CA LC U L AT I O N S · D ES I G N · A PPL I CAT I O N S B . 1 .

Spur gears with gear wheels made from

Hostaform ®, Celanex ® and GUR ®
COPYRIGHT:

All rights reserved, in particular for reproduction and copying, and for distribution as well as for
translation. No part of this publication may be reproduced or processed by means of electronic
systems, reproduced or distributed (by photocopying, microfilm or any other process), without written
permission by Ticona.

© 2004 Ticona GmbH, Kelsterbach

NOTICE TO USERS:

To the best of our knowledge, the information contained in this publication is accurate, however we do
not assume any liability whatsoever for the accuracy and completeness of such information. The
information contained in this publication should not be construed as a promise or guarantee of specific
properties of our products.

Further, the analysis techniques included in this publication are often simplifications and, therefore,
approximate in nature. More vigorous analysis techniques and prototype testing are strongly
recommended to verify satisfactory part performance. Anyone intending to rely on any recommendation
or to use any equipment, processing technique or material mentioned in this publication should satisfy
themselves that they can meet all applicable safety and health standards.

It is the sole responsibility of the users to investigate whether any existing patents are infringed by the
use of the materials mentioned in this publication.

Properties of molded parts can be influenced by a wide variety of factors including, but not limited to,
material selection, additives, part design, processing conditions and environmental exposure. Any
determination of the suitability of a particular material and part design for any use contemplated by the
user is the sole responsibility of the user. The user must verify that the material, as subsequently
processed, meets the requirements of the particular product or use. The user is encouraged to test
prototypes or samples of the product under the harshest conditions to be encountered to determine the
suitability of the materials.

Material data and values included in this publication are either based on testing of laboratory test
specimens and represent data that fall within the normal range of properties for natural material or were
extracted from various published sources. All are believed to be representative. These values alone do
not represent a sufficient basis for any part design and are not intended for use in establishing
maximum, minimum, or ranges of values for specification purposes. Colorants or other additives may
cause significant variations in data values.
We strongly recommend that users seek and adhere to the manufacturer’s current instructions for
handling each material they use, and to entrust the handling of such material to adequately trained
personnel only. Please call the numbers listed for additional technical information. Call Customer
Services at the number listed for the appropriate Material Safety Data Sheets (MSDS) before
attempting to process our products. Moreover, there is a need to reduce human exposure to many
materials to the lowest practical limits in view of possible adverse effects. To the extent that any
hazards may have been mentioned in this publication, we neither suggest nor guarantee that such
hazards are the only ones that exist.

The products mentioned herein are not intended for use in medical or dental implants.

Ticona GmbH
Information Service
Tel. +49 (0) 180-584 2662 (Germany)
+49 (0) 69-305 16299 (Europe)
Fax +49 (0) 180-202 1202 (Germany and Europe)
e-mail infoservice@ticona.de
Internet www.ticona.com
Contents

L Introduction 3 6. Calculation example 19

2. Requirements for spur gears 3 7. Design notes 20

7.1 Selection of module 20
3. Principal specifications 4 7.2 Complementary profile 20
3.1 Straight-toothed spur wheel 4 7.3 Backlash 21
3.2 Helical spur wheel 5 7.4 Reduction of operating noise 22
3.3 Addendum modification 6
3.4 Internal toothing 7 8. Examples of applications 24
8.1 Pump drive for aquapick 24
4. Materials and material combination 7 8.2 Planetary gear for disc motor 25
4.1 Materials 7 8.3 Manually operated drive for window
4.2 Material combinations 7 verticals 26
4.3 Lubrication 9 8.4 Food processor attachment with
gearwheels made from Hostaform
5. Design calculations for straight-toothed and Celanex 27
and helical spur wheels 10
5.1 Straight-toothed spur wheels 10 9. Explanation of symbols 28
5.1.1 Determination of loadbearing capacity
using load characteristic c 10 10. Literature 29
5.1.2 Tooth flank temperature 11
5.1.3 Loadbearing capacity of the tooth root 12
5.1.4 Loadbearing capacity of the tooth flank 14
5.1.5 Tooth deformation 14
5.2 Helical spur wheels 15
5.3 Flow chart for designing spur gears
using load characteristic c 17
5.4 Flow chart for designing spur gears
using tooth root strength 17
5.5 Flow chart for designing spur gears
using tooth flank stress 18
5.6 Checking tooth deformation 18

Hostaform
acetal copolymer (POM)

Celanex
polybutylene terephthalate (PBT)

Hostalen GUR
ultrahigh molecular weight, high density polyethylene
(PE-UHMW)

'
=
registered trademark
1. Introduction 2. Requirements for spur gears
Thermoplastic gearwheels have found wide application, Spur gears transmit rotary motion and power between
particularly in precision drive system for watches, time non-aligned shafts. This power transmission generally
switches, meters etc. which are produced in large num also involves speed or torque conversion.
bers. In such applications, the low production cost made
possible by injection moulding is a decisive factor in the The requirements for spur gears vary greatly according
choice of plastics. to the type of gear and operating conditions. In watch
movements, constant torque transmission with low fric

A more demanding application with

regard to the drive tion loss is necessary. In drives for meters and recording

power being transmitted is gearing for small electrical instruments, it is important to avoid jamming as a result
appliances such as food processors, mixers, ironing of dirt contamination. Power gears including drives for
presses, floor polishers etc. In addition to low cost food processors, sewing machines, windscreen wipers,
production, a compelling argument for the use of vehicle seat adjustment etc. must be capable of operating
engineering thermoplastics is their good sliding prop over awide temperature range and guaranteeing an
erties which make for silent running and maintenance- adequate service life with low tooth flank wear. Another
free operation. In the Hoechst range of engineering important requirement which has come more to the fore
polymers, the Hostaform acetal copolymer grades and in recent years and has actually favoured the use of
Celanex thermoplastic polyester grades offer a wide plastics is the demand for gears to operate as silently
variety of possibilities for meeting the requirements as possible.

of different gears.
These various requirements are met by different tooth
For special applications in which high chemical resis designs (e. g. cycloidal or round flank toothing in watch
tance, e. g. against acids, is required, machined gear mechanisms) and gear fits (quality classes) (see section
wheels made from the ultrahigh molecular weight poly 7.3).
ethylene Hostalen GUR are suitable. Hostalen GUR
is also notable for its high resistance to abrasive wear. In power gears, only involute teeth are used and so the
Gearwheels made from this material are therefore also following designs are restricted to these.
ideal for conditions in which abrasive particles (dust,
mud) are likely to get into the gear mesh.
 The following equations apply (see fig. 1):
3. Principal specifications
Pitch diameter d =
m z [mm] (1)
3.1 Straight-toothed spur wheel
Pitch circle pitch p =
m jt [mm] (2)
The principle specifications for
straight-toothed spur
wheels with involute teeth (fig. 1) according to the basic Tooth thickness s =
m ft = e [mm] (3)
tooth profiles in DIN 867 (fig. 2) and DIN 58 400
(fig. 3) are the module m plus associated dimensions and
the number of teeth t. Tooth space e [mm]

Fig. 1 : Tooth dimensions, pitch surface and tooth trace Base circle diameter db = d cos

spur wheel m z cos [mm] (4)

=
on a

left flank
Pressure angle n
right flank
pitch For module values up to m 1 mm the basic tooth pro
=

surface
file in DIN 58 400 (precision engineering) should be used
right and for m > 1 mm the basic tooth profile in DIN 867
tooth trace
(general mechanical engineering).

The basic toothprofile in DIN 58 400 has the following

advantages over the profile in DIN 867:
-
Greater engagement factor because common tooth
height hg 2.2 m whereas in the basic tooth profile
=

according to DIN 867 hg = 2 m (figs. 2 and 3).

