Flender Technical Handbook

18 19
Contents
Section 1 Page
Technical Drawings
Surface Texture 23/24
Geometrical Tolerancing 25-38
Sheet Sizes, Title Block, Non-standard Formats 39
Drawings Suitable for Microfilming 40/41
Section 2
Standardization
ISO Metric Screw Threads (Coarse Pitch Threads) 43
ISO Metric Screw Threads (Coarse and Fine Pitch Threads) 44
Cylindrical Shaft Ends 45
ISO Tolerance Zones, Allowances, Fit Tolerances 46/47
Parallel Keys, Taper Keys, and Centre Holes 48
Section 3
Physics
Internationally Determined Prefixes 50
Basic SI Units 50
Derived SI Units 51
Legal Units Outside the SI 51
Physical Quantities and Units of Lengths and Their Powers 52
Physical Quantities and Units of Time 53
Physical Quantities and Units of Mechanics 53/55
Physical Quantities and Units of Thermodynamics and Heat Transfer 55/56
Physical Quantities and Units of Electrical Engineering 56
Physical Quantities and Units of Lighting Engineering 57
Different Measuring Units of Temperature 57
Measures of Length and Square Measures 58
Cubic Measures and Weights 59
Energy, Work, Quantity of Heat 59
Power, Energy Flow, Heat Flow 60
Pressure and Tension 60
Velocity 60
Equations for Linear Motion and Rotary Motion 61
Section 4
Mathematics/Geometry
Calculation of Areas 63
Calculation of Volumes 64
Section 5
Mechanics/Strength of Materials
Axial Section Moduli and Axial Second Moments of Area
(Moments of Inertia) of Different Profiles 66
Deflections in Beams 67
Values for Circular Sections 68
Stresses on Structural Members and Fatigue Strength of Structures 69
20
Contents
Section 6 Page
Hydraulics
Hydrostatics 71
Hydrodynamics 72
Section 7
Electrical Engineering
Basic Formulae 74
Speed, Power Rating and Efficiency of Electric Motors 75
Types of Construction and Mounting Arrangements of Rotating Electrical Machinery 76
Types of Protection for Electrical Equipment (Protection Against Contact and Foreign Bodies) 77
Types of Protection for Electrical Equipment (Protection Against Water) 78
Explosion Protection of Electrical Switchgear 79/80
Section 8
Materials
Conversion of Fatigue Strength Values of Miscellaneous Materials 82
Mechanical Properties of Quenched and Tempered Steels 83
Fatigue Strength Diagrams of Quenched and Tempered Steels 84
General-Purpose Structural Steels 85
Fatigue Strength Diagrams of General-Purpose Structural Steels 86
Case Hardening Steels 87
Fatigue Strength Diagrams of Case Hardening Steels 88
Cold Rolled Steel Strips for Springs 89
Cast Steels for General Engineering Purposes 89
Round Steel Wire for Springs 90
Lamellar Graphite Cast Iron 90
Nodular Graphite Cast Iron 91
Copper-Tin- and Copper-Zinc-Tin Casting Alloys 92
Copper-Aluminium Casting Alloys 92
Aluminium Casting Alloys 93
Lead and Tin Casting Alloys for Babbit Sleeve Bearings 94
Comparison of Tensile Strength and Miscellaneous Hardness Values 95
Values of Solids and Liquids 96
Coefficient of Linear Expansion 97
Iron-Carbon Diagram 97
Fatigue Strength Values for Gear Materials 97
Heat Treatment During Case Hardening of Case Hardening Steels 98
Section 9
Lubricating Oils
Viscosity-Temperature-Diagram for Mineral Oils 100
Viscosity-Temperature-Diagram for Synthetic Oils of Poly--Olefine Base 101
Viscosity-Temperature-Diagram for Synthetic Oils of Polyglycole Base 102
Kinematic Viscosity and Dynamic Viscosity 103
Viscosity Table for Mineral Oils 104
21
Contents
Section 10 Page
Cylindrical Gear Units
Symbols and Units 106/107
General Introduction 108
Geometry of Involute Gears 108-119
Load Carrying Capacity of Involute Gears 119-127
Gear Unit Types 127-130
Noise Emitted by Gear Units 131-134
Section 11
Shaft Couplings
General Fundamental Principles 136
