Gear Repair Seminar

year Lufkin Industries, Inc. Art Nelson, P.E.

Seminar Topics

Gear Design Basics

AGMA, API, and ISO Standards
Gear Manufacturing & Quality Assurance
Gear Teeth Alignment
Metallurgy
Bearings used in Gearboxes
Lubrication
Unit installation & start-up
Vibration problems & troubleshooting
Tooth failures
Repair
Gears Go Back in History Many Centuries
Early Chinese Gear Application
Grist mill gear
Primitive Parallel Shaft Gearing
Primitive Right Angle Gearing
Gear Built in Early 20th Century
21st Century Gearing

Speeds in excess of 70,000 RPM

Velocity of teeth over 300 MPH
Some units designed and built to run 7-10 years
continuously
Output torque over 25 million in-lbs
Transmit over 100,000 HP
The Involute Curve

Webster defines an
involute as a curve
traced by a pint on a
string kept taut as it its
un-wound from a
cylinder.
The profile of most
gear teeth
manufactured in the
US are an involute
Involute

It doesnt
matter
where on
the involute
you
operate, you
will have
conjugate
motion
between the
rotors.
Relative Sliding & Rolling Motion

Used with permission from Dr. Douglas Wright

University of Western Australia
Gear Tooth Loading Patterns
Gear Nomenclature
Large Spur Gear
Forces from Spur Gears

Tangential Force
Separating Force
Bluing Contact Shows Multiple Teeth in Contact
Forces from Helical Gears

Tangential Force
Separating Force
Axial or Thrust Force
Single Helical Gears Generate Thrust
Single Helical Gears with Rider Rings
Double Helical Gear
Destructive Pitting
Tooth Breakage
Gear Set Rating

Gear Rating

120
High
100

Strength
80 Pitting Wear Scoring
Torque Capacity

60

40

20

0
0
Pitch2000
Line Velocity 4000 Very High
6000
PLV
Rating Factors

Pitch diameter of pinion & gear

Material properties of pinion and gear
Chemistry
Hardness
Face width
Torsional & bending deflection
Tooth accuracy
Speed
Tooth shape & size
Effect of Geometry on Load Distribution LUFKIN

L
TORQUE
- - - --4:7-

F
y

BENDING

TORSION

Cot-JIBINED
D E FL E C T I O N
----------- , Jd
.I.U.!- - - ;_-......,+ I- - - -+_.1
!J
THEORETICA L ..------------ '"'L- - _ J I
LONG!TUDINAL.---- -- CORRECTION

FIG . 9 F'INION DEFLECTIONS AND LONGITUDINAL CORR ECT

IONS
 Typical Tooth Alignment Chart

DESIRED TOOTHALIGNMENT
-

APEX 1/
-TOLERANCE BAND WING
I

lf) 'I r-,...

t lf) :1
r; O-r t
ENDEASEOFF
t v P2 P/; TOOTHALIGNMENTCORRECTION

v N
----<,

*
I
ENDEASEOFF
i
I
ENDEASEOFFLENGTH E EASEOFFLENGTH

LENGTH OFHELIX
Typical Operating Stresses

Durability (Pitting) 90-140 KSI

Strength (Bending) 40-60 KSI

Metallurgy and Heat Treat

Through Hardened
Case Hardened
Through hardened gearing

Historically, the most common gearing-

particularly for large gearing
Wide range of Alloys
Wide Range of Hardness
200 BHN-420 BHN
Generally homogeneous hardness throughout
tooth
All heat treating is done prior to cutting teeth.
No heat treating after teeth are cut
Case hardened gearing:

Higher performance gearing

Teeth are cut and then hardened
Carburized
58-62 Rc Case Hardness
0.020 0.250 Deep
Nitrided
50-54 Rc Hardness
0.015 0.025 Deep
Induction hardened
50-52 Rc Hardness
0.020- 0.250 Deep
Flame hardening
War & Scoring

Wear-will be discussed during section on

lubrication
Scuffing (Scoring)
Flash temperature index (AGMA 217) ISO VG
32 = 270
ISO VG 46 = 285
Other Gears used in Industry

Right angle gears:

Bevel
Spiral bevel
Worm
Single enveloping
Double enveloping (Cone Drive)
Spiral Bevel Gearset
Worm Pinion
Worm Gear
Gear Standards

AGMA
API
ISO 6336
AGMA Gear Specifications

AGMA 6013 Low Speed Gearboxes

Limits:
Pinion Speed < 4500 rpm
PLV < 7000 fpm (35 mps)
Splash lube OK
Thermal HP Rating:
Operation without sump temp. exceeding 200 F
May use driver HP or driven equipment BHP
for rating-However agreed between gear
manufacturer and end user
20% Rating Range Typical
AGMA Gear Specifications