Fig. profile for spur wheels with invol
2: Basic tooth
ute teeth for general mechanical engineering, DIN 867
-
Reduced risk of jamming from dust or abraded particles
getting into the tooth root because of the greater

backlash of SK = 0.4 m where m 0.1 0.6 mm

= -
as
*| * mating profile with the basic tooth
opposed to SK = 0.25 m profile
in DIN 867.

With a few
exceptions, it is usually possible to exchange
a pair of gearwheels with teeth as specified in DIN 867
effective
for a pair with teeth as in DIN 58 400. Even individual
flank
gearwheels with different basic tooth profiles can be
paired together.
~2Q nnerendofthe
H
effective flank
flank angel 2 a In the English-speaking world, the diametrical pitch
(DP) quoted in inch"1 is used instead of the module.
For conversion to module the following formula applies:
Fig. profile for spur wheels with invol
3: Basic tooth
ute teeth for precision engineering, DIN 58 400

m =_[inch] (5)

mating profile DP [inch- H =

profile
reference line
Example:

effective DP = 10 inch-'
flank

inner end of the

m =

-jL inch
effective flank 25.4
10
"flank angel 2d
= 2.5 mm
Table 1 : Comparison of different basic tooth profiles

BS 978, Part 1
DIN 867 DIN 58 400 AGMA 20 706

Fig.l Fig. 2

1 1 1 1 1 1
Tooth thickness s
2
n m =

2
p
F
y*-m
=

yP T^m={p 1.4136m
y*-m
=

yP
1 1 1 1 1 1 1 1
Tooth space e = n m =
p =
-p 1.728 m -X-m =
-p
Y*-m yP 2 2V yr-m
2.6 m for
m<0.6
Tooth height h 2.25m 2.4m 3.4m 2.2 m + 0.0508
2.45 m for
m>0.6

Addendum ha 1 m l.lm 1 m 1 m 1 m

1.5 m for
m<0.6
Dedendum hf 1.25m 1.4m 1.4m 1.2 m + 0.0508
1.35 m for
m>0.6

0.4 m for
m<0.6
Backlash SK 0.25m 0.4m 0.4m 0.2 m + 0.0508
0.25 m for
m>0.6

Table 1 compares the basic tooth profiles specified in

Fig. 4: Effect of pressure angle on tooth shape
DIN 867 and DIN 58 400, British Standard BS 978 and
the American Gear Manufacturers' Association standard
20706.

With regard to tooth stress, the tooth width b is impor

ftftfb
tant. Root stress af and flank stress OH are inversely pro

portionate for a given tangential force Ft on the pitch

circle of tooth width b, i. e. a ; (see section 5).
b

The pressure angle is established as 20 for involute

teeth (DIN 867 and others). Exceptions to this rule are

sometimes necessary, for example in order to reduce the

critical tooth number. The effects of pressure angle on
tooth shape are shown in fig. 4.

With increasing pressure angle, the tooth becomes more Fig. 5: Production of helical teeth with oblique normal
pointed but at the same time has a higher load-bearing profile
capacity. Sliding conditions are improved. normal profile
^=20

tool v -iV-
3.2 Helical spur wheel

For helical spur wheels, the equations quoted in section

direction
3.1 apply. One additional dimension is the helix angle ß of rotation
in the pitch circle (fig. 5).

The helical teeth are produced by angling the normal

generating profile
M
FsÜSm: h- Pt 1
profile (normal module m). In transverse section
(see fig. 5), this gives a tooth profile with straight flanks
6: Addendum modification, principal dimensions
Fig.
but increased transverse pitch pt

path of contact A E
m
=
mt-a it (6) tool profile
Pt:
cos ß cos ß

so that the flanks of the helical spur wheel in transverse

section are involutes (fig. 5).

For the pitch diameter, the following applies:

m
d =
z [mm] (7)
cos ß

The pressure angle at is calculated by the equation

tan Fig. 7: Effect of addendum modification on tooth

tan t =
(8)
cos ß shape

As a result of the helical

toothing, tooth engagement no
longer begins and ends
simultaneously over the whole
tooth width as with straight-tooth gears but is spread
over a finite angle of rotation. In this way, gear engage

ment jolts are moderated and noise is reduced. The total

contactratio er, i. e. how many teeth are on average

engaged at the same time, is found from a positive addendum
modification

er = ea + % (9)

where ea =
transverse contact ratio = ratio of the
path of contact to the base pitch, fig. 6

i
b tan 8
CL
Bß =
overlap ratio, Sß =
(10)
Pt

b normal teeth

3.3 Addendum modification

The addendum modification is characterized by the

dimensionless addendum modification coefficient x

related to the module. The distance of the

profile centre

line MM (fig. 6) of the basic rack tooth profile from the

rack pitch line of engagement WW is x m.

Addendum modification is carried out to c negative addendum

modification

adapt a pair of gearwheels specified centre distance

to a

-
balance the stresses between pinion and gearwheel
-
avoid weakening the tooth root by an undercut
(fig. 7 d) when there is a small number of teeth.

The addendum modification coefficient is positive when

the addendum modification increases tooth thickness.

d undercut
With addendum modification,
increasing 4. Materials and material
-
the outside diameter of the gearwheel da increases combination
-
the flank curve is smaller and
-
the tooth tip is more pointed (fig. 7).
4.1 Materials

3.4 Internal toothing Table 2 gives a survey of the plastics in the Hoechst

range which can be used for gearwheels.

The internally toothed wheel corresponds to a negative
spur wheel. Hence helical toothing and addendum modi Depending on the gear requirements and operating con
fication are possible. ditions, the most desirable material properties may be

The formulae for geometry of spur

calculating the -

rigidity for high tangential force and low peripheral

wheels remains valid if the number of teeth t and the speed
diameter of the internally toothed wheel derived from -

toughness for jolt-stressed gears, e. g. reciprocating

this are as minus quantities and the addendum
inserted motion
modification coefficient when increasing tooth thickness -

wear resistance for dry running.

is definied as a plus (fig. 8).
Frequently silent gear operation is an additional priority.
Fig. 8: Involute internal teeth

4.2 Material combinations

The teeth of a gearwheels slide against each other

pair of
during engagement. The sliding speed created is not
constant. It has a maximum value at the beginning of

engagement, drops to 0 at the pitch point and then

increases again to the end of engagement. The sliding
speed vg, which averaged over tooth engagement is
about 0.2 times peripheral speed v, causes friction
between the tooth flanks.

vg
=* 0.2 v [m/s] (11)

d- it n
v =
(12)
Through the use of internal toothing, it is possible to 60

design planetary gears in which power transmission is where d [m]

spread over several planet wheels so that the relatively
low strength and rigidity of plastics as compared with
metals can be partially offset.
Spur gears withplastic gearwheels generally receive a
once-only lubrication during assembly or, if this is not
possible, run dry. Both in the case of solid/solid friction
between dry-running gearwheels and the mixed friction
to be expected with once-only lubrication, the combina

tion of materials used has an important effect on the

amount of friction and on wear.

