General Aspects of Speed Increaser Gearboxes

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International Conference on Applied Sciences (ICAS2017) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 294 (2017) 012032 doi:10.1088/1757-899X/294/1/012032
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General aspects of speed increaser gearboxes
A Băra1, D Nedelcu1, C Haţiegan2, A C Bejinariu3 and L (Filip) Nedeloni1

1
Eftimie Murgu University of Resita, Department of Mechanical and Materials
Engineering, Traian Vuia str., no.1-4, 320085 Resita
2
Eftimie Murgu University of Resita, Department of Electric Engineering and
Informatics, Traian Vuia str., no. 1-4, 320085 Resita, Romania
3
Politehnica University of Timisoara, Faculty of Management in Production and
Transportation, Remus str., no.14, 300191, Romania
E-mail: abara@resitareductoare.com
Abstract. This study aims to present the general aspects of the speed increaser gearboxes.
The second part of this study will focus on the identification of the possibility to replace the
special materials used for gearing execution of the speed increaser gearboxes with materials
having inferior mechanical characteristics. Gearing execution from 18CrNiMo7-6 material is
expensive in terms of price and applied execution technology. Also to obtain the mechanical
characteristics for these materials is necessary to apply some special expensive heat treatments
as carburizing heat treatment. We will replace this material with C45 steel for gear and pinion
execution, we will apply an induction hardening heat treatment for getting a surface teeth
hardness HRC 45 an for the increase the safety for tooth root stress coefficient we will apply a
supplementary operation consisting in a tooth root shoot peening.
1. Introduction
The gears represent mechanical transmissions used in many applications due to the fact that they have
high efficiencies and could cover a large scale of the speed and powers. Because the gears are
executed from alloy special steel with specific heat treatments, these transmissions have small
dimensions [1].
The speed increaser gearboxes are mechanical transmissions with subunit ratio. Depending on the
imposed total ratio, the speed multipliers could be constructed in one or more stages.
The gears of the speed increaser gearboxes can be with cylindrical teeth or cylindrical helical teeth.
We recommend cylindrical teeth when the peripheral speeds are low and the axial forces in the sleeve
bearing are not accepted. When the peripheral speed are high (over 12m/s) [2] and the function is
silent, we recommend using gears with cylindrical helical teeth.
Speed increaser gearboxes used in the Kaplan turbines are constructed with cylindrical helical
teeth, the multipliers sleeve bearings are dimensioned so that to take the forces from the cylindrical
gearing and the axial forces generated by the turbine.
2. Short description of the gears system