AGMA 6011-I03 High Speed Gearboxes

Replaced AGMA 421
Turbomachinery Applications
Pinion Speed > 4500 rpm
PLV > 7000 fpm (35 mps)
Gearboxes sized on rated HP of Driver
Reasonable repeatability between
manufacturers
The Evolution of API 613 & 677
Engineering in Reliability
API 613, 1st Edition

1st Edition released in 1968

AGMA 421.06 Rating
4 Hour Mechanical Test
API 613, 2nd Edition

2nd Edition Additions (1977)

Conservative K-Factor Rating
Tilt-pad Thrust Bearing
Provisions for Vibration Probes
Axial Stability Check
Lateral Critical Speed Analysis
15 minute testing at 110 % over speed
Include Service Factor of Driver in Rating
API Gear Rating Method

Equation for De ter mining Tooth Pitting

Index K

K = Wt / (Fw)(d) x (R+1) / R
where,
K = Tooth Pitting Index (lbs/in2)
Wt = Transmitted tangential load (lbs)=126,000 (Pg) / (Np) (d) Fw =
Net Face Width (in)
d= Pinion Pitch Diameter (in)
R = Ratio (Number of Teeth in Gear / Number of Teeth in
Pinion)
Pg = Gear Unit Rated Power (hp) Np = Pinion Speed (rpm)
API 613, 3rd Edition

3rd Edition Additions (1988)

Observed vs.
Witnessed
Inspection
API 613, 4th Edition (1995)

Gear Tooth Charts > 30,000 fpm (150 mps)

Minimum Instrumentation Requirements
4 Radial Vibration Probes
2 Axial Vibration Probes
2 Accelerometers
12 Temperature Sensors
API 613, 5th Edition

Integrally flanged shaft ends are standard

1.0 mil maximum vibration
High quality material grade per ISO 6336
specified
Taper land thrust bearings are allowed with
customer
approval below 2000 RPM
API 677, 2nd Edition (1997)

Basic Requirements & Features

Conservative K-Factor Rating

Anti-Friction or Hydrodynamic Bearings
1-hr. Full Speed, No Load Mechanical
Run Test
Size Comparison of API vs. AGMA 6011

The API unit will be about 50% larger than an

AGMA rated gear for the same application
Cost of Specifications

1800 rpm Electric Motor to 4000 rpm Compressor,

1800 HP

AGMA 6013 AGMA 6011 API 677 API 613

Center Distance 10 10 14 14
Net Face Width 6 7 7 7
AGMA 6011 S.F. 1.20 1.38 2.70 2.70
Cost 100% 110% 180% 290%

Benefit: Reliability
ISO 6336 Ratings

Durability Ratings:
Carburized Gears may be comparable to
AGMA
ISO 6336 derates through hardened gears
ISO 6336 Strength ratings are more
liberal than AGMA
ISO 6336 favors use of smaller teeth
Gear Manufacturing
Hobbing Process
Herringbone Gear Generation
Sykes Cutters
Sykes Generating System LUFKIN
Typical Sykes Cut Tooth Surface Finish LUFKIN
Lapping
Gear Tooth Lapping
Gear Grinding
Quality Assurance
Part Data
Part Geometry
Quality
Requirements
Left & Right Flank
Measured Values
Profile
Variation from true
involute
Tip relief
Lead variation
Variation from helix
angle
Lead modification
End ease-off
Spacing
Measurement
Pitch
Accumulated
Pitch
Runout
Gear Tooth Quality Numbers

New ISO 1328-1 Quality numbers range from

0 to 12, with the 0 being the best
Sykes cut teeth 9
Hobbed teeth 7-8
Ground Teeth 2-6

Old AGMA 2000 Quality numbers ranged

from 3 to 15, with the Q 15 being the best
Sykes cut teeth Q8
Hobbed teeth Q9-Q10
Ground Teeth Q11-Q15
Magnetic Particle Inspection
Ultrasonic Inspection
UT Angle Beam
Electrical & Mechanical Runout Check
Residual Magnetism Check
Apex Runout Inspection
Gear Tooth Alignment
Tooth Contact Check
Double Helical Contact

A. Perfect contact -
no modification needed

B. Acceptable contact -
Gear with end ease-off modification -
slight crowning .

C. Acceptable contact-
Gear with crowning modification

D. Acceptable contact-
Gear shafts slightly off parallel
E. NOT Acceptable contact -
Gear shafts out of parallel

F. NOT Acceptable contact -

Gear shafts out of parallel

G. NOT Acceptable contact-

(if no lead modification present)
gear and/or pinion miscut - correct parts
H. NOT Acceptable contact-
(if no lead modification present)
gear and/or pinion miscut - correct parts
Offset Carrier
Offset Carrier
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Questions?