It is therefore important to aim for material combina

tions which

-
ensure low friction and smooth, even sliding
-
show the leastpossible wear
-
have high thermal conductivity to remove frictional
heat quickly.
Table 2 : Survey of the Hoechst engineering plastics used for gearwheels

Material Elastic Dimensional Coefficient Notes on special

modulus stability of linear material properties
DIN 53 457 under heat expansion
DIN 53 461 between
(method A) 20 and 100 C
DIN 53 752
N/mm2 C K-i

Hostaform C 9021 2950 104 1.1 -10-4 standard grade

Hostaform C 2521 2750 101 1.1 -10- withstands jolt stress basic grades
Hostaform T 1020 2700 97 i.i-io-4 void-free parts corresponding
Hostaform C 27021 3000 107 1.1 -10-" increased rigidity, to required
Hostaform C 13021
Hostaform C 13031
3000
3200
106
113
1.1 -10-4
1.1 -10-4
} small gear
dimensions
melt flowability

Hostaform C 902 IK 2950 99 i.i-io-4 reduced abrasion even in dry

Hostaform C 9021 TF 2400 98 1.1-10-* running low friction coefficient

Hostaform S 9063 2100 89 1.5-10-0 I impact modified grades,

Hostaform S 9064 1700 83 1.6 -10- 1 low noise,
Hostaform S 27063 2200 91 1.5- 10-" [ reduced abrasion,
Hostaform S 27064 1800 87 1.6-10-4 > jolt stressed gearwheels

Celanex 2500 2600 60 1.3 -10-" good sliding partner for Hostaform

Hostalen GUR 850 47 2.0 10-4 low abrasion, chemical resistance

Rapid removal of frictional heat is achieved if Hostaform While for high-speedplastic should generally be
gears,
or Celanex ispaired with steel gearwheels. The steel paired with steel other
plastics, in watches, meters and
or

wheels should be hardened; the roughness height Rz of time switches, gearwheel pairs made from the same plas
the tooth flanks should not exceed 2 //m, to minimize tic are frequently encountered although their tribological
wear on theplastic gearwheel. Wear can be further redu properties are poorer.
ced with plastic/steel gearwheel combinations if the
modified grades Hostaform C 9021 K and C 9021 TF Surprisingly, wear properties are improved by the
with improved sliding properties are used instead of the impact modification in the Hostaform S grades. This
standard grades. If the gear only has to transmit low applies both to the combination of impact modified
power inputs or if the total operating period is relatively grades with each other and their combination with basic
short, gearwheels made from unhardened steel or non- grades.
ferrous metals (brass, aluminium alloys) can be paired
with plastic gearwheels. 9 shows tooth flank of the
Fig. wear following unlubri-
cated gearwheel combinations (module 2 mm) :
Hostaform/Celanex and Hostaform/polyamide combi 50/z2 54 and z, 40/z2 50 after 107 load
Zj = = = =
cycles
nations exhibit good sliding properties under conditions for different material combinations. Compared with the
of solid/solid or mixed friction. Incomparison with combination Hostaform C 9021 /Hostaform C 9021,
plastic/steel combinations they give rise to lower friction wear of the combination Hostaform S 9063/Hostaform

coefficients and reduced wear. Their tendency to stick- S 9063 and Hostaform S 9064/Hostaform S 9064 is
slip is also much reduced. On the other hand, the risk negligibly small.
of overheating (melting of tooth flanks) is greater.
Tooth flank wear of the combinations Hostaform
C 9021/Hostaform S 9063 and Hostaform C 90217
Hostaform S 9064 while slightly higher than in the above
combinations is still significantly lower than in the com-
bination Hostaform C 9021/Hostaform C 9021. In the
Fig. 9: Effect of impact modification on tooth flank
combinations Hostaform C 9021/Hostaform S 9063 and
wear in Hostaform/Hostaform combination
Hostaform C 9021/Hostaform S 9064 wear took place
in each case only on the gearwheel made from impact U.JU

At wear wheel 1: 0.55 mm; wheel 2: 0.37 mm

modified Hostaform. mrn 7

In the combination of the impact modified grades with

0.25
tj wear wheel 1 : 0.53

0H
=2mm;N
mm;

19 N/mm2;
wheel 2: 0.43

= 107
v 10 m/s
mm

steel, only reduction in is evident dry-runni ig operation

a slight wear as com
| 0.20

pared with the combination of basic grades with steel. g ul

-$
*">
0 O O 0
0 0 g § g
0.15
un Tfr H ^t ^ : T*"
-^
"0 ^ O TO -* o
U"} tT! 1/1 Lf> Lfi lA in
u-> iTi
Fig. 10 shows the average equilibrium temperature of II || ^ II II IÏ H II I II
o - - -

the tooth flank in the combination Zj =

50/z2 = 54 with Om
i\j
o^
c/5 "^J <*ï fi
§
.

<^ <N s s s rSi § 3

*
different of materials. The lowest temperature
pairings o
a--
O
O-> sÖ 47*1 ^ & o^ § S !>

U U ^ ^ ^ 5Ç ^ U U U
occurs in the combination Hostaform C 9021 /steel 0.05 **, .
g^-^. _^--_ *1 ~
rf- *$- f^ r^
v> s3
rTj <N
. M

1 O O
^D
O
O O sD \D
00 O O
owing to the good thermal conduction of the steel O
^
O
O"-
I
j
^
C/ï
O>
</)
CN
c/5
o^
c/i
o
en
ov
v)
^

*o
U U 1 ii
gearwheel. The slightly higher temperatures in the com 0 r~i i i 1 |

binations Hostaform S 9063/steel and Hostaform

S 9064/steel indicate the increased friction coefficient
of the impact modified grades when sliding against steel. Fig. 10: Average equilibrium temperature of the tooth
flanks in Hostaform/steel and Hostaform/Hostaform
The combinations Hostaform C 9021/Hostaform S 9063 combinations (<JH flank stress, see section 5.1.4)
and Hostaform C 9021/Hostaform S 9064 (Nos. 4 and 5)
behave in a similar way, reaching a higher equilibrium
temperature than the combinations Hostaform S 9063/ 100-
10
Hostaform S 9063 and Hostaform S 9064/Hostaform c
OH = 30 N/mm2
S 9064.
11
90-

4.3 Lubrication
1
s 8-

i
Spur gears with
plastic gearwheels are only rarely
OH = 19 N/turn^
provided with splash lubrication because the cost of
sealing the gear housing is high. The normal procedure I -

is to give the gears a once-only grease lubrication during 4

5*
assembly. Although the grease is forced out of the tooth H 60- > OH = 25 N/mm2
flanks during operation or is hurled out at high periphe
ral speeds, the reduction in wear as compared with dry-
50 7<
running gearwheels is considerable.
-

1 1 shows the percentage of the tooth thickness 19 N/mm2

Fig. wear
40 -
.
OH =

of a Hostaform gearwheel paired with

gearwheel a steel
under dry-running conditions and with initial once-only
lubrication. Under the chosen conditions, wear of the 30 -

lubricated gearwheel combination after 2 107 load is Wheel l:z, = 50

only one third of the value in dry-running operation. Wheel2:z2 = 54

m = 2 mm
20 -

b = 15 mm
3.08 6.7
The lubricants used are mineral-oil based greases
usually
with lithium soap regulate consistency (multi-purpose
to
10 15 N- m 20
greases). Through the use of special additions, adhesion
Torque Md
of the grease to the plastic gearwheel surface can be
improved. Hostaform and Celanex are resistant to mine Wheel 1 Wheel 2 Wheel 1 Wheel 2
ral-oil based greases at all temperatures. With Hostalen 1 S 9064 steel 7 S 9063 S 9063
2 S 9063 steel 8 S 9064 S 9064
GUR, reversible diffusion of oil into the surface is likely 3 C 9021 steel 9 C9021 C9021
S 9064 C9021 10 C9021 C9021
at operating temperatures above 65 C. Hardness and 4
5 S 9063 C9021 11 S 9064 S 9064
rigidity decline as a result. 6 S 9064 S 9064
 Fig. 11: Percentage decrease in tooth thickness due to 5. Design calculations for
in gearwheels made from Hostaform running
wear

against steelgearwheels straight-toothed ana helical

spur wheels

20 5.1 Straight-toothed spur wheels

A correctly designed pair of gearwheels made from

Hostaform, Celanex Hostalen GUR, once-only lubri
or

10
cated with oil or grease, will normally fail due to tooth
fracture when overloaded. Design calculations should
therefore be based on stress at the tooth root, section
e4ubncated^^'aSSembly 5.1.3. With dry-running gearwheels, on the other hand,
the wear on the intermeshing teeth is the predominant

0.5 1.0 1.5 2.0 -107

factor; there is also increased thermal stress owing to the
Number of load cycles greater friction. In this case, flank stress is the criterion
which should be calculated, section 5.1.4.

