 6.281 Jh/r—0.121h/r ~ {Ks} ~0.632~ 6.115 Jhi/r + 2.568h/r_|-0.138-2.876 vhjr + 0.031h/r : T Yep Wo * 35 < 3.0 25 = 2.0 << a a 18 SS 10 0.0 O41 02 03 O4 Os 06 Dhlde Figure 9 - Theoretical stress concentration factor in bending for a circular shaft with a u-notch, K; STD+AGMA bODL-DA7-ENGL L997 Sobran ty amp (nominal stress is calculated at diameter d,) [13] 13ANSV/AGMA 6001-D97 AMERICAN NATIONAL STANDARD. 40: kw ky +R (Z SOW ror d/é. < 09 and 2/d, < 03 7%] 3.000 3.67] | -s0-rerssds + a0me/e,7 Ki] 44.739 + 107244/d_ — 1992%4/do)? ga Kl ~53307~ 259984 dy + 85K)? 32: 3.0 284 rote 24 0.00 0.05 0.10 018 0.20 0.25 0.30 Pride Figure 10 ~ Theoretical stress concentration factor in bending for a circular shaft with a radial hole, -K, (based on full section without considering hole) [13] Table 2 gives typical values for iy for standard keyways in solid round steel shafts. Changes in keyway proportions, comer radi, size of shaft, andfit ‘with mating members can greatly alter the values of 'y. Often press-fit assembly of hub and shaftis used with or without provisions of a key. Fatigue stress ‘modifying factors for interference fits vary widely but are often quoted as being in the general range of 0.50. Combinations of interference fit and keyway ive values of fy typically in the range of 0.4 to 0.33. ‘Table 2 ~ Modifying factor for stress concentration, ky - typical values for keyways. im solid round stee! shatts") [7] Profiled | Sted-runner keyway | keyway bending | bending Steel stress | stress ‘Annealed (less than 200 HB) 063 077 Quenched and drawn (over 200HB) | 0.50 0.63 NOTE: 1) Nominal stresses should be based on the section modulus for the shatt section wih the keyway effect ignored. “4 STD-AGMA LOOL-D97-ENGL 1997 Experimental verification is preferred for super- Position of stress concentration factors. Without verification, the smaller values should be used. One reason is that the possibilty of a fatigue failure Criginating in the region of an interference fit is often ‘aggravated by fretting corrosion. 4.6.7 Miscellaneous effects factor, k Since tatique failures nearly always occur at or near the surface of the shaft where the stresses are greatest, surtace condition strongly influences fatigue life. A number of factors affecting the fatigue limit have values nct readily found in design texts. ‘Some of these factors are: = fesidual stresses (such as cold rolling, eening, and welding); = _heat treatment (such as case hardening and decarbonization); = corrosion (such as stress corrosion cracking, ‘fretting corrosion); ~ plating or surtace coating, Atthough only limited quantitative data have been Published for these factors, they should be consid- ‘ered and accounted for f applicable. Some of these factors can have a considerable effect on the shatt ‘endurance characteristics. In the absence ofAMERICAN NATIONAL STANDARD Published data, it is advisable to conduct fatigue ‘ests that closely simulate the shaft condition and its operating environment. Use published deta or test data when available. If none of the above conditions for other miscellaneous effects contribute to the endurance ofthe shaft being analyzed, kz may beset to 1.0. if any of these conditions reduce the ‘endurance strength, consider setting f, to less than 4.0; if any of these conditions increase the ‘endurance strength, Ay may be greater than 1.0. 4.6.8 Permissible number of peak load cycles. Hf the number of momentary peak load (F, x the unity service factor load) cycles are significant, they can become the dominant factor in the stress analysis. if a Miner's Rule analysis has not been Performed including these loads, the permissible ‘number of momentary peak oad cycles, Nj, 10. avoid excessive fatigue is determined as follows: M10 = Fy a: y= FOE ol — tak +22) ay 0, = fea Tei 2al + 4?) (67) Forx>aand(l~a)> a: y= FO =n i? a+ 2 = oy = ROME 3P = 2-2) where y is deflection of shatt at x, in (mm), (positive upward as shown in figures 12 - 15); FF _ isconcentrated load, Ib (N), (positive down- ‘ward as shown in figures 12 ~ 15); L__islength of shaft between supports, in (mm); @ is distance from support to concentrated toad, in (mm); x is distance from support to cross section of interest, in (mm); E is shaft material modulus of elasticity, ibfin? (Nimm?); (1 is shatt siope ats, (2) J is second area moment of cross section, in* (m4), 1= J (a - ai) +=(60) 4.72.2 Overhung concentrated load Figure 13 is a diagram of a simply supported shaft ‘subjected to a concentrated overhung load. Forces and reactions are assumed to act at right angles to the shatt. Zero deftection at the reactions (bearings) % ANSVAGMA 6001-Ds7 ‘The equations for defiection and slope for a simply ‘Supported shatt subjected to an concentrated over- hhung load are different depending upon the relative Position of the section of interest to the supports. Hee Fa(s){b? ~ 22) ye ee) (51) Mx>L oe. o, = Role = 32) ts @ - 2] @ ~ 1)? - or - 1 _ Fea Bien? - eex~ 0] ET four aee- 0) gu 4.7.2.3 Intermediate concentrated moment Figure 14 is a diagram of a simply supported shatt with @ concentrated moment applied between the supports. The reactions are assumed to act at right ‘angles to the shat. Zero deflection at the reactions, (bearings) is assumed. Figure 14 - Bending deflection intermediate concentrated moment ‘The equations for dettection and slope for a simply supported shaft subjected to an intermediate con- Centrated moment are different depending upon the LE elle relative positon of the load to the shaft section of interes. Wxee _ M@=(6ab - 212 - 322 - 22) = ye ce (65) 1000MCe(6al ~ 212 - 362 — 22) ye te (85M) Mibal. ~ 212 ~ 342 222 6= cer ) 68) Figure 19 ~ Bending detiecton overhung oom 21? 32 ~ 32) gy concentrated load SEE 7 STD-AGMA bOOL-D97-ENGL 1997 mM [etmeANSVAGMA 6001-D97 tee M@0%L ~ 30% ~ 20% + 31x? - 33) EL =(87) 1000M{30% — 302s — 2% + ax? — 23) " Ca 7M) yo Moen Bet = at 2) gy en og = Mma = 22 ~ 20? - 34) coyy where Mis concentrated moment, Ib in (Nm). 