Rigid Couplings 136
Torsionally Flexible Couplings 136/138
Torsionally Rigid Couplings 138
Synoptical Table of Torsionally Flexible and Torsionally Rigid Couplings 139
Positive Clutches and Friction Clutches 140
Section 12
Vibrations
Symbols and Units 142
General Fundamental Principles 143-145
Solution Proposal for Simple Torsional Vibrators 145/146
Solution of the Differential Equation of Motion 146/147
Symbols and Units of Translational and Torsional Vibrations 148
Formulae for the Calculation of Vibrations 149-151
Evaluation of Vibrations 151/152
Section 13
Bibliography of Sections 10, 11, and 12 153-155
22
Table of Contents Section 1
Technical Drawings Page
Surface Texture
Method of indicating surface texture on drawings acc. to DIN ISO 1302 23
Explanation of the usual surface roughness parameters 23
Comparison of roughness values 24
Geometrical Tolerancing
General 25
Application; general explanations 25
Kinds of tolerances; symbols; included tolerances 26
Tolerance frame 26
Toleranced features 27
Tolerance zones 27
Datums and datum systems 27-29
Theoretically exact dimensions 29
Detailed definitions of tolerances 29-38
Sheet Sizes, Title Blocks, Non-standard Formats
Sheet sizes for technical drawings 39
Title blocks for technical drawings 39
Non-standard formats for technical drawings 39
Drawings Suitable for Microfilming
General 40
Lettering 40
Sizes of type 40
Lines acc. to DIN 15 Part 1 and Part 2 40
Ink fountain pens 41
Lettering example with stencil and in handwriting 41
23
Technical Drawings
Surface Texture
1. Method of indicating surface texture on drawings acc. to DIN 1302
1.1 Symbols
Symbol without additional indications.
Basic symbol. The meaning must be explained by additional indications.
Symbol with additional indications.
Any production method, with specified roughness.
Removal of material by machining, without specified roughness.
Removal of material by machining, with specified roughness.
Removal of material is not permitted (surface remains in state as supplied).
Made without removal of material (non-cutting), with specified roughness.
1.2 Position of the specifications of surface texture in the symbol
a = Roughness value R
a
in micrometres or microinches
or roughness grade number N1 to N12
b = Production method, surface treatment or coating
c = Sampling length
d = Direction of lay
e = Machining allowance
f = Other roughness values, e.g. R
z
Examples
Production method
Explanation
Any Material
removing
Non-cutting
Ex lanation
Centre line average height R
a
:
maximum value = 0.8 m
Mean peak-to-valley height R
z
:
maximum value = 25 m
Mean peak-to-valley height R
z
:
maximum value = 1 m at cut-off = 0.25 mm
2. Explanation of the usual surface rough-
ness parameters
2.1 Centre line average height R
a
acc. to DIN
4768
The centre line average height R
a
is the arithme-
tic average of the absolute values of the distan-
ces y between the profile heights and the centre
line within the measuring length. This is equiva-
lent to the height of a rectangle (A
g
) with a length
equal to the evaluation length l
m
and with an area
equal to the sum of the areas enclosed between
the roughness profile and the centre line (A
oi
and
A
ui
) (see figure 1).
24
Technical Drawings
Surface Texture
Centre line
Figure 1
S A
oi
+S A
ui
A
g
+S A
oi
)S A
ui
l
e
= Sampling length
l
m
= Evaluation length
l
t
= Traversed length
z
1
-z
5
= Single irregularities
Run-out length
Figure 2
Start-up length
2.2 Mean peak-to-valley height R
z
acc. to
DIN 4768
The mean peak-to-valley height R
z
is the arith-
metic average of the single irregularities of five
consecutive sampling lengths (see figure 2).