To meethigher requirements with regard to oxidation
resistance (ageing resistance), service temperature range
or physiological safety (e. g. food transport or packaging),
greases based on synthetic oils are used. Suitable oils
include alkoxyfluoro oils, polyglycol ether oils and sili-
cone oils. It has been observed that diester oils
Ifonly a rough design calculation is required for the
gearwheels, the distinction is not necessary. It is suffi
cient to check loadbearing capacity with the c value or to
use the c value to estimate the required dimensions of
the gearwheel for a specified power input (section 5.1.1).
cause

swelling of Celanex and increase wear in Hostaform/ The symbols chosen here correspond to DIN 3990
Celanex combinations. Methyl silicone oils have a "Calculating the loadbearing capacity of spur and bevel
softening effect in both Hostaform and Celanex while gears" and largely conform to those used in the VDI
phenylmethyl silicone oil has no effect. Guideline 2545 (VDI-Richtlinie 2545) "Gearwheels
made from thermoplastics".

5.1.1 Determination of loadbearing capacity using

load characteristic c

The load characteristic c takes account of several varia

bles. It is dependent on the combination of materials
used, loading conditions and tooth geometry. It is also
influenced by lubrication, temperature and peripheral
speed. There is no mathematical relationship between
these factors however. The load characteristic c is deter
mined experimentally and is
only valid for
gearwheel
pairs operating under similar conditions. In all other
cases, deviations are likely but experience has shown
them to be small.

The load characteristic c is defined as:

c =
T^-Seperm.
bk'P
[N/mrrf] (13)

10
 where w here

_Mi $!,2 tooth flank temperature of gearwheel 1 or gear

F, =
tangential force [N] (14) wheel 2 [C]

p = m n pitch [mm] (equation 2) $a temperature in the immediate operating environ

m module [mm] ment of the gear [C]

bk smallest tooth width [mm] /I dynamic friction coefficient of the mating materials
P power input [W]
M
P 1000 9549.3 P A surface area of the gear housing [m2]
^
^=-1^r =

-n [N-mm] (15)
bk smallest tooth width [mm]
30 m module [mm]
9.549 P
-

[N m] torque zli2 number of teeth (gearwheel 1 or 2)

n
i gear tooth ratio z2/zt
r pitch radius
[mm] v peripheral speed [m/s]
P power input [W] kz auxiliary value
n speed [min"'] k3 auxiliary value [K mVW]
K index
Fig. 1 2 shows permissible c values for the different
Hostaform grades as a function of the number of load The following empirical values should be used:
cycles.
k2 = 2.5 Hostaform/Hostaform (basic grades)
5.1.2 Tooth flank temperature Hostaform/Celanex
k2 = 7.0 Hostaform/Hostaform C 9021 K
The strength of thermoplastics is temperature-depen k3 = 0 oil-lubricated gear /open gear with free
dent. High tooth temperatures reduce the permissible air access

tooth root stress and influence tooth deformation. k3 = 0.04 partially open gear,
The permissible flank
depends among other factors
stress to 0.13 air cannot circulate freely
on tooth flank temperature. In gearwheels with periphe k3 = 0.17 closed gear
ral speeds exceeding 5 m/s, the tooth flank temperature x = 0.4 Hostaform (basic grades) and Celanex
is calculated as: x =0.75 Hostaform C 9021 K
(also applies to polyamide)
+63JE3l Hostaform/Hostaform
^^a+0.136.P^.AiM7100.k2 A J
H = 0.28
5 z2 + Lbk-Zij2-(v-m)* /J. = 0.20 Hostaform/steel
[C] (16) Celanex/steel dry running
B: It should be noted that in this numerical value , = 0.18 Hostaform polyamide
Hostaform/Celanex
equation (16), the values should be used in the units
^ = 0.05 above material combinations,
specified as follows:
to 0.01 lubricated

Fig. 12: Load characteristic cperm. for

gearwheels made from Hostaform
(material combination Hostaform/
Hostaform v = 12 m/s)

10' 107
Number of load cycles

11
With small gears, such as those used in precision engi The so-called application factor also quoted in DIN 3990
neered drives, the ambient temperature must be assumed. isgiven the value 1 like the other factors for which no

The additional frictional heat arising as a result usually empirical values for plastic gearwheels are yet available.
insignificant when the peripheral speed of the gearwheel
is less than 5 m/s. The tooth shape factor YF takes into account the effect
of tooth shape on force application on the tooth while
the load proportion factor Ye allows for the effect of the
5.13 Loadbearing capacity of the tooth root transverse contact ratio. YF and Ye for straight-toothed

spur wheels (pressure angle a 20) can be read off =

The basis for tooth design is the flexural likely to

stress figs. 13 and 14. Strictly speaking these factors apply to
be produced in the tooth root by the tangential force Ft. metal gearwheels but they are also suitable for use in
designing plastic gearwheels. In this case, however, they
The following applies for tooth root stress ignore the fact that the teeth of a plastic gearwheel
deform more severely under load and that bottom clear
ance and backlash change more when the gearwheel
YF-Y85erpp [N/mm'] (17)
U
'

JL11 becomes hot than with metal gearwheels. A more precise

where calculation of tooth shape factor YF, particularly for spe
cial profiles, can be carried out according to DIN 3990,
OFP permissible tooth root stress [N/mm2]
sheet 2. For internally toothed spur wheels, the tooth
(see equation 22)
Ft tangential force on the pitch circle [N] shape factor is calculated as
YF tooth shape factor, fig. 13;
according to DIN 3990, part 3 YF = 2.06 -
1.18 (2.25 -

h*) (19)

Yf =

"
load proportion factor, fig. 14; (18) h* tooth height factor, h* =

m
= ^-df-
2
according to DIN 3990, part 3 h tooth height
e transverse contact ratio da outside diameter df root circle diameter

Fig. 13: Tooth shape factor YF (x addendum Fig. 14: Load proportion factor Y8 for straight-toothed
modification factor) spur wheels (a 20, x 0, i Za/zJ
= = =

3.8 0.70

i=1.0

i=1.2\

0.65
i =
2.0\^
\\\\
1=3
A\ ^v
i S 0 \ \ ss
0.60
\ \N
S\N^
^
i 10.0\
I =

a.
VsYSN\\
\A\\\s^
\\ V ?$ k
0.55
s V SX ^s
\ ss ^ ^ \ "\

K \N S$§ ^ "^

Vs sS: ^
>
\^^^ "X "N "X "*

0.50
V , ','
15 20 25 30 40 50 400 16 20 30 40 50 70 100 200

Number of teeth z Number of teeth Zi

12
If the radius of the toothroot curve is greater than
Fig. 16: Operating pressure angle wt and tan wt
0.25 x module, the notch factor YS (according to DIN
3990 sheet 1) is given the value 1. With this proviso,
(^ u u./
^
equation (17) contains no notch factor. ^
O ^^
"s^
For teeth with addendum modification the wt U O ,<< ^ 0.6
transverse
a '/
contact ratio is / '/
angle /, '/
K> ^ 0.5

/, /
w. here
e = -~-

2 Jt
(tan EI -
tan aA1) (20) presure KJ O
// /
0.4
1
^

//
tan EI,
tan A,

tanAa
=

are
tan awt

auxiliary
( 1 + i) i

values used in
tan a A2 (21)

determining
Operating -* U>
Y 0.3

the transverse contact ratio.

*"* O 0.2
The function values for tan E1 and tan A2 are
shown 0 0.02 0.04 0.06 0.08 0.1

in fig. 15 in relation to an auxiliary factor D. (x, + x2)/(z, + z2)

With D, =
-~, tan E1 can be read off fig. 15 and
dbi
Fig. 17: Tooth root strength oFlim for gearwheels made
with D2 =
-~, the value for tan A2. from Hostaform C 9021, C 2521, C 13021, C 27021,
db2 C 9021 K and C 9021 TF

Fig. 15: Graph to assist calculation of transverse

contact ratio e

1.0

0.8

0.6

0.4 105 10* 107

Number of load cycles

0.2
For safety factor SF, the following empirical values apply:

[
1.0 1.10 1.20 1.30 1.40
SF = 1.1 -
1.2 for normal operating
SF = 1.3 -
1.4 for
frequent engagement and
Auxiliary factor D
disengagement

The operating pressure angel a w,

is plotted for straight- In special cases, even greater safety factors may be
toothed spur wheels in fig. 16. required.