The gears system is classified according to the following criteria [3], [4]:
I. Axes position: A)Gears with parallel axes Figure 1.a; B)Gears with crossed axes Figure 1.d;
C) Gears with intersected axes Figure 1e-f;
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II. Teeth form: A) Gears with cylindrical teeth; B)Gears with cylindrical helical teeth; C) Gears
with teeth in V,W,Z form; D) Gears with bevel helical teeth;
III. Relative position of the meshing surfaces: A)External meshing; B)Internal meshing
IV. Direction of rotation: A) In the same direction; B) In opposite direction;
Ratio: A) Constant ratio; B) Variable ratio;
Size of the ratio: A) Ratio i≥1-gearbox; B) Ratio i≤1-speed multipliers
Teeth profile: A) Evolving profile; B) Archimedean spiral for worm gear; C)
Cycloidal profile; D) Straight line just for rack
Figure 1. Types of gears
3. The geometric elements of the speed increaser gearboxes. The meshing low
The meshing low, also known as Willis theory, status the condition that has to the fulfilled by the
profile curves of the teeth in contact so that the moment can be transmitted at a constant transmission
ratio [3].
n 
i12  1  1 (1)
n2  2
In order that two gears wheels to transmit the rotation moment at a constant transmission ratio it is
necessary that the teeth profiles to be generated in such manner that their common normal straight line
in the contact points to pass through a fixed point C (pitch point) (Figure 2) from the centre line. The
conjugate profiles are those to satisfy the meshing low [3], [5].
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Figure 2. The geometric elements of the speed increaser gearboxes
Involute (also known as evolvent ) is a curve obtained from another given curve by attaching an
imaginary taut string to the given curve and tracing its free end as it is wound onto that given curve
Narrow Figure/wide caption [6].
The pressure angle α is the angle between the line of pressure (which is normal for the tooth
surface) and the plane tangent to the pitch surface. The involute equation is [3]:
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Inv  tg   (2)
rb
r  (3)
cos
4. The forces acting in the cylindrical helical teeth of the speed increaser gearboxes. The stresses
appearing in the cylindrical helical teeth of the speed increaser gearboxes
The normal force (Fn) which appears in gearing, decomposes in two components: the tangential force
(Ft) and radial force (Fr). The tangential force introduce tooth root maximum stretching stresses in
point A and maximum compression stresses in point B, and the radial force introduce the compression
stresses in the ABC plan [1].
So, adding these stresses result that the stretching stresses in point A have a maximum value of σi-
σc2 and in point B the compression stresses have a maximum value of σc1+σc2[1].
The tooth crack, as the result of the fatigue bending and shock stresses, appears due to the
stretching stresses that occur around point A [2], [7].
We observe that an increase of the compression stress around this point would lead to decrease of
the stretching stress. This can be done applying a supplementary operation consisting in a shoot
peening in zone point A [2], [7].
Figure 4. The forces in the cylindrical helical teeth
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Figure 5. Tooth root stress schema
During the meshing the teeth are exposed to dynamic stressing [1].
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The static stresses increase with following coefficients:

KA – transverse load factor,
KFβ – face load factor at tooth root,
KV – dynamic factor,
KFα – transverse load factor at tooth root.
Taking into account all these coefficients according to ISO 6336-3:2006 results that the tooth root
stress is:
 F   Fo  K A  KV  K F  K F (4)
where:
σFo – nominal tooth root stress in static conditions;
Considering:
Ft
 Fo  YF  YS  Y  YB  YDT (5)
bmn
Results:
Ft
F   YF  YS  Y  YB  YDT  K A  KV  K F  K F (5)
bmn
where:
YF – tooth form factor,
YS – stress correction factor,
Yβ – helical load factor,
YB – gear rim factor,
YDT – deep tooth factor,
Ft – nominal circumferential force at pitch circle,
b – face width,
mn – normal module.
The safety for tooth root stress coefficient according to ISO 6336-3:2006 is:
 FG
F   S f min (6)
 F1
where:
σFG – limit strength toot root;
According to ISO 6336-3:2006:

 F lim  YST  YNT
 FP  YrelT  YRrelT  Yx (7)
S F min
Considering:
 FE   F lim  YST (8)
Result:
 FE  YNT
 FP  YrelT  YRrelT  Yx (9)
S F min
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where:
Sfmin – required safety,
σF – tooth root stress,
YδrelT – support factor,
YRrelT – surface factor,
Yx – size coefficient,
YST – stress correction factor.
5. Materials used for gear construction of the speed increaser gearboxes