Note:
An exact conversion of the peak-to-valley height
R
z
and the centre line average height R
a
can
neither be theoretically justified nor empirically
proved. For surfaces which are generated by
manufacturing methods of the group metal
cutting, a diagram for the conversion from R
a
to
R
z
and vice versa is shown in supplement 1 to
DIN 4768 Part 1, based on comparison measure-
ments (see table Comparison of roughness
values).
2.3 Maximum roughness height R
max
acc. to
DIN 4768 (see figure 2)
The maximum roughness height R
max
is the larg-
est of the single irregularities z occurring over the
evaluation length l
m
(in figure 2: z
3
). R
max
is stat-
ed in cases where the largest single irregularity
(runaway) is to be recorded for reasons impor-
tant for function.
2.4 Roughness grade numbers N.. acc. to
DIN ISO 1302
In supplement 1 to DIN ISO 1302 it is
recommended not to use roughness grade num-
bers. The N-grade numbers are most frequently
used in America (see also table Comparison of
roughness values).
3. Comparison of roughness values
Roughness
m 0.025 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
DIN
ISO
Roughness
values R
a
in 1 2 4 8 16 32 63 125 250 500 1000 2000
ISO
1302
Roughness
grade
number
N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12
Suppl. 1
to DIN
Roughness
values R
from 0.1 0.25 0.4 0.8 1.6 3.15 6.3 12.5 25 40 80 160
to DIN
4768/1
values R
z
in m to 0.8 1.6 2.5 4 6.3 12.5 20 31.5 63 100 160 250
25
Technical Drawings
4. General
4.1 The particulars given are in accordance with
the international standard DIN ISO 1101, March
1985 edition.
This standard gives the principles of symboliza-
tion and indication on technical drawings of tol-
erances of form, orientation, location and run-
out, and establishes the appropriate geometrical
definitions. The term geometrical tolerances is
used in this standard as generic term for these
tolerances.
4.2 Relationship between tolerances of size,
form and position
According to current standards there are two
possibilities of making indications on technical
drawings in accordance with:
a) the principle of independence according to
DIN ISO 8015 where tolerances of size, form and
position must be adhered to independent of each
other, i.e. there is no direct relation between
them. In this case reference must be made on the
drawing to DIN ISO 8015.
b) the envelope requirements according to DIN
7167, according to which the tolerances of size,
form and parallelism are in direct relation with
each other, i.e. that the size tolerances limit the
form and parallelism tolerances. In this case no
special reference to DIN 7167 is required on the
drawing.
5. Application; general explanations
5.1 Geometrical tolerances shall be specified
on drawings only if they are imperative for the
functioning and/or economical manufacture of
the respective workpiece. Otherwise, the
general tolerances according to DIN 7168 apply.
5.2 Indicating geometrical tolerances does not
necessarily imply the use of any particular meth-
od of production, measurement or gauging.
5.3 A geometrical tolerance applied to a feature
defines the tolerance zone within which the fea-
ture (surface, axis, or median plane) is to be con-
tained.
According to the characteristic which is to be tol-
erated and the manner in which it is dimension-
ed, the tolerance zone is one of the following:
- the area within a circle;
- the area between two concentric circles;
- the area between two equidistant lines or two
parallel straight lines;
- the space within a cylinder;
- the space between two coaxial cylinders;
- the space between two parallel planes;
- the space within a parallelepiped.
The toleranced feature may be of any form or
orientation within this tolerance zone, unless a
more restrictive indication is given.
5.4 Unless otherwise specified, the tolerance
applies to the whole length or surface of the
considered feature.
5.5 The datum feature is a real feature of a part,
which is used to establish the location of a datum.
5.6 Geometrical tolerances which are assigned
to features referred to a datum do not limit the
form deviations of the datum feature itself. The
form of a datum feature shall be sufficiently accu-
rate for its purpose and it may therefore be
necessary to specify tolerances of form for the
datum features.