The permissible tooth root stress <TFP is found from the The permissible tooth root stress <TFp should be multi
tooth root strength Opiim and the safety factor SF: plied by the factor 0.7 if the gearwheel engages with
several other gearwheels at the same time and tangential
OF lin
force changes direction during one rotation.
<TFP _
=
(22)
If a gear jams, the teeth break off when the tooth root

The tooth root strength of Hostaform is shown in fig. 17 exceeds (TF 65

stress -
70 N/mm2, e.g. in the case of
and of Celanex and Hostalen GUR in fig. 18. Hostaform C.

13
 The flank shape factor is ZH = 1.76 for straight- toothed
Fig. 18: Tooth root strength <7F!im for gearwheels made
from Celanex and Hostalen GUR spur wheels with a pressure angle a 20, without =

at room
addendum modification. For other pressure angles, the
temperature
following equation applies:

z -
l
COSft
1/Ï
'
(24)
tana
50 where
N/mm2
a normal pressure angle
wt operating pressure angle
\ Celanex

40
\ Fig. 19: Material factor ZM as a function of tooth
flank temperature &

55

I
I 30

20

Hostalen GUR

lubricated with
X water in oil emulsion

10
_,
dry-running
'also oil-lubricated)

1Q5 10* 107 10

Number of load cycles

5.1.4 Loadbearing capacity of the tooth flank

Dry-running or once-only lubricated gearwheels made

from plastic normally fail on overloading because of
excessive tooth flank wear. Sometimes pitting occurs.
In both cases flank stress 0H is critical.

For flank stress, the following equation applies

(according to DIN 3990 sheet 1): 20 40 60 80 100 120 C 160
Tooth flank temperature I?

0H =
1/b^d ^T1 ' '
Z '
ZM = HP [N/mm2] (23) With addendum modified teeth, flank shape factor ZH
where can be read off fig. 20.

OH flank stress
Fig. gives typical values for permissible flank stress
21
(Hertzian stress) [N/mm2]
ÖHP for Hostaform gearwheels at flank temperatures of
ÖHP permissible flank stress, fig. 21 [N/mm2]
& ^ 60C; fig. 22 does the same for Celanex.
Ft tangential force on the pitch circle [N]
bk smallest tooth width [mm]
d pitch diameter [mm]
5.1.5 Tooth deformation
i tooth number ratio z2/zt
ZH flank shape factor ^_^_
The noise of intermeshing gearwheels is increased by
ZM material factor, fig. 19 V N/mm2
tooth defects and load-induced deformation of the

14
engaged teeth, which produces the same effect as a tooth 20: Flank factor ZH for addendum modified
defect during operation. Tooth deformation must there
Fig. shape
teeth
fore be limited.
z.u

For displacement of the tooth tip in the circumferential v

\
1.9
direction (see fig. 23), the following equation applies:
1.8
\
3Ft N V
À
2 bk cos
Kt+t) [mm] (25)
I
1.7

1.6
\
s
where \
D,
1.5
X
F tangential force [N]
_C
<n X
M \
bk smallest tooth width [mm] 1.4 *-^. *

pressure angle on the pitch circle [ j

.

1.3 ,

^
auxiliary value, fig. 24
1.2
i auxiliary values, fig. 25
F dynamic elastic moduli [N/mm2] 1.1
-0.01 0 0.02 0.04 0.06 0.08 0.1
of the gearwheel materials used, fig. 26
(x, + x2)/(zi + z2)
(DIN 53 445)

Fig. 21 : Typical values for permissible

flank stress oHp in Hostaform
gearwheels, without lubrication,
peripheral speed v =12 m/s, flank
temperature $ ïs 60 C

Number of load cycles

Fig. Typical values for permissible

22:
flank 0Hp in Celanex gearwheels,
stress

peripheral speed v 10 m/s =

a Celanex 2500/steel,
dry-running
b Celanex 2500/Hostaform
C 9021, dry-running
c Celanex 2300 GV 1/20/
Hostaform C 2521, dry-running
d Celanex 2300 GV 1/20/
Hostaform C 2521, once-only
Number of load cycles grease lubricated during assembly

Displacement tip under load is the criterion

of the tooth If this value is exceeded, operating noise increases sharply.
for tooth deformation. The permissible limit of this dis
placement depends on the quiet-running and service life 5.2 Helical spur wheels

requirements which the gear has to meet. Experience has

shown that the maximum permissible displacement is: Plastic gearwheels normally designed with helical
are

teeth when the aim is to reduce operating noise. Unlike

with metal gearwheels, the increase in tooth root load-

Vm,~o.i mn [mm] (26)
bearing capacity obtained through the use of helical teeth

15
and represented by the factor Y^ (DIN 3990) is not On the other hand it is important to remember that the

absolutely guaranteed in the case of plastic gearwheels. relative movement between the tooth flanks and hence -

It is therefore advisable to calculate the loadbearing 1

the expected wear -
is greater by a factor of than
capacity of the tooth root as for straight-toothed spur cos ß
wheels. with straight-toothed
spur wheels. Tooth flank load
limits have far been determined for helical spur
not so
The same applies to determination of flank stress. wheels. The values for straight-toothed spur wheels are
The increased overlap is taken into account by the factor therefore used as an approximate basis for calculation.
ZE so that the following equation applies for flank
stress <TH: Fig. 25: Factor ip for calculating tooth deformation

H
I/
/ T
Ft
T
'
i+1
~~î
7
^-H '
7
*4t
'
7
A; [N/mm*] (27)
V bk-d i

where

2 =
]/f^
' 6s
(28) 2

The overlap eas of the helical teeth can be approximately <

determined by the equation

8ßs 8 COS' ß (29) 14 25 30 40 50 100

Number of teeth ï\ j
(ea see section 5.1.3)

Fig. 23: Tooth deformation values At and A2 Fig.26: Temperature curve of the dynamic elastic
modulus E' for Hostaform C 9021, Celanex 2500 and
driven Hostalen GUR, calculated from shear moduli
" measured in accordance with DIN 53 445 (ISO 537)
i ^V
wheel 2 (frequency about 10 Hz)

4000
Hostaform C 9021

N/mm2

3000

w
Celanex 2500

Fig. 24: Factor y for calculating tooth deformation

J3

1 "T-T
,
Hostalen GUR
'S
ä
1 2000

V
\
b>
\ S
§
1000

Calculation example^
section 6.
5.8
14 16 18 20 25 30 40 50 100
-20 20 40 60 80 C 100
Number of teeth zt
Temperature

16
5.3 Flow chart for designing spur gears using load 5.4 Flow chart for designing spur gears using tooth
characteristic c root strength

Given:

Power input P [W] or torque Md [N m] Power input P [W] or torque Md [N m]

Speeds n,, n: [min"1] Speeds ni,n2 [min"1]
Operating time t pi] Operating time t [h]

Selected: Selected:

Pitch diameters dt, d2 [mm] Pitch diameters d,, d2 [mm]

Module m [mm] Module m [mm]
Tooth width b [mm] Tooth width b [mm]

Calculate tangential force Ft Calculate tangential force Ft as in flow

chart 5.3
9 %49 .
P . 10
I*-"
F''-^
f
_ _
' *
__ _
1-K.Ti

j-jsjj
1 -f
where d
r
[mrnj
l

I
Estimate tooth flank temperature $ according
to section 5.1.2
^ =
2-10'^- [N]