4.7.2.4 Overtung concentrated moment Figure 15 is a diagram of a simply supported shaft subjected to an overhung concentrated moment. Reactions are assumed to act at right angles to the shatt. Zero deflection at the reactions (bearings) is assumed. Figure 15 - Bending deflection overhung concentrated moment ‘The equations for deflection and slope for a simply ‘supported shaft subjected to an overhung concen- ‘rated moment are different depending upon the relative postion of the section of interest to the shaft supports Hxek Mey? — 22) (88) EIL Joonuisyt? — 2?) (89M) (60) (60M) STD-AGMA bOOL-D97-ENGL L957 MM ibsctare iy itnmnnecsy St AMERICAN NATIONAL STANDARD xe = Mlb ~ =) - 32) 7 oe a a) a) s000M(L - x\t - 2) ee = Mie ~ a2) ET y -(61M) (62) 1000M(6« — 42) = er 4.7.3 Axial Elongation is axial deformation and is measured parallel to the axis of the shaft. A positive elongation is the result of a tensile shaft stress and a negative elongationis the result of a compressive shaft stress. Figure 16 is a sketch of a shaft subjected to an axial force. Elongation of this ideal shaft can be calculated ‘from the foliowing equation. Pb ona (63) where is elongation, in (mm); P, is axial force, tb L__ islength, in (mm); Acs i$ cross sectional area, in? (mm?). Figure 16 ~ Axial deformation For cylindrical shafts: ~(64) For sold cyindrcal steel shatts equation 63 can be simpitied to: 424 x 10-8PL & b= (65) ae (65M)AMERICAN NATIONAL STANDARD 4.7.4 Permissible deflection ‘The amount of deflection permissible in a shaft is dependent, to @ great extent, upon the particular ‘condition of operation encountered: hence, no generat rules can be given. However, the shaft must be stiff enough to limit the deflection of key power elements such as gears and pulleys. The allowable slope of the shaft through the bearings should not ‘exceed the allowable misalignment limits of the bearings. Moreover, the judgment and the experi fence of the designer must be relied upon to determine the extent to which either lateral or torsional detection may be permitted. 5 Keys Keys are detachable components which, when assembled into keyways, provide a positive means ‘for transmitting torque between the shaft and hub. Four common types of keys are square, rectangular, tapered, and Woodruff. 5.1 Sizes and tolerances Standard key and keyway sizes, tolerances and fits may be obtained from ANS! B17.1, Keys and Keyseats, ANS! 817.2, Woodruff Keys and Key- ‘seats, or AGMA 9002-A86, Bores and Keyways for Flexible Couplings (inch Series). 5.2 Allowable compressive stress The allowable key, shaft and hub compressive stresses are commonly based on 70 percent of the component material yield strength. Sea = 0.78, (68) where Seq 18 allowable compressive stress, Ib/in? (ummn?); S; is tensile yield strength of key, shaft or hub at the keyway section, lbjin? (N/mm?). ‘See annex, table A. for typical values of ., andS,. NOTE: The allowable stress for surface hardened ‘components shall be based on the corehardness ofthe ‘material except when a detailed analysis justifies higher allowable stress, 5.3 Allowable shear stress ‘The allowable key shear stress shall be based on 50 Percent of the allowable key compressive stress. STD-AGNA bOOL-D9?7-ENGL 1997 I ANSVAGMA 6001-D87 Sus = O05 Scg where ‘Siz is allowable shear stress, Ijin? (N/mm?). ‘See annex A, table A.1 for typical values of S._ and Sea. 5.4 Compressive stress calculation ‘The compressive stress in a key or keyway resulting {rom the transmitted torque may be calculated using ‘equation 68. The caloulated compressive stress, s., should not exceed the allowable compressi stress, Sea Tp (67) Se Tae (68) se = OTT (60%) & is calculated compressive stress, tb/in? (Nim); T _ is shaft torque, tb in (Nm); ac iS average radius at compressive load area, in (mm) (Gee figure 17); ‘Ac 8 compressive area of key in contact with shaft or hub, in® (m2); Fp 18 peak load factor =2.0or spur, helical, herringbone and bevel gear drives = 3.0 for worm gear drives. NOTE: Each component shall be evaluated based on the allowable stess for its materiel and hardness, Figure 17 ~ Average shatt and hub radius 5.5 Shear stress calculation The shear stress in a key resulting from the ‘transmitted torque may be calculated using equation 69. The calculated key shear stress, xz, should not ‘exceed the allowable shear stress, S, 19ANSVAGMA 6001-D97 sane (68) where 4 is calculated key shear stress Ib/in? (Nimm?); is shear area, in? (mm?); t~ _ (Saverage shatt radius along the key length, in (mn). 5.6 Keyed interference ft When an interference fitis used in conjunction with 2 key, the torque to be transmitted by the key may be teduced by the minimum torque capacity of the interference fit. The minimum torque capacity of the interference fit is the minimum capacity at the most unfavorable conditions of speed, temperature, di- mensional tolerances and sliding coefficient of friction. For reversing loads, either atight ft key isto bbe used or the restraining torque of the interference fit must exceed the peak torque applied to the joint. Due to the irregular shape created by the keyway, the calculation of this torque capacity is beyond the ‘Scope of this standard and must be established by experiment. &7 Keyless interference fit ‘When an interference fit is used without a key, the restraining torque resutting from the interference fit shall exceed the peak torque at the joint. ‘Annex © presents one method for calculation of torque due to interference fit CAUTION: When calculating the torque capacity of an {interference fit, consideration should be given to: = thermal effects of dissimilar materials; ~~ centrifugal effects; ~ hoop stresses; - residual stresses; - dimensional tolerances; coefficient of friction as determined by ‘surface finish, material, and lubrication. 6 Bearings Bearings are required to support shatting in accurate ‘alignment while supporting shatt loads and allowing ‘shafts torotate or transiate, orbath. Proper selection 20 STPSAGAR boou-v97-ENGL 1992 © AMERICAN NATIONAL STANDARD Of the bearing system and bearing lubrication system is critical to proper functioning of gear drives. 