5.7 See Page 26
5.8 Tolerance frame
The tolerance requirements are shown in a
rectangular frame which is divided into two or
more compartments. These compartments
contain, from left to right, in the following order
(see figures 3, 4 and 5):
- the symbol for the characteristic to be toler-
anced;
- the tolerance value in the unit used for linear
dimensions. This value is preceded by the
sign if the tolerance zone is circular or cylin-
drical;
- if appropriate, the capital letter or letters iden-
tifying the datum feature or features (see fig-
ures 4 and 5)
Figure 3
Figure 4
Figure 5
26
Technical Drawings
Remarks referred to the tolerance, for example
6 holes, 4 surfaces, or 6 x shall be written
above the frame (see figures 6 and 7).
Figure 6 Figure 7
6 holes 6 x
If it is necessary to specify more than one tol-
erance characteristic for a feature, the tolerance
specifications are given in tolerance frames one
below the other (see figure 8).
Figure 8
5.7 Table 1: Kinds of tolerances; symbols; included tolerances
Tolerances Symbols
Toleranced
characteristics
Included tolerances
Straightness
Flatness Straightness
Form tolerances
Circularity (Roundness)
Cylindricity
Straightness, Parallel-
ism, Circularity
O i t ti
Parallelism Flatness
Orientation
tolerances
Perpendicularity Flatness
Angularity Flatness
Tolerances
of
Position
of
position
1)
Location to-
lerances
Concentricity, Coaxiality
lerances
Symmetry
Straightness, Flatness,
Parallelism
Runout
tolerances
Circular runout,
Axial runout
Circularity, Coaxiality
1) Tolerances of position always refer to a datum feature or theoretically exact dimensions.
Table 2: Additional symbols
Description Symbols
Toleranced feature indications direct
Dat m indications
direct
Datum indications
by capital letter
Theoretically exact dimension
27
Technical Drawings
5.9 Toleranced features
The tolerance frame is connected to the toler-an-
ced feature by a leader line terminating with an
arrow in the following way:
- on the outline of the feature or an extension of
the outline (but clearly separated from the
dimension line) when the tolerance refers to
the line or surface itself (see figures 9 and 10).
Figure 9 Figure 10
- as an extension of a dimension line when the
tolerance refers to the axis or median plane
defined by the feature so dimensioned (see
figures 11 to 13).
Figure 11
Figure 12
Figure 13
- on the axis or the median plane when the tol-
erance refers to the common axis or median
plane of two features (see figure 14).
Figure 14
Note:
Whether a tolerance should be applied to the
contour of a cylindrical or symmetrical feature or
to its axis or median plane, depends on the func-
tional requirements.
5.10 Tolerance zones
The tolerance zone is the zone within which all
the points of a geometric feature (point, line, sur-
face, median plane) must lie. The width of the
tolerance zone is in the direction of the arrow of
the leader line joining the tolerance frame to the
feature which is toleranced, unless the tolerance
value is preceded by the sign (see figures 15
and 16).
Figure 15 Figure 16
Where a common tolerance zone is applied to
several separate features, the requirement is in-
dicated by the words common zone above the
tolerance frame (see figure 17).
Figure 17
Common zone
5.11 Datums and datum systems
Datum features are features according to which
a workpiece is aligned for recording the tolerated
deviations.
5.11.1 When a toleranced feature is referred to a
datum, this is generally shown by datum letters.
The same letter which defines the datum is re-
peated in the tolerance frame.
To identify the datum, a capital letter enclosed in
a frame is connected to a solid datum triangle
(see figure 18).
Figure 18
28
Technical Drawings
The datum triangle with the datum letter is
placed:
- on the outline of the feature or an extension of
the outline (but clearly separated from the di-
mension line), when the datum feature is the
line or surface itself (see figure 19).
Figure 19
- as an extension of the dimension line when
the datum feature is the axis or median plane
(see figures 20 and 21).
Note:
If there is not enough space for two arrows, one
of them may be replaced by the datum triangle
(see figure 21).
Figure 20 Figure 21
- on the axis or median plane when the datum
is:
a) the axis or median plane of a single feature
(for example a cylinder);
b) the common axis or median plane formed by
two features (see figure 22).