Calculate tooth root stress or

Determine c value

0p =
FL_ Yf Y,
.
[N/nun]
b -m
FI
c= , [N/mm*]
bk r *
m
tooth shape factor YF from fig. 13

load proportion factor Yf from fig. 14

Calculate load cycle number N

N = 60 n t
Determine load cycle number

N = 60 n t

Compare calculated c value with

Cpfrm=f(N)seefig.l2
Compare calculated tooth root stress Of with

<Tn,m =
f(N)

Check factor S ^Ü*

safety =

17
5.5 Flow chart for designing spur gears using tooth 5.6 Checking tooth deformation
flank stress

Given: Given

Power P Tangential force Ft [N]

input [W] or torque Md [N m]
Tooth width bk [mm]
Speeds nl5 n2 [min~1]
Operating time t [h]

Selected:

Pitch diameter dl5 d2 [mm]

Calculate displacement A of the tooth tip
Module m [mm] 3Ft
Tooth width b
A =

2 bk cos
"(§+*)
t \LI L2/
[mm]
[mm]
t= for straight teeth,
otherwise according to equation (8)
Calculate tangential force Ft as in flow
<p from fig. 24
chart 5.3
ty from fig. 25

F from fig. 26
Estimate tooth flank temperature & according
to section 5.1.2

Check whether X < 0.1 mn

Calculate tooth flank stress 0H

H =

l/Vd'1!1 "
ZH ZM (Ze) [N/mm2J
' '

ZH =
1.76, for wheels without addendum
modification

ZH from fig. 20 for addendum modified wheels

ZM from fig. 19

Z6 according to equation (28) for helical spur wheels

Determine load cycle number

N = 60 n t

Compare calculated tooth flank stress <TH with

<JHP =
f(N)

Check safety factor S =

OH

18
6. Calculation example Ft =
^k[N]
2 351 N mm
The last gear step m a domestic appliance drive is to be =

37.5 mm
produced with two gearwheels made from Hostaform
C 2521. Straight-toothed gearwheels are envisaged (basic = 18.72 N
tooth profile according to DIN 867, no addendum modi 18.72 N
c =

fication). A service life of 107 load cycles is required at 12 mm 3.93 mm

a maximum service temperature of about 30C. The

= 0.397 N/mm2 < cperm.
gearwheels will not be lubricated.

Given: The permissible load characteristic, read off fig. 12,

IS
Cperm. = 1.7 N/mm2.
Power input P =5W

Speed, wheel 1 ni = 136 min"1 b) As explained in section 5.1.2, it is not necessary to

Wheel 1 zi = 30 calculate the tooth flank temperature for small gear
Wheel 2 z2 = 105 wheels provided their peripheral speed is less than
5 m/s. In the present example, the peripheral speed
Gear ratio i =1 = 3.5
Zl is 0.267 m/s. It can therefore be assumed that the
Helix angle ß =0 tooth flank temperature corresponds to ambient
Module m = 1.25 mm
temperature.
Pitch diameter, wheel 1 Zi m =
di = 37.5 mm

Pitch
c) The tooth root stress OF is calculated according to
m n =
pt =
3,93 mm

Tooth width b
equation (17).
= 12 mm

TrqUe
according to equation (15) M<j
9549 3 P <TF =
-j-^ YF Y6 <
ÖFP [N/mm2]
= - -

[N mm] b m
Hi

9549.3 5 Tooth shape factor YF from fig. 13:

136
= 351 N mm YF=2.65

The peripheral speed v is calculated as Load proportion factor Y from fig. 14:

d, n n. Y = 0.567
V =

T [m/s] with dj in mm
1000 30
So equation (17) gives:
= 5.236 d, n, 10~5

= 5.236 37.5 136 lO"5

18. 72 N
af = 2.65 0.56
= 0.267 m/s 12 mm 1.25 mm

= 1.875 N/mm2 <qF|im

Questions:

a) Does the load characteristic c fall within the The tooth root strength for gearwheels made from

permissible range? Hostaform C 2521 is taken from fig. 17:

b) What is the calculated temperature of the tooth

flank in operation? <7Flim = 38N/mm2

c) What is the tooth root stress (TF?

d) What is the flank stress OH and the safety factor SH? Thus the tooth root stress occurring in operation is far

e) Does tooth deformation exceed the permissible below the maximum permissible stress.
limit?
d) For flank stress OH, equation (23) is used:

a) For load characteristic c according to equation (13)

c=-^-2cperm. [N/mm2]
OH =
l/b^- '

^Y~ '
ZH ZM '
^ (THP [N/mm2]

z2 105 , c
where i = = = 3.5
Zi 30

19
 ZH = 1.76 (see page 14)
l/ from
7. Design notes
ZM = 33 N/mm2 fig. 19

7.1 Selection of module

Thus we obtain for flank stress:

The tooth root stress <JF is inversely proportionate to the

18.72 N 3.5 + 1 N
OH
-Ite mm 37.5 mm 3.5
1.76 -33
mm2
module m

=
-^ 33^ OF'
J_
m
(30)

= 13.42 N/mm2<(THP
It therefore follows that with a larger module, a higher
The
tangential force Ft and hence a greater torque Md can
permissible flank stress oHp is taken from fig. 21
be transmitted. For given gearwheel
a diameter d, the
module is limited by the smallest
possible tooth number
OHP = 19 N/mm2
^smallest"

This gives a flank safety factor

mm*. = (31)
^smallest
c
HF
SH=
<7H
A large module also means a large tooth height, which is
19 N/mm2
_

~
an advantage with regard to permissible centre distance
13.42 N/mm2 tolerance (also affected by temperature changes). For
= 1.42 centre distance tolerance see section 7.3.

For tooth With regard to tooth flank

wear, it is important to aim
e) deformation, equation (25) applies
for the smallest possible module because with a smaller
3Ft module, frictional energy drops. Frictional energy is
A =

2-b-cos
*(^ + |f) ' [mm] defined as the product of flank stress <JH and average
\F, E'2y
cos 20 0.9397
sliding speed vg. Lower flank stress results from the
cos = =

smaller curvature, lower sliding speed from the smaller

y (from fig. 24) = 6.8 tooth height.

Vi (from fig. 25) = 1.0

% (from fig. 25) = 1.0 7.2 Complementary profile

E', =
E'2 (from fig. 26) = 2980 N/mm2
In combination of a metal gearwheel with a plastic
Thus
wheel, the transmittable tangential force Ft can be
we obtain for tooth deformation:
increased by the use of complementary profiles (fig. 27).
In this case, the tooth thickness of the plastic gearwheel
3 18.72 N /2mm2
A =
_
'
6 8 '

2 12 mm 0.9397 \2980N ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^M

Fig. 27: Complementary profile

= 0.0114 mm.

Aperm. = 0-1 '

mn [mm] according to equation (26)

Aperm. = 0-1 '
1-25 mm

= 0.125 mm

The tooth deformation occurring is thus only just a tenth

of Aperm. so no increased operating noise is likely.

20
can be increased at the expense of the tooth thickness of to the nominal dimension for tooth thickness (nominal
the metal wheel. The ratio of tooth thickness s to tooth dimension = tooth thickness = tooth space) without

space e can be up to 2 : 1. impairing the quality of the gearwheel. The position of

the tooth thickness tolerance range is indicated by small
letters from h to a. The letter h denotes a theoretically
73 Backlash backlash-free gear engagement (upper limit of the range
h corresponds to the nominal dimension for tooth thick
The tooth design calculations are based on teeth free ness). A g tolerance range means lower circiumferential
from defects of dimensional variations. To compensate backlash etc. right down to the letter a which allows the
for unavoidable manufacturing error and heating up, greatest clearance.
deformation etc. gearwheels must
during operation, the
be designed with a certain backlash (flank clearance). Fig. 29: System of gear fits
Of the three different possibilities for providing backlash,
DIN standards 3961-3967 and 58405 specify reduction
Tolerance ranges for centre distance T
of tooth thickness. A distinction should be made between
line of action backlash je -
the distance measured along
the line of action between the flanks of the gearwheel
0--J
and mating wheel (easy to measure with a metal sheet
gauge) and circumferential backlash jv
- -
measured on

the pitch circle (fig. 28).