6.1 Roller and bail bearing selection criteria Roller and bell bearings generally are selected according to L10 life calculated by the methods ofthe bearing manufacturer and adjusted for the factors given below. A minimum calculated life of 5000 hours L10, without consideration of adjustment factors, has historically been the standard for gear drives. The L10 life is the length of time that 90, Percent of a group of apparently identical bearings vill equal or exceed before a subsurface originated fatigue spall reaches a predetermined size at the surface. The L1Olife is associated with a 90 percent reliabilty level ‘A bearing’s dynamic load rating is the load that the bearing will cary for a specified number of revolu- tions at a spectied reliabilty level. Bearing life shall bbe calculated according tothe load supported by the. bearing resulting from both internal and external loads. Life in hours shall be calculated using the rotational speed of the bearing. |n addition to dynamic load rating, other selection criteria such as static load rating, minimum load requirements, and speed limitations should be considered, 6.1.1 Reliability Reliability levels other than 90 percent may be calculated. For more specific analysis, consutt the bearing manufacturer. 6.1.2 Life adjustment factors ‘A bearing’s rating is given for operation under a ‘speciiied set of operating conditions. The life should be adjusted for the following factors: Lubrication. A bearing’s dynamic rating is estab- lished for speciic conditions of lubricant viscosity, ‘speed and temperature which affect lubrication. Adjustment should be made for actual lubricant viscosity, speed and temperature as specified by the gear drive designer. Load zone. A bearing’s dynamic rating is generally based on @ nominal amount of intemal clearance ‘hich generates a load zone (loaded arc) within the bearing of between 150° and 180°. Adjustment ‘should be made for the actual load zone under the loads imposed cn the bearing, Alignment. Adjustment should be made for ‘misalignment magnitudes which may reduce bear- @ &AMERICAN NATIONAL STANDARD ing Ife. The misalignment may be due to size, form (or position tolerances; shaft or housing deflection ‘under load; oF a combination of the above, Bearing material. A bearing’s dynamic rating is based upon hardened, good quality bearing steel. If premium steels are used, the life may be adjusted ‘due to the reduction of impurities in the steel. Usable life. A bearing’s dynamic rating is based upon a laboratory spall size which normally wil not hinder the performance of a gear drive. A spall size which is considered detrimental to the performance of the gear drive may be a usable life criterion. NOTE: The life calculation methods used by bearing ‘manufacturers ere based upon subsurtace originated fatigue damage which leads to spalls. Other types of ‘bearing damage which may reduce bearingiife include, ‘but are notlimited to, surface originated spaling dueto bruises from contaminants in the lubricant, plastic yielding or brineling due to overload, retainer damage ‘and scoring or scuffing due to lack of lubrication, Consult the bearing manufacturer for specific life adjustment factors. 62 Sleeve bearing selection criteria Sleeve bearings operate in three basic regimes: = boundary lubrication; = mixed fim lubrication; = full fim hydrodynamic lubrication. Figure 18 illustrates the typical variation of the Coefficient of ftiction as a function of the bearing Parameter forthe three lubrication regimes. 62.1 Boundary and mixed film regimes Inthe boundary and mixed film lubrication regimes, a pressure-velocity criterion for the specific material of the bearing should be checked. 6.2.2 Hydrodynamic regime Inthe hydrodynamic regime, the main design criteria, are: Unit loading. in general, bearings are operated at Jess than 750 Ibjin? (6.2 Nimm2) unit loading, Ol! film thickness. In general, oil fim thickness is greater than 0.0008 in (0.02 mm). ANSV/AGMA 6001-D57 Coefficient of friction —— ( Cibican’ Rare ) parameter Projected aca presse Figure 18 - Variation of coefficient of friction versus the bearing parameter Operating temperature. In general, for tin based babbitt, metal temperature does not exceed 260°F (127°Q), NOTE: The criteria above may be exceeded when ‘sophisticated analyses are performed on bearing materials, constuction, clearance, eccentricity ratio, ‘shaft slope, length to diameter ratio, lubricant viscosity, and operating temperature. Hydrodynamic bearings subjected to infrequent ‘momentary peak loads shall be designed such that the yield point of the bearing materials Is not exceeded. For specific information refer to the bearing ‘manufacturer, ori]. 7 Housings The housing provides accurate alignment of the gears and bearings with sufficient strength and stiness to maintain alignment under maximum internal and extemal loading. The housing also Provides some, but not necessarily all, of the following: ~ reservoir for retention of lubricant; exclusion of contaminants; = drain and fil locations; 24 STD-AGHA GOOL-D97-ENGL L997 mm Cope SSL SSR teANSVAGMA 6001-D97 ~ inspection covers; = ail level indicators; = surface area for heat dissipatic - feet or mounting pads; motor mounting surface; - iting tugs. 8 Threaded fasteners ‘The purpose of threaded fastenersis to clamp two or ‘more joint members together. The asteners shallbe of sufficient tensile strength and quantity to with- stand the maximum internal and external design foads and prevent movement between the joint members. Fasteners may also be subjected to shear loading. This condition requires additional analysis and is beyond the scope of this standard. 8.1 Tensi ‘The forces to be considered are those developed by the mechanical rating of the gear drive in addition to the extemal loads. ‘The equation for calculating tensile stress is as follows: (70) * orasio - osssar)? tee) Sie i calculated tensile stress, Ib/in? (N/mm); Wy is applied tensile load on fastener, Ib (N); Fp _ is peak ioad factor =2.0 for spur, helical, herringbone and bevel gear drives = 3.0 for worm gear drives; D__ is fastener nominal diameter, in (mm); nis fastener threads per inch, in"; P__ sfastener thread pitch, mm. ‘The calculated tensile stress should not exceed the allowable stress. The allowable stress is 80% ofthe fastener tensile preload stress in order to ensure joint integrity. The fastener tensile preload stress is 75% of the proof load stress in order to avoid fastener breakage. Allowable stress values for STD-AGMA bOOL-D97-ENGL 1997 AMERICAN NATIONAL STANDARD typical threaded fasteners for tensile preloads of 75% of proof load are shown in annex B. Other values may be used based on testing or experience. 