Figure 22
If the tolerance frame can be directly connected
with the datum feature by a leader line, the datum
letter may be omitted (see figures 23 and 24).
Figure 23 Figure 24
A single datum is identified by a capital letter (see
figure 25).
A common datum formed by two datum features
is identified by two datum letters separated by a
hyphen (see figures 26 and 28).
In a datum system (see also 5.11.2) the se-
quence of two or more datum features is impor-
tant. The datum letters are to be placed in differ-
ent compartments, where the sequence from left
to right shows the order of priority, and the datum
letter placed first should refer to the directional
datum feature (see figures 27, 29 and 30).
Figure 27
Figure 26 Figure 25
Secondary datum
Tertiary datum Primary datum
5.11.2 Datum system
A datum system is a group of two or more datums
to which one toleranced feature refers in com-
mon. A datum system is frequently required
because the direction of a short axis cannot be
determined alone.
Datum formed by two form features (common
datum):
Figure 28
Datum system formed by two datums (short axis
A and directional datum B):
Figure 29
30
29
Technical Drawings
Datum system formed by one plane and one per-
pendicular axis of a cylinder:
Datum A is the plane formed by the plane con-
tact surface. Datum B is the axis of the largest
inscribed cylinder, the axis being at right angles
with datum A (see figure 30).
Figure 30
5.12 Theoretically exact dimensions
If tolerances of position or angularity are pre-
scribed for a feature, the dimensions determining
the theoretically exact position or angle shall not
be toleranced.
These dimensions are enclosed, for example .
The corresponding actual dimensions of the part
are subject only to the position tolerance or angu-
larity tolerance specified within the tolerance
frame (see figures 31 and 32).
Figure 31
Figure 32
5.13 Detailed definitions of tolerances
Symbol Definition of the tolerance zone Indication and interpretation
5.13.1 Straightness tolerance
The tolerance zone when projected in a
plane is limited by two parallel straight
lines a distance t apart.
Figure 33
Any line on the upper surface parallel to the
plane of projection in which the indication is
shown shall be contained between two
parallel straight lines 0.1 apart.
Figure 34
Any portion of length 200 of any generator of
the cylindrical surface indicated by the arrow
shall be contained between two parallel
straight lines 0.1 apart in a plane containing
the axis.
Figure 35
30
Technical Drawings
The tolerance zone is limited by a parallel-
epiped of section t
1
t
2
if the tolerance is
specified in two directions perpendicular
to each other.
Figure 36
The axis of the bar shall be contained within
a parallelepipedic zone of width 0.1 in the
vertical and 0.2 in the horizontal direction.
Figure 37
The tolerance zone is limited by a cylinder
of diameter t if the tolerance value is
preceded by the sign .
Figure 38
The axis of the cylinder to which the toler-
ance frame is connected shall be contained
in a cylindrical zone of diameter 0.08.
Figure 39
5.13.2 Flatness tolerance
The tolerance zone is limited by two paral-
lel planes a distance t apart.
Figure 40
The surface shall be contained between two
parallel planes 0.08 apart.
Figure 41
5.13.3 Circularity tolerance
The tolerance zone in the considered
plane is limited by two concentric circles
a distance t apart.
Figure 42
The circumference of each cross-section of
the outside diameter shall be contained
between two co-planar concentric circles
0.03 apart.
Figure 43
The circumference of each cross-section
shall be contained between two co-planar
concentric circles 0.1 apart.
Figure 44
31
Technical Drawings
5.13.4 Cylindricity tolerance
The tolerance zone is limited by two
coaxial cylinders a distance t apart.
Figure 45
The considered surface area shall be
contained between two coaxial cylinders
0.1 apart.
Figure 46
5.13.5 Parallelism tolerance
Parallelism tolerance of a line with reference to a datum line
lines a distance t apart and parallel to the
datum line, if the tolerance zone is only
specified in one direction.
Figure 47
The toleranced axis shall be contained
between two straight lines 0.1 apart, which
are parallel to the datum axis A and lie in the
vertical direction (see figures 48 and 49).
Figure 48 Figure 49