Tolerance ranges
for tooth thicknesses Ts
LLS
1 H*
Fig. 28: Line of action backlash je and circumferential and tooth widths Tw c
^
bl 1 tN
backlash j

AÜO
T,
Aau
-

13 without taking into account

the radial eccentricity of the
shafts, bearing clearance
A wo and shaft parallelity
Tw
AWU~~
-'

I .1

Table 3 gives recommendations for the assignment of

tolerance ranges which have proved successful for injec
tion moulded plastic gearwheels.

By reducing the tooth thickness determined for the

theoretical centre distance ao, the wheels operate in a

The amount of backlash is determined by housing smaller centre distance a' free from backlash.
tolerance, manufacturing accuracy (dimensional devia
tions should not eleminate the backlash) and peripheral The difference Aa. =
ao a' is defined as centre distance
speed (thermal expansion). clearance.

According to the system of standard centre distance, If relatively high operating temperatures are expected,
the theoretical nominal centre distance (zero centre this centre distance clearance must be increased by the
distance given tolerances according to either the
ao) is factor Ac by which it is reduced owing to thermal expan
J or K ranges (K range 2 J range) to form 12 different
= sion.

quality classes. Quality class 1 specifies the closest and

quality class 12 the widest tolerances. The circumferential For Ac the following equation applies
backlash is also assigned 12 different tooth thickness
tolerances ranges quality classes (h to a) according to
= Ac =
A#(Tt'ßl+r2-ß2) [mm] (32)
the module and pitch diameter of the gearwheel and
ßi.z coefficient of linear thermal expansion
these classes are linked to centre distance quality classes
(table 2) [Kr1]
(fig. 29). To achieve different backlashes within one
fj.2 pitch circle radii [mm]
quality class, the position of the tooth thickness tolerance
can be shifted in the minus direction with respect
A$ temperature difference K]
ranges

21
Table 3 : Tolerance range combinations for injection moulded teeth

Type of gear Special features Tolerances in accordance with DIN 58 405, sheet 2

gearwheels centre distance"""")

High speed gear highly stressed 1.5 Tw::") 9J

ranges
e.g. 9 ed

lightly stressed 1.5 Tw*) 10J

ranges
e.g. 10 ed

Drive assembly circumferential 1.5 Tw:|-) 9J

backlash small ranges
e.g. 9 ed

circumferential 2.0 Tw 10J

backlash large ranges
e.g. 10 fed

*) Tool correction usually necessary

**) Tool correction may be necessary depending on the way in which the gear is mounted in the housing

For the temperature-dependent change in backlash, A resilient design is achieved by e. g. thin, long teeth
the following applies: (fig. 30) or by incorporating radial slits in the carrier disc
(fig. 31).
Aje = 2 Ac sin [mm] (33)
Another possibility is to connect the gearwheel rim to
Example: the hub by spring elements (fig. 32) so that throught
deformation of these elements, backlash-free and hence
The temperature of a pair of gearwheels made from
silent operation can be achieved.
Hostaform (centre distance a 80 mm) increases during
=

operation by about 60 K.
According to equations 32 and The impact modification of the plastics renders the mate
33 a reduction in backlash during operation of about
rial softer and more resilient. The impact jolts are thus
0.36 mm can be expected (coefficient of thermal expan
less hard and operating noise is reduced.
sion for Hostaform ßL2 1,1 10~4). The specified back
=

lash should therefore be increased by this amount.

The operating noise attributable to friction can be
reduced with suitable lubricants.
To prevent notch effect at the tooth root, the radius of
the tooth root fillet should be at least 0.25 module.
Fig. 30: Reduction of operating noise by thin, long
teeth

7.4 Reduction of operating noise

In addition to friction between the

sliding tooth flanks,
impact jolts as the gearwheels engage make
a significant

contribution to operating noise. Impact jolts can be

softened by using helical teeth, as already mentioned,
and by

tip relief
-
resilient design of the gearwheels
-
more flexible materials
-
modified tooth shape.

22
Fig. 31: Reduction of operating noise by radial slits
in the carrier disc

radial slit

Fig. 32: Reduction of operating noise by flexible

connection of the gearwheel rim and hub

23
8. Examples of applications

8.1 Pump drive for aquapick Tooth data:

To produce water pressure up to about 10 bar, a pump Module m = 0.5 mm

is actuated via gearwheel made from Hostaform

a
Metal pinion z, = 12
C 9021 with integral eccentric. The drive wheel is a
metal pinion. This gearwheel combination, highly n, up to 9000 min"1
stressed on one side by the eccentric, is given an initial
Hostaform wheel z2 = 104 (special teeth)
once-only lubrication with silicone grease and operates
reliably in thousands of units. da2 = 52.5 mm

b = 4 mm

n2 = 500 to 1040 min-1

Gear ratio 1 = ^=8.67

Zl

24
8.2 Planetary gear for disc motor Tooth data for the two indentical steps:

The photo shows

two-step planetary gear with gear
a Module m = 1 mm

wheels made from Hostaform C 9021 and C 2521 for the

Sun wheel z = 46
drive of golf trolley. The 12 volt disc motor and gear
a

are incorporated directly into the trolley wheels pro b = 11 mm

viding a compact, spacesaving design. wheels

3 planet z = 42

b = 8.5 mm

Internal gear 2 = -120

b = 35 mm

Material for all the gearwheels: Hostaform C 9021

Gear ratio itot. = 1 : 80
Material for internally toothed sun wheel: Hostaform
C2521 P = 42 W

25
8.3 Manually operated drive for window verticals Tooth data:

The window verticals are brought into the required posi Module m = 0.7 mm

tion manually with the aid of a ball chain. The ball chain
Chainwheel with
passes over an internally toothed wheel which transmits
internal teeth z= -66
the rotary motion via three double gearwheels to a sun
da= -64
wheel mounted in the housing. Hostaform C 9021 is
b = 10 mm
used as the gearwheel material.
Planet wheels
(double gearwheels) ï = 12/18
b = 5/3 mm

Sun wheel z = 36
b = 5 mm

Gear ratio i = 1.83

26
8.4 Food processor attachment with gearwheels Tooth data:
made from Hostaform and Celanex
Module m = 1 mm

This attachment is used for whipping cream. For this Drive wheel z = 10
purpose it is necessary to reduce the speed of the pro
cessor from nj 1800 min^1 via
=
an intermediate gear b = 6 mm

wheel to n2 = 900 min"1. This intermediate gearwheel Intermediate wheel z = 40

made from abrasion resistant Hostaform C 9021 K drives
the mixing bowl via a second gearwheel which turns at b = 4.8 mm

n3 = 200 min"1. The drive and driven wheels made from

Driven wheel z =20
Celanex 2500 slide in the housing made from Hostaform
C 9021, a material combination with low coefficient of b = 7 mm

friction and
extremely low wear. Sliding properties are
Power input P =50 W
furtherimproved by once-only lubrication during
assembly.