82 Torque ‘The following equation may be used to estimate torque for inducing a given tensile preload [5}: Ty=KeD Wp o) KeDW, ke Mp t,= ape (71M) where Jy is fastener torque, Ib in (Nm); Kee Is fastener torque coefficient; .2 for nonplated steel fasteners. In applications where lubricants such as thread locking compounds, greases, olls and waxes are applied to the fasteners, Kj. may be assumed to be as low as 0.12 (5}; D__ is nominal diameter of threaded fastener, in (mn); Wp is fastener tensile preload, Ib (N). Common practice is to torque the fastener to provide tensile preload of 75 percent of the proot load. = ons om (p - ony | sa(72) Wp =075 5, (0.785 (D 0.9382 P}] where 5, _ is proofload stress, Ib/in? (N/mm?). CAUTION: The pretoad shall be adequate to prevent movement between the joint members with due ‘consideration given to deformation of the members. 8.3 Engagement length The thread engegement in tapped holes shall be of sufficient length thatthe shear strength in the internal and external threads is greater than the tensile preload in the fastener. (72M) 9 Miscellaneous components ‘The following sections discuss frequently used components of industrial enclosed gear drives. A specific gear drive may not require all of the components listed and may utilize other ‘components which are not included. 9.1 Shims Shims are generally used to position gears, bear- ings, or other components. When also used as @AMERICAN NATIONAL STANDARD. ‘gaskets, shims shall provide proper sealing. The shim materia! must withstand the minimum ambient and maximum operating temperatures at the shim. ‘The material shall remain dimensionally stable at initial assembly and when exposed to temperature ‘extremes for the life of the drive. The shim material shall be compatible with the gear drive lubricant and outside atmosphere, including contaminants. CAUTION: The total shim pack thickness should not ‘exceed the shim manufacturer's recommendation. 9.2 Gaskets Gaskets are used to retain lubricant and to exclude contaminants. They should not be used to position ‘components, The gasket material shal! be compat- ible with the minimum ambient and maximum ‘operating temperatures at the gasket Gasket material is generally intended to compress at assembly but shall remain dimensionally stable when subjected to temperature extremes. The ‘gasket material shail be compatible with gear drive lubricant and outside atmosphere, including contaminants. 9.3 Oil seals Oil seals are used with rotating shafts to retain the lubricant and to exclude contaminants. Considera- tions concerning oil seal selection include but are not limited to hardness, material, pressure at the seal, shaft finish, roundness, concentricty, bearing endplay, speed, minimum ambient and maximum ‘operating ternperatures at the oil seal, lubricant, outside environment and expected life. CAUTION: Oil seals should be selected in accordance with the seal manufacturer's recommendations. Can- tact type seals should be considered wearable and ‘eplaceable items over the life of the gear drive 9.4 Breathers. Breathers maintain pressure balance between the inside of the drive and the external atmosphere, while excluding environmental contaminants, The location should be such that ol leakage through the breather is prevented. When the pressure differen- tial is less than the acceptable component sealing limits, a breather may not be required. 9.5 Expansion chambers Expansion chambers are devices that maintain Pressure balance between the inside of a gear drive SUERBTASUOL-DI7-ENGL 3997 il ‘ANSVAGMA 6001-097 and the external atmosphere while isolating the two. Environmental conditions and some applications ‘may preclude the use of breathers, in which case ‘expansion chambers may be used. 9.6 Oil level indicators Oil level indicators are used to identify the proper oil level with the gear drive mounted in a specified Position. The manufacturer shall specify under which condition the oil level is to be checked, static or ‘operating. ‘Typical oil level indicators include pipe plugs, sight ‘gauges, standpipes and dipsticks. CAUTION: A pressure buildup inside e gear dtive will cause a false reading on a vented oil gauge. 9.7 Bearing retainers Bearing retainers are devices other than the housing that maintain the axial or radial positions of the bearings. All retainers shall be designed to locate and maintain dimensional stability for the bearings and gears in accordance with the bearing and gear ‘manufacturers’ specifications. Bearing retainers in- ‘clude but are not limited to locknuts, Keeper plates, end caps, cartridges or carriers and snap rings. 9.8 Grease retainers Grease retainers are generally located between the bearing cavity and oil sump to retain grease in the bearings. 9.9 Dowels and pins Many different types of dowels and pins are used to provide positive location or to prevent movement between two or more parts under load. 9.9.1 Dowels and pins used for positive lacation ‘These devices are generally used to return parts to the exact position required if disassembly is neces- sary. Care should be taken to assure that the required holes are the proper size. 992 Dowels and pins used to prevent movement ‘These devices shall be selected based on the maximum design loads. Generally two or more of these devices are used. Care should be taken to ‘assure that the required holes are the proper size. CAUTION: In the above cases, the dowel and pin ‘manufacturers’ recommendations for fi and strength, should be followed,‘ANSVAGMA 6001-D57 9.10 Spacers ‘Spacers are generally used to position bearings, gears, and other components. The spacer construc- tion and material shall be of sufficient strength, slifness and size to provide proper support for agjacent components under maximum intemal and extemal design loads. Spacers shall withstand required assembly forces. 24 STD-AGMA bOGL-D97-ENGL 1997 AMERICAN NATIONAL STANDARD 9.11 Seal retainers ‘Seat retainers are generally used to position the seal in proper relationship to a shaft, orto locka splittype seal in place. 9.12 Fastener locking devices Locking devices may be provided to lock fasteners in place. Typical locking devices include lockwashers, self-locking fasteners, locking compounds, locking tabs, and lock wiring.AMERICAN NATIONAL STANDARD ‘Annex A (informative) ANSVAGMA 6001-D87 Allowable stresses for typical key and keyway materials €B _eterns nts ster tn a csi ter pe nae cotne ae a part of ANSI/AGMA 6001-D87, Design and Selection of Components for Enciosed Gear Drives.) ‘A. Purpose ‘The purpose of this annex is to provide reference information required for key and keyway calculations: for typical materials used in enclosed gear drives. Reter to 5.2 and 5.3 of ANSVAGMA 6001-D97 to A2 Allowable stress determine allowable stresses for materials and hardnesses not listed in this annex. ‘Table A.1 - Allowable stresses for typical key and keyway materials The allowable stress values in the following table are based on 70 percent of the material yield point, Other values may be used based on testing ot experience. Allowable stress, Ib/in® (N/mm?) Hardness | Yield strength, S, — Key or hub material HB. | Ibfin?(Nimmé)” | Shear, S, | Compressive, S.. | Source AIS! 1018 126 54.000 18 900 37 800 Cold drawn - (870) (130) (260) AIS! 1045 179 77 000 26 950 53 900 y Col drawn (630) cS) 70) gf AIS 4140 320 110.000 38 500 7000 9 Heat treated (760) (265) (530) Cast iron 160 - 190 85 0007) - 59500 3 Class 30, (690) (415) Duc iron 187 - 255 80 0007) _ 56.000 a 80-55-06 (850) (385) Heat treated forged bronze 162 48.000 _ 33.600 4 (copper alloy no. 90673) (330) (230) Nickel-tin bronze (SAE 65) 102 30.000 = 21000 4 (copper alloy no. C90700 (205) (145) centifugal east) ‘Aluminum bronze (copper 195 54000 5 37 800 4 alloy no. C95499 heat (870) (260) treated) NOTES: SAE - Society of Automate Engineers 2) Compressive yield strength 3) MH Machinery's Handbook “1CDA - Copper Development Assocation & 2 STOCRORABTDL-D97-ENGL 1997ANSYAGMA 6001-D97 AMERICAN NATIONAL STANDARD (This page is intentionally let blank.) STD-AGMA BODL-D9?-ENGL LA97 simtmmnroorinmemesenatioce SS ialAMERICAN NATIONAL STANDARD ANSVAGMA 6001-097 Annex B (informative) Allowable stresses for typical threaded fasteners ©) ratwons ones. ad avers tyre pene erhrometon pupae nso coset fat of aNSUAGN COT“ OOT boc ane Snssone Cnburens er Ehscus Goer omcs! B1 Purpose ‘The purpose of this annex is to provide reference information required for fastener calculations. Table B.1 - Allowable tensile stress for typical inch threaded tasteners Grade Proof load_ | Tensile preload” | Allowable designation | Products | Nominal diameter, in | stress, Ibfin? | stress, tb/in? | stress?) Ib/in? ‘SAET Bolts, Screws, | 1/4 through 1-1/2 33.0007 24750 19800 ‘Studs | SAE 2 Botts, 1/4 through 3/44) +55 0009 41250 Screws, Studs’ | Over 3/410 1-1/2 33.000 24750 ASTM A-449 | Bolts Over 1-1/2103 5000 | 41250 SAE4 | Studs 1/4 through 1-1/2 65 000 48 750 ( : al x SAES Bots, | 1/4 through 1 85.000 63 750 Screws, Studs’ | Over 1 10 1-1/2 74.000 55500 SAE 7 Botts, | 1/4 through 1-1/2 105 000 78 750 Over 1/4 to 2-1/2 “105 000 7750 | 63000 Over 2-1/2104 95000 71250 57000 114 through 1-1/2 120 000 80.000 72.000 ‘Va through 1-1/2 | 120000 "90000 72000 “V4 through t 120000 | 90000 72.000 ‘V The fastener tensile preload stress values in he table are based on torquing the fastener to produce atensile preload of ‘75% ofits proot load to avoid fastener breakage. Other values of percentage of prootload may be used, based on testing ‘or experience. 2. The allowable stress values in the table are based on 80% of the fastener tensile preload stress in order to ensure joint integnty. ' Proof load test: Requirements in these grades apply only to stress relieved products. “Grade SAE 2 requirements for sizes 1/4 through 3/4 inch apply only to bolts and screws Ginches and shorter in length, ‘and to studs of all lengths. For botts and screws longer than 6 inches, Grade SAE 1 requirements shall apply. 5)Grade SAE 7 bolts and sorews are roll threaded after heat treatment. Reference: Fastener Standards, Cleveland, Ohio: (ee Industrial Fasteners Institute, 1988, Soah Edition. STD-AGHA BOOL-D9?-ENGL 2997 MM Ob Si, Sotaener Scere nemaANSVAGMA 6001-D97 AMERICAN NATIONAL STANDARD ‘Table B.2 ~ Allowable tensile stress for typical metric threaded fasteners Proot oad] "(Tanailspre- | Allowable 1SO property | Nominal diameter, load") stress, stress?), class mm Neer? Néenm? ‘N/mm? 46 ‘5.0 through 36 225 169 185 48 1.6 through 16 310 282 186 58 5.0 through 24 380 285 228 a8 16.0 through 36 600 450 380 98 1.6 through 16 650 488, 390 10.9 5.0 through 36 830 22 498 129 1.6 through 36 970 78 582 NOTES: +) The fastener tensile preload stress values in the table are based or torquing the fastener to produce a tensile preload of 75% of ts prootload to avoid fastener breakage. Other values of percentage of proofload ‘may be used, based on testing or experience. 2 The allowable stress valves inthe table are based on 80% of he fastener tensile preload stressinorderto ‘ensure joint integrity. Reterence: SAE Handbook, Warrendale, Pennsylvania: Society of Automotive Engineers, Inc., 1986. STD-AGNA LODL-DA7-ENGL 1997 sitaSnrmvirimwgntimnn omar E * tmognecicy area EB® AMERICAN NATIONAL STANDARD ANSVAGMA 6001-D97 Annex C (inform: ative) Interference fit torque capacity [The foreword, footnotes, and annexes, i any, are provided for informational purposes only and should not be construed as a part of ANSV/AGMA 6001-D97, Design and Selection of Components for Enclased Gear Drives.) C.1 Purpose ‘The purpose of this annex is to provide a typical calculation method for determining the amount of torque that can be transmitted by an interference fit between cylindrical surfaces without discontinuities. €.2 Calculations. P. 8 +42 C24+B?_ _ Hi, to 7 Ee A) * BC - BF) Ei * Ey (Ct) For similar metals E = E; = E, and w= Uo Ee (C? ~ B?)(B? ~ A?) 7 = OO ary (C2) (C3) (C4) (C5) (C.5M) A _sinside diameter — inner member, in (mm); Bis nominal outside diameter ‘member, in (mm); Cis outside diameter - outer member, in (mm); = inner STD-AGMA BOOL-D7-ENGL 1997 mM OE! is modulus of elasticity, Ib/in? (N/mm2); is modulus of elasticity - outer member, \bfin? (Nimam2); ‘is modulus of elasticity - inner member, Ibn? (Nimm?); is coefficient of friction; 's fit length, in (mm); P. is interface pressure, Ibfin? (N/mm2); Si is tangential stress at the interface-inner tJ abt) BS member, Ibn? (N/mm?); Sio is tangential stress at the interiace-outer ‘member, Ibfin? (Nimm2); T is torque capacity resulting from interference fi, bin (Nm); 3 is diametal interference, in (mm); 14 is Poisson's ratio - inner member; Yo is Poisson's ratio - outer member. Inner member Outer member Figure C.1 - Calculation terminology 29‘ANSUAGMA 6001-D97 AMERICAN NATIONAL STANDARD (This page is intentionally blank) 30 STD-AGMA bOOL-DS7-ENGL 15997AMERICAN NATIONAL STANDARD ANSVAGMA 6001-DS7 Annex D (informative) Previous method - shaft design D.1 Purpose ‘The purpose of this annexis to include the previous shaft design section of ANSVAGMA 6001~C88 (formerly AGMA 260) for reference purposes. [The foreword, footnotes, and annexes, i any, are provided for informational purposes only and should net be construed as {a part of ANSVAGMA 6001-D97, Design and Selection of Components for Enclosed Gear Drives.) D.2.1 Shaft stress calculation Nominal shaft stresses are calculated as follows. The applicability of equations D.1 and D.2 to the design of thin wall shafts where the ratio (d/d,) > 0.9 has not been established. D2 Shatting _ 16rd ‘The general equations for torsional and bending o x(a — a) (0.1) ‘stress are shown in equations D.1 and D.2. Whilethe oan allowable stresses shown in figure D.1 do not a = OTe (om) ‘separately consider the effects of such things as (@§ - af) ae shaft size, surface finish, operating temperature, corrosion, residual stresses and reliability, this (0.2) ‘method was the accepted practice for shaft design thathas been included in AGMA standards and used (02M successfully for many years. “Eo ‘| CS 178 3 =} ‘a 20 jing _[ 125 16 + acs £ | a2 1 Bis 3 Torsion { Bat * z ay 4 of 0 _L 1 160 200 240 260° 320 960 400 440 Brinell hardness 8 100 120 140 160,180, 200 220 ‘Tensile strength, 1000 tbfin? oo wo 1000 “i000 Tensile strength, Nn Ga Figure D.1 - Allowable stress for steel shafts, 3 STD-AGMA LOOL-D47-ENGL 1997 Ml OLB nomen gen ee aeANSVAGMA 6001-D87 where Is calculated torsional shear stress, tb/in? (Nimm?); is shaft torque, Ib in (Nm); is shaft outside diameter, in (mm); is shaft inside diameter, in (mm); {s calculated bending stress, Ib/in? (N/mm?); is bending moment, Ib in (Nm). For solid shatting, equations D.1 and D.2 simply to: Re RaAN 35 = 16 xd se ara .(D.3M) =e 0 Bie (04M) 22 Allowable stress Forsteel shatts the calculated stress due to bending and the calculated stress due to torsion shall not exceed the values shown in figure D.1. These stresses may exist simultaneously. The allowable stress for stool shafts that are hardened by processes such as case carburizing or nitriding should be based on the core hardness ofthe material unless a detailed analysis or experience indicates that a different allowable stress be used. 0.2.3 Stress concentration ‘Shaft stresses concentrate near a change in the shaft or where a load is applied to the shaft. Typical stress concentrators include but are not limited to (03) (0.4) 92 STD-AGMA BOOL-DI7-ENGL 1997 AMERICAN NATIONAL STANDARD. key joints, shoulders, grooves, splines and interter- ence fits. Notch sensitivity accounts for different ‘materials reacting differently to the same theoretical ‘tress concentration. The allowable stresses shown in figure D.1 provide for stress concentrations, including notch sensitivity, upto 3.0. When the actual stress concentration is greater than 3.0 a detailed analysis is required. D.24 Specific ite ‘When designing a shaft for a specific number of rotating cycles, the allowable bending stresses of figure D.1 may be multiplied by the factors in table Da. ‘Table D.1 - Allowable stress multipliers for ‘shatting Cycles Factor Upto 1000 cycles Ba Over 1000 to 10 000 cycles 18 Over 10 000 to 100 000 cycles 14 ‘Over 100.000 to 1 milion eycles 44 Over 1 milion cycles 1.0 D.2.5 Deflection Deflection (lateral, torsional and axial) is a function ot the loading on the shaft, modulus of elasticity andthe size of the shaft, andis independent of the hardness. Damage to beatings, gear teeth or other compo- nents may occur if deflection is excessive. D.2.6 Peak loads Bending and torsional stresses resulting from peak loads must be analyzed to assure that the mechanical properties of the shaft material are not exceeded. SERS ittgerene sae SP €AMERICAN NATIONAL STANDARD ANSVAGMA 6001-D97 Annex E (informative) ‘Sample problems - transmission shaft design {The foreword, footnotes, and annexes, itany, are provided for informational purposes only and should notbe construed as ‘part of ANSVAGMA 6001-97, Design and Selection of Components for Enclosed Gear Drives.) E.1 Purpose ‘The purpose of this annex is to provide examples of the application of clause 4, Shatting. The equations of this section will be applied to practical shatting problems. 2 Sample problem number 1 ‘An AISI 4140 steel helical pinion shatt, through hardened to 360 HB is subject to 10 000 peak load cycles @ 200% operating load and has the following loads imposed on it at the shatt’s critical section: T = 15651 in (60% alternating); ‘M = 328 in Ib (100% altemating - shaft is rotating); V_ = 678 Ib (100% alternating - shaft is rotating); Pz = 424 tb (constant) ‘The sectional properties of the shaft at this point are: & =094in; 4 =00 4 25 in (as shown in figure 8); 12 in (as shown in figure 8). The critical section is at a radius adjacent to a shoulder. ‘The stresses are: = SOLED). 1201 wnt (058 48 op = Aen, (0.94) cu = 4022c088 Xe = 1201 sin + 4798, 611 Ibjin (4022)? ~_3(1201)” 3(201) Since ta is greaterthan ta, then the max stress is at 0, = 90°, Therefore oa: = 0 and tare = 5999 Ib/in2. Ten = = 3289 < ty, G = {OP +55999)7)95 = 10 391 tin? Ge = {(611)? + 3(4798)2}05 = 8333 Ion? Ghoxal = {(611 + OF + 3(4798 + 5999)2)05 = 18711 Ib/in? S, = 500(360 HB) = 180 000 Ibfin? S; =0.94(180 000) ~ 12500 = 156 700 Ibvin? Se =0.5(180 000) = 90 000 tb/in? sted below are the fatigue limit modification factors ‘or this example: 4k, =303(180 000)-9215 = 0,670 NOTE: Shafts machined to a 125 R, surface finish. fy =0.869(0.94)-°97 = 0.874 ke =0.512(1n 1/0.99)0-11 + 0.508 = 0.817 (99% reliability) fa ke .0 (108 cycles) = 11 +093 (16-1) = 0.66 where 0.386 Ao ween <093 K, = 1.60 (from figure 8) ke =10 k — =0.670 (0874) (0.817) (1.0) (1.0) (0.64) (1.0) 306 Sf = 0306 (90 000) = 27 557 Ib/in?® ‘The resulting safety factors for fatigue failure analysis and the peak load failure analysis are: Fey = 140391727 557)? + (8333/156 700} =263 75 (156 te =Jasmy Np is not calculated as Fy > Fp (Fp = 2 for helical gears). 23.14 STD+AGHA BOOL-DA7-ENGL 3597 Mm Oot ora Maem swen tee‘ANSVAGMA 6001-D97 E.3 Sample problem number 2 ‘An AIS! 4140 steel worm gear shaft through hardened to 360 HB is subject to 10 000 peak load cycles @ 300% operating ioad and has the following loads imposed on it at the shatt’s critical section: T = 182751 in Ib (25% alternating); ‘M_— = 56 498 in Ib (100% alternating - shat is rotating); V_ = 28 000 Ih (100% alternating - shaft rotating); Be 20 ‘The sectional properties of the shatt at this point are: 4 =4.46in; 4 =00in. This critical section has a keyway and a gear pressed onto it with an interference ft (fy taken as 0.39). ‘The stresses are: = 16052751) 6769 pint (4.46) For a 25% alternating torque (torque is fluctuating between the maximum value and one-half ‘maximum value): Tar = WA = 2192 fin? Tou = 34/4 = 6577 Ibn? = Yee = 32056498) «6457 tin? (446) ay = 43000023) «2904 tin? (4.46 = 0= on Ger = 6487 08 6 Tee ©, = {[6487 cos (31.8°)P + 3[2204 sin (31.8°) + 2192}2}°5 = 8008 Ib/in? Gm = {02 +3 (65772}05 = 11392 vin? 34 STD-AGMA bOOL-D97-ENGL 1997 Ml Dba AMERICAN NATIONAL STANDARD. Goat = {[0-+ 6487 cos (81.8%)]? + 316577 +2204 sin (31.8°) + 2192]2}05 = 18 061 Ibvin? ‘The calculation of the fatigue (endurance) limit ofthe shaftis as follows: Sy = 500 (360 HB) = 180 000 Ibyin? S, = 0.94(180 000) ~ 12 500 = 156 700 Ibfin? Se =0.5 (180.000) = 90 000 bin? Listed below are the fatigue limit modification factors for this example: = 303(180 000)-%515 = 0.670 NOTE: Shaft is machined to.a 125 R, surtace finish. = 0,869(4.46)-0-097 = 0.752 = 0.512(in 1/0.99)°-"1 + 0.508 = 0.817 (99% reliability) =10 = 1.0 (105 cycles) 20.33 =10 += 0,670 (0.752) (0.817) (1.0) (1.0) (0.33) (1.0) = 0.136 5} =0.136 (90 000) = 12.240 tbvin? ‘The resulting satety factors for the fatigue failure analysis and the peak load failure analysis are as follows: Fey =1/{(@008/12 240)4(11 392/156 700)2}05 =152 12 075 (156 “3(18 061) As 1.0 Fys F,, calculate the permissible number of Peak load cycles. % =———®8____. 2 & a7 24 617 tin? a Fy =217 ‘AS No is greater than the 10 000 peak load cycles ‘expected in service, this is acceptable.AMERICAN NATIONAL STANDARD. E.4 Sample problem number 3 A carburized and hardened AIS! 8310 stee! helical pinion shatt has a core hardness of 300 HB and a63 R, surface finish at the shat’s critical section. Only 100 000 cycles are required during service, and no peak loading is present. The loading is: T= 4000 Ib in (25% alternating); M>— = 3000 in tb (100% alternating - shaft is rotating}; V = 1000 Ib (100% altemating - shatt is rotating); Pos ‘The sectional properties are: 4 =1.25in; 4 =00in; 4 =1.75in (as shown in figure 8); r= 0.06 in (as shown in figure 8). The critical section is at a radius adjacent to a ‘shoulder. ‘The stresses are: 16.40 . > (125) For a 25% altemating torque; 10 430 Ibyin? Ter = W/4 = 2607 Bon? Tor = 34/4 = 7823 Iblin? = ter = 52000) 2 15 646 win? (125) = 420000029) _ 1002 tin? *(25)" > =0* Gur Gee = 15646 005 8 Tux = 1002sin 6 +2607 _ 45.646)? 1002)? en = ES HOO — 80434 Therefore, 4% Set 8, =0. 2.0ac= 15 646 Ibn? and tyes = 2607 Ibn? STD©AGHA BOOL-D97-ENGL 1997 ml ‘ANSVAGMA 6001-D37 (25 64692 + 3(2607)2)05 = 16 285 tbvin? = {(O)? + 3(7823)2}95 = 13 550 Ibjin? (0+ 15 646)? + 3(7823 + 2607)2)05 ‘= 23 899 Ibvin? gpa For a surface hardened part, itis usually conserva- tive to analyze it at its core hardness. For this example, 300 HBis arbitrarily chosen. This particu- lar part has a sur‘ace hardness of greater than 600 HB and also some residual compressive stress at the surface, whose beneficial effect is beyond the ‘scope of this standard. The calculation ofthe fatigue (endurance) limit atthe 300 HB core hardness is as follows: = 500 (300) = 150 000 Ibyin? = 0.94 (150 000) - 12 500 = 128 500 Ibyin? = 0.5 (150 000) = 75 000 Ibj/in? = a hbk he by by 4.2 (150 000)0244 = 0.775 = 0,869 (1,25)097 = 0.850 = 0817 @ 99% reliability =10@ 100°F = 1/(14087@.14-0) = =10 503 rarer ge Tocalculates,, set k= 1.0,k=0.271;S, =k Se =20304 jin? -For this example, the part will nly be run for 100 000 cycies. Therefore, 4, willbe calculated al 10° cycles, m #18. [0s (2)] 257 © = logo (0.8.5,)2/Se] = 5851 __(105851}100 000-2257) ke 35304 = 1.81 @ 105 cycles, Sy = 20304 (1.81) = 36 750 Ibvin? ‘Thus, Fey = 1/{(16 285/36 750)? + (13 550/128 500)?}05 1 Fy = Tsay 7202ANSVAGMA 6001-D97 AMERICAN NATIONAL STANDARD. (This page is intentionally blank) STD-AGMA LOOL-DI7-ENGL 15997 Weiitedsonsmscritmommccaoutoeis a”AMERICAN NATIONAL STANDARD ‘ANSVAGMA 6001-D97 Annex F 5 (informative) 1 Purpose ‘The purpose of this annex isto illustrate the method ‘of numerical integration in the determination of shaft detiection and slope. A sample shaft will be Presented broken into various nodes. Then deflection and slope about its neutral axis will be determined at the various nodes. The main objective of this example is to calculate the slope of the shaft through the journal bearing so that the bearing can be analyzed for sufficient clearance. F.2 Sample problem number 1 Determine the slope and the deflection of the shaft at a point A as shown in figure F.1. Solution: Refer to 4.7.2.1. The various parameters, are: L__ islength of the shaft = 90 in; 2 is distance where deflection and slope are ; required = 30 in; is distance trom support to the concentrated load = 70 in; Sample problems - deflection {The foreword, footnotes, and annexes, it any, are provided for informational purposes only and should not be construed as a part of ANSI/AGMA 6001-D87, Design and Selection of Components for Enclosed Gear Drives.) F istoad = 1201b, Since x < a, use equation 46 for determining the deflection and equation 47 for slope. FL - ax? - 2ab +a? aa a ‘cEIL md FUL ~ 0) 302 = ab + a? Oo ane (47) Substituting in the above equations, we get: 3120(30)(90 ~ 70) 30° ~ 2(90)(70) + 70? 0) 10° C7ESSH90) ey (qninus sign indicates deflection is downward) __ 221690 ~ 701302) ~ 270390) + 702] ‘6(30)(109)(0.7854\(90) su(F.2) = 0.0009 rad (minus sign indicates slope is pointed downward as x increases) F.3 Sample problem number 2 Determine the slope and the deflection ofthe shatt at a point A as shown in figure F:2. Solution: Referto 4.7.2.1. The various parameters y = -0.0385in 6% 1 ismoment of inertia = (x/64)e =0.7854int; SO E is Young's modulus = 30 x 108 Ibfin2; Ls longth of the between supports « 90 in yt eg is distance where deflection and slope are © is shaft slope at x, rad; required = 70 in; Shaft Diameter = 2 in 129 1b = 30in: 40in a 20 in RL R 201b RL STD-AGMA bOOL-D97-ENGL L997 Ml Shaft Diameter = 2 inANSVAGMA 6001-D57 1 Is moment of inertia = (2/64)2* = 0.7854 in’; E is Young's modulus = 30 x 108 Ibjin?; yi deftection of shaft atx, in; ©, is shaft slope atx, rad; is load = 80 ib. ‘Since x > a, use equation 48 for determining the defection and equation 49 for slope. F(a)(L — x){x? + a? - 21x) rs 7 as F(@)(6tx ~ 3x2 ~ 212 ~ 02) rr 7 | (48) % (49) ‘Substituting in the above equations, we get: 80(80\(90 ~ 70)[702 + 30? - 2(90)(70)] . 6(30)(109/(0:7854Y90) = 0.0256 in y 3) (mimus sign indicates deflection is downward) £80(30){6(90)(70) ~ 3(702) - 2(902) - 30°] 20 205}.07854)90) = 0.0011 rad : 4 Sample problem number 3 Determine the slope and the deflection of the shaft at @ point A as shown in figure F:3. 4 _isdistance from support to the concentrated load = 30 in. Solution: Referto 4.7.2.2. The various parameters are: L__Is length of shaft between supports = 90 in; x is distance where deflection and slope are required = 30 in; 2 _isdistance from supportto the concentrated load = 20 in; J is moment of inertia = (n/64)¢ = 0.7854 in’; E is Young's modulus = 30 x 10° ibfin?; ¥ is deflection of shaft at x in; 5 is shaft slope atx, rad; F isload = 1201. ‘Shatt Diameter = 2 in ——— | Since x < L, use equation 51 for determining the deflection and equation 52 for slope. y= RO ==) (61) = roe) (82) ‘Substituting in the above equations, we get: 120(20)(80)(90? ~ 302) 7 * “6 0)(10°}(0.7854)(90) 120(20)[90? — 3(302)] * G0yI05 (0.785460) F.5 Sample problem number 4 The steel pinion shaft presented above in figure F.4 will be analyzed. The slope of the shatt about its neutral axis at point A and F will be determined for further bearing analysis. ‘The shear and moment diagrams for this problem are illustrated in figure F.5. = 004079 5) = 0.0010 rad. AF6) The deflection and slope of the simply supported ‘beam will be calculated at the points indicated in the figure. Numerical integration will be used to determine these values [14]. ‘The following two successive integrals will be used: AF) we J ode (FB) 0 ‘The slope is calculated from: ‘Second integration yields deflection: Pewee Cr <(F.10) 120 ib 38 STD-AGMA bOOL-D97-ENGL 1997 I [sive demesne oem tomet se a @Figure F4 - Shaft geometry and loading Figure F5 - Shear and moment diagrams ‘Where C; and C> are determined by the values of x ‘and wp at the supports where deflection is zero: ee eenea) 1) c= ea 11) Hee ~ 244 cy = EL tata (F.12) Rewriting equation F:7 using the trapezoidal rule at @]be2 20 Se (P13) STD-AGMA LOOL-D97-ENGL 1997 Mm ‘Applying Simpson's rule, equation F.8 produces: We Wt U6 Oise + 4042 +O) (Res —a) wolF.14) Table F.1 presents the tabulated values for the equations presented, applied to the example to determine the defiection and slope of the shaft. ‘Therefore, the slope of the shaft through the center of bearing A is ~0.000 28 radians and through the ccenter of bearing F is 0.000 16 radians. 39ANSVAGMA 6001-D97 AMERICAN NATIONAL STANDARD 5 ‘Table F.1 : = ‘OD T M > v y 6 a Station | (in) Gin)_|_ Gn) | int) | M/EI_| (rad) | (rad) in) (rad) oy oy oy oy of 0 @ A 1 3.50] 7.366 0 0 o 0 0} -0.000 28 0.875 2) 3.50] 7.366} 6002} 27.16 . 3| 350] 7966] soo2| 27.16| 11.88 8 | 175] 4] 350] 7.366] 12003] 54.32 5 5.00) 31.42) 12003) 12.73/ 47.53| 27.72| -0.00037! -0.00018 (3.375 6 5.00} 31.42] 23149) 24.56 7) 5.00} 31.42] 23149) 24.56] 77.83 c 5.00 8 5.00] 31.42] 34295] 36.38 9 5.00] 31.42| 34295} 36.38] 127.3] 291.1 | -0.000 85] -0.000 10 750| 10] 5.00 31.42/28 198] 20.92 11] 5.00] 31.42] 28198] 29.92] 2102 D | 10.00} 12] 5.00] 31.42] 22100} 23.45 13] 5.38] 41.12| 22100] 17.92] 2769] 1329] -0.00096) 0.000 05 13.875] 14) 5.38} 41.12] 12649] 10.25 15] 5.38] 41.12] 12649] 10.25] 331.5 e | 1775/16] 538] a112| 3195] 259 7 250| 1.918] 3195] 55.53] 3564] 3860| -0.00020| 0.00013 year] 18] 250] 1916] 1588) 2755 19 2.50! 1.918] 1585) 27.55| 363.8 F | 106} 20) 250] 1918) 0| 0 zi|_ of 0] __o|_o| swa8| asse 0} 0000 16 PE = 30 x 10° ibjin= (steel shaft) C= 0.000 225 > Values for MIEI, @ and w are x 10° G=0 € 40 STD-AGMA GODL-DAP-ENGL LAVciihasecmerowstomemerscpacooecte Tad”AMERICAN NATIONAL STANDARD ANSVAGMA 6001-D87 ‘Annex G (informative) References [The foreword, footnotes, and annexes, i any, are provided for informational purposes only and should not be construed as ‘part of ANSI/AGMA 6001-087, Design and Selection of Components for Enclosed Gear Drives.) The following documents are either referenced inthe text of included for additional information 1. AGMA 04-096, Metric Usage. 2, ANSVAGMA 8002-A86, Bores And Keyways for Flexible Couplings. 3. ANSI/ASME B106.1M-1985, Design Of Trans- mission Shafting (second printing). 4. Cast Bronze Bearing Design Manual. Evanston, IL: Gast Bronze Bearing Institute. 5, Fastener Standards. Cleveland, Ohio: industrial Fasteners Institute, 1988. Sixth Edition. 6. Hopkins, Bruce R. Design And Analysis Of Shafts And Beams. New York: McGraw Hill Book. Company, 1970. 7. Juvinall, Robert C. Stress, Strain And Strength. New York: McGraw Hill Book Company, 1967. 8. Metric Fastener Standards. Cleveland, Ohio: In- dustrial Fasteners Institute, 1983, Second Edition. 9. Peterson, R. E. Stress Concentration Factors. ‘New York: John Wiley and Sons, 1974. 10. Shigley, Joseph E. and Mitchell, Larry D. Me- chanical Engineering Design. New York: McGraw Hill Book Company, 1983, Fourth Edition. STOTACHACBO1-D97-ENGL 1997 11, SAE J 429 January, 1980. 12, Wellauer, Edward J, Design Of Shatting For Gear Drives, AGMA Technical Paper P246.01, Oc- ‘tober 1966, 48. Roark, Reymond J. and Young, Warren C., Formulas for Stress and Strain, New York: McGraw Hill Book Company, 1975, Fifth Edition, 14, Shigley, Joseph E. and Mischke, Charles R., ‘Standard Handbook of Machine Design. New York: McGraw-Hill Book Company, 1986. 15. Shigley, Joseph E. and Mischke, Charles R., ‘Mechanical Engineering Design, New York: ‘McGraw-Hill Book Company, 1989, Fifth Edition. 46. Sullivan, J L., “Fatigue Life Under Combined Stress,” Machine Design, January 25, 1979. 17. ANSV/AGMA 2001~C95, Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. 18. NASA, Reference 1123, Design of Power ‘Transmitting Shafts, S. Lowenthal, 1984. 19. Bethlehem Stee! Corp., Modem Steels and ‘Their Properties, Seventh Edition, 1972. aSTD-AGMA bOOL-D9?-ENGL 1997 MH ObA7S75 OOOSH7, OTb mm PUBLISHED BY ‘AMERICAN GEAR MANUFACTURERS ASSOCIATION, ‘1500 KING STREET, ALEXANDRIA, VIRGINIA 22314