Depending on the mechanical stresses that result from the calculation, the materials used in RRR
company for the execution of the gears and pinions are:
Steel for quenching and tempering: I) 42CrMo4 according to EN 10083-3; II) 30CrNiMo8
according to EN 10083-1; III) 30MoCNi20 according to STAS 791 [8].
Case hardening steel: 18CrNiMo7-6 according to EN 10084 [9].
Carburized and heat treated this steel develops: I) Surface hardness- HRC 61; II) Tensile strength -
Rm=1010-1300 [N/mm²]; III ) Yield point -Rp=815-1050 [N/mm²].
For my application I will use C45 steel for gear and pinion execution with the following
mechanical properties in the quenched and tempered conditions.
Tensile strength -Rmmin=630 [N/mm²];
Yield point -Rpmin=370 [N/mm²].
We will apply an induction hardening heat treatment for getting a surface teeth hardness HRC 57.
To increase the safety for tooth root stress coefficient, we will apply a supplementary operation
consisting in a shot peening.
6. Choose of the constructive solution for speed increaser gearbox type AV 11.25. Geometric
gears calculation of the speed increaser gearbox
Choosing the constructive variant was made starting the following input data: power P = 34.50 (kW);
input speed n1=250 (rpm); output speed n2 = 1000 (rpm); application factor KA = 1;
The main geometrical elements of this speed increaser gearbox are [10]: center distance a =
112.500 (mm); centre distance tolerance ISO 286:2010 measure js7; normal module mn = 2.0000
(mm); pressure angle at normal section αn = 20.0000 (°); helix angle at reference circle β = 10.0000
(°); number of teeth z1= 22 and z2 = 88; face width b1= 47.50 (mm) and b2 = 45.00 (mm); accuracy
grade [Q-ISO 1328:1995], [6].
Figure 7. The geometric elements of the Figure 8. Engagement between

speed increaser gearboxes two gears
Materials used for pinion and gear wheel are [11]:

A) Gear 1: C45 , Through hardened steel, flame/induction hardened according to ISO 6336-5
Figure 11/12 (MQ)
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B) Gear 2: C45 Through hardened steel, flame/induction hardened according to ISO 6336-5
Figure 11/12 (MQ)
C) Surface hardness HRC 57
The geometric gears calculation was made using the Kisssoft gear software and was made
according to DIN 3960:1987, [12].
Table 1. Tooth root strength calculation