27
9. Explanation of symbols

Symbol Unit Explanation Symbol Unit Explanation

a mm centre distance <

o
normal pressure angle
a0 mm zero centre distance <i
o
transverse angle
pressure
A m2 surface area of the gear housing <wt
0
operating pressure angle
b mm tooth width ß K"1 coefficient of linear expansion
bk mm smallest tooth width <ß o
helix angle
c N/mm2 load characteristic e transverse contact ratio
d mm (m) pitch diameter Bß overlap ratio
da mm outside diameter total contact ratio with
S,
db mm base circle diameter helical teeth
D auxiliary factor (fig. 15) Sas engagement factor with
helical teeth
DP inch"1 diametral pitch (DP =
)
& c tooth flank temperature
e mm tooth space #. c temperature in the operating
E' N/mm2 dynamic elastic modulus environment of the gear
Ft N tangential force on the pitch circle K exponent (equation 16)
h mm tooth height A mm deformation of the tooth tip
h:;- tooth height factor P dynamic friction coefficient
ha mm addendum OTp N/mm2 tooth root stress

hf mm dedendum ÖFHm. N/mm2 tooth strength

root

i
Z2 n. OFF N/mm2 permissible tooth root stress
gear ratio i = =

Zj n2 OH N/mm2 flank stress

line of backlash
)e mm action
0HP N/mm2 permissible flank stress
iv mm circumferential backlash auxiliary factor (equation 25)
<P
k auxiliary value (equation 16) V auxiliary factor (equation 25)
m mm module (normal module)
Md N mm torque Indices
n mm"1 speed
N load cycle number
t in transverse section
P mm pitch
P
(except Ft)
W power input 1 relating to gearwheel 1
r mm pitch radius 2 relating to gearwheel 2
Rz fj.m roughness height
s mm tooth thickness
SF safety factor
SK bottom clearance
t h operating time

v m/s peripheral speed

vg m/s average sliding speed
X addendum modification
\ load proportion factor
(equation 17)
YF tooth shape factor
(equation 17)
Ys notch factor
z number of teeth
ze overlap factor (equation 27)
ZH flank shape factor
(equation 23)
ZM V N/mm2 material factor (equation 23)

28
10. Literature

[1] G. Niemann, H. Winter:

Maschinenelemente, vol II, Springer-Verlag
Berlin/Heidelberg/New York/Tokyo, 1985

[2] VDI 2545

Zahnräder aus thermoplastischen Kunststoffen

[3] DIN 3960

Begriffe und Bestimmungsgrößen für Stirnräder und

Stirnradpaare mit Evolventenverzahnung

[4] DIN 58 405

Stirnradgetriebe der Feinwerktechnik

[5] DIN 58 400

Bezugsprofil für Stirnräder mit Evolventenver
zahnung für die Feinwerktechnik

[6] DIN 867

Bezugsprofil für Stirnräder mit Evolventenver
zahnung für den allg. Maschinenbau

[7] DIN 3964

Achsabstandsabmaße und Achslagetoleranzen von
Gehäusen für Stirnradgetriebe

[8] DIN 3967

Getriebe-Paßsystem, Flankenspiel, Zahndicken
abmaße und Zahndickentoleranzen, Grundlagen,
Berechnung der Zahndickenabmaße, Umrechnung
der Abmaße für die verschiedenen Meßverfahren

[9] H. Hachmann, E. Strickle:

Polyamide als Zahnradwerkstoffe
Konstruktion 18 (1966) 3

29
 In this technical information brochure, Hoechst aims
Technical plastics to provide useful information for designers who want
Design Calculations Applications to exploit the properties of technical plastics such as

Hostaform. In addition, our staff will be glad to advise

Publications so far in this series: you on materials, design and processing.

A. Technical plastics This information is based on our present state of knowl

A. 1.1 Grades and properties -
Hostaform edge and is intended to provide general notes on our

A. 1.2 Grades and properties -

Hostacom products and their uses. It should not therefore be con

A. 1.4 Grades and properties -

Hostalen GUR strued as guaranteeing specific properties of the products

A. 1.5 Grades and properties -

Celanex, described or their suitability for a particular application.

Vandar, Impet Any existing industrial property rights must be observed.
A.2.1 Calculations principles The quality of our products is guaranteed under our
A. 2. 2 Hostaform -
Characteristic values and General Conditions of Sale.
calculation examples
A. 2. 3 Hostacom -
Characteristic values and Applications involving the use of the Hoechst materials
calculation examples Hostaform, Celanex and Hostalen GUR are devel
opments or products of the plastics processing industry.
B. Design of technical mouldings Hoechst as suppliers of the starting material will be
B.I.I Spur gears with gearwheels made from pleased to give the names of processors of plastics for
Hostaform, Celanex and Hostalen GUR technical applications.
B.2.2 Worm gears with worm wheels made from
Hostaform
B.3.1 Design calculations for snap-fit joints in
plastic parts
B.3.2 Fastening with metal screws
B.3.3 Plastic parts with integrally moulded threads
B.3.4 Design calculations for press-fit joints
B.3.5 Integral hinges in engineering plastics
B.3.7 Ultrasonic welding and assembly of
technical plastics

C. Production of technical mouldings

C.2.1 Hot runner system Indirectly heated,
-

thermally conductive torpedo

C.2.2 Hot runner system Indirectly heated,
-

thermally conductive torpedo

Design principles and examples of moulds
for processing Hostaform
C.3.1 Machining Hostaform
C.3.3 Design of mouldings made from
engineering plastics
C.3.4 Guidelines for the design of mouldings
in engineering plastics
C.3.5 Outsert moulding with Hostaform

© Copyright by Hoechst Aktiengesellschaft

Issued in August 199672nd edition

30
World-Class Engineering Polymers Contact Information

n Celanex® thermoplastic polyester (PBT) Americas

Ticona Engineering Polymers
n Celcon® and Hostaform® acetal copolymer (POM) Product Information Service
8040 Dixie Highway
n Celstran® and Compel® long fiber   Florence, KY 41042
reinforced thermoplastics (LFRT) USA
Tel.: +1-800-833-4882
n Fortron® polyphenylene sulfide (PPS) Tel.: +1-859-372-3244

n GUR® ultra-high molecular   Customer Service

Tel.: +1-800-526-4960
weight polyethylene (UHMW-PE) Tel.: +1-859-372-3214
Fax: +1-859-372-3125
n Impet® thermoplastic polyester (PET)
email: prodinfo@ticona.com
n Riteflex® thermoplastic polyester elastomer (TPC-ET)
Europe
n Vandar® thermoplastic polyester alloy (PBT) Ticona GmbH
Information Service
n Vectra® liquid crystal polymer (LCP)
Professor-Staudinger-Straße
65451 Kelsterbach
Germany
Tel.: +49 (0)180-584 2662 (Germany)*
+49 (0)69-305 16299 (Europe)**
Fax: +49 (0)180-202 1202
NOTICE TO USERS: To the best of our knowledge, the information See example below for rate information:
contained in this publication is accurate; however, we do not assume any * 0.14 €/min + local landline rates
liability whatsoever for the accuracy and completeness of such information.
Any values shown are based on testing of laboratory test specimens and
**0.06 €/call + local landline rates
represent data that fall within the standard range of properties for natural
material. Colorants or other additives may cause significant variations email: infoservice@ticona.de
in data values. Any determination of the suitability of this material for
any use contemplated by the users and the manner of such use is the sole Ticona on the web: www.ticona.com
responsibility of the users, who must assure themselves that the material
subsequently processed meets the needs of their particular product or
use, and part design for any use contemplated by the user is the sole
Asia
responsibility of the user. The user must verify that the material, as Celanese (China) Holding Co., Ltd.
subsequently processed, meets the requirements of the particular product 3F, China Development Bank Tower
or use. It is the sole responsibility of the users to investigate whether any
existing patents are infringed by the use of the materials mentioned in this
500 South Pu Dong Road
publication. Shanghai, 200120
P.R. China
Please consult the nearest Ticona Sales Office, or call the numbers listed
above for additional technical information. Call Customer Services for Customer Service
the appropriate Materials Safety Data Sheets (MSDS) before attempting to
process our products. Ticona engineering polymers are not intended for
Tel.: +86-21-3861 9266
use in medical or dental implants. Fax: +86-21-3861 9599
Except as otherwise noted, all of the trademarks referenced herein are email: infohelp@ticona.com
owned by Ticona or its affiliates. Fortron is a registered trademark of
Fortron Industries LLC. www.ticona.cn

© 2009 Ticona