Gear 1 Gear 2
Tooth form factor [YF] 1.79 1.53
Stress correction factor [YS] 1.81 2.15
Working angle [alfFen] (°) 21.05 21.20
Bending lever arm [hF] (mm) 2.48 2.84
Tooth thickness at root [sFn] (mm) 4.07 4.07
Tooth root radius [roF] (mm) 1.06 0.80
Contact ratio factor [Yeps] 1.000
Helical load factor [Ybet] 0.917
Deep tooth factor [YDT] 1.000
Gear rim factor [YB] 1.000 1.000
Effective facewidth [beff] (mm) 47.50 45.00
Nominal stress at tooth root [sigF0] (N/mm²) 461.84 492.75
Tooth root stress [sigF] (N/mm²) 599.17 639.26
Permissible bending stress at root of Test-gear
Support factor [YdrelT] 0.994 1.004
Surface factor [YRrelT] 0.957 0.957
Size coefficient (Tooth root) [YX 1.000 1.000
Finite life factor [YNT] 1.000 1.000
Alternating bending coefficient [YM] 1.000 1.000
Technology factor [YT] 1.200 1.200
Stress correction factor [Yst] 2.00
Yst*sigFlim [sigFE] (N/mm²) 740.00 740.00
Permissible tooth root stress (N/mm²) 563.13 568.69
Limit strength tooth root [sigFG] 844.69 853.03
Required safety [SFmin] 1.50 1.50
Safety for Tooth root stress 1.41 1.33
Table 2.Tooth root stresses and safeties taking into account the pretension force
Gear 1 Gear 2
Pretension [sigmaP] (N/mm²) 45 85
Limit strength for tooth root with pretension
[sigFG'] (N/mm²) 898.99 956.92
Safety for Tooth root stress [SF=sigFG'/sigF] 1.50 1050
[sigFG'] (N/mm²) 959.32 1023.64
Safety for Tooth root stress [SF=sigFG'/sigF] 1.60 1.60
[sigFG'] (N/mm²) 1019.66 1084.57
Safety for Tooth root stress [SF=sigFG'/sigF] 1.7 1.7
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We notice that without a pretention at tooth root, the safety coefficients for tooth root stress are
smaller than required safety coefficients.
7. Conclusion
The speed increaser gearboxes are mechanical transmission with subunit ratio. The pinions and the
gears of the speed increaser gearboxes are executed from case hardening steel. Carburised and heat
treated these materials develop high values for surface hardness and for the tensile strength. We will
replace these materials with C45 steel. Appling an induction heat treatment we will get a teeth surface
hardness, HRC 57.
To increase the safety factor for tooth root stress we will apply a shoot peening process. This
process will be performed by bombarding the tooth root teeth of the gears with small spherical media.
By this process we will introduce the residual compressive stresses in the superficial layer of the
tooth root and will improve the bending fatigue strength of the gears.
In conclusion, taking into consideration that applying an induction hardening heat treatment, we
will get a surface teeth hardness HRC 57 and applying and a soot peening process for growing the
safety factor for the tooth root stress it is possible to replace the special materials like 18CrNiMo7-6
or 16MnCr5 with normal steel like C45.
References
[1] Popescu N 1969 Alegerea si Tratamentul Termic al Otelurilor pentru Roti Dintate, Editura
Tehnica, Bucuresti, Romania
[2] Anghel S and Ianici S 1993 Proiectarea transmisiilor mecanice, Universitatea Tehnica
Timisoara, Facultatea de Inginerie, Resita
[3] Constantin V and Palade V 2005 Organe de Masini si Mecanisme, Editura Fundatiei
universitare ”Dunarea de Jos”, Galati, Romania
[4] Ianici S, Ianici D and Potoceanu N 2008 Design of Double Harmonic Transmission, 6th
International Conference of DAAAM Baltic Industrial Engineering, DAAAM Int Vienna,
Tallinn, ESTONIA, April 24-26
[5] Ianici S and Ianici D 2010 Design of mechanical systems, Editura Eftimie Murgu, Reşiţa,
Romania
[6] ***http://en.wikipedia.org
[7] Ianici D, Nedelcu D, Ianici S and Coman L 2010 Dynamic Analysis of the Double Harmonic
Transmission (DHT), 6th International Symposium about Forming and Design in Mechanical
Engineering (KOD 2010), Palic, Serbia, September 29-30
[8] *** https://goo.gl/7w93VJ
[9] *** https://goo.gl/bHtdb1
[10] Ianici S and Ianici D 2015 Constructive Design and Dynamic Testing of the Double Harmonic
Gear Transmission, Analele Universităţii “Eftimie Murgu” Reşiţa 22(1) 231-238
[11] ***ISO 6336/1996 Calculation of load capacity of spur and helical gears, part 1-5
[12] ***DIN 3990/1965 Tragfahigkeisberechnung von stirnrader, Teil 1-5 Deutscher

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IOP Conference Series: Materials Science and Engineering

PAPER • OPEN ACCESS Related content

- Heat Treatment of Zn-Doped p-Type InP

- Extraction of Gearbox Fault Features from

This content was downloaded from IP address 179.61.162.121 on 13/01/2018 at 10:01

General aspects of speed increaser gearboxes

A Băra1, D Nedelcu1, C Haţiegan2, A C Bejinariu3 and L (Filip) Nedeloni1

2. Short description of the gears system

Figure 1. Types of gears

Figure 2. The geometric elements of the speed increaser gearboxes

Figure 3. The geometric elements of the speed increaser gearboxes

Inv  tg   (2)

Figure 4. The forces in the cylindrical helical teeth

Figure 5. Tooth root stress schema

Figure 6. The geometric elements of the speed increaser gearboxes

The static stresses increase with following coefficients:

According to ISO 6336-3:2006:

5. Materials used for gear construction of the speed increaser gearboxes

Figure 7. The geometric elements of the Figure 8. Engagement between

Materials used for pinion and gear wheel are [11]:

Table 1. Tooth root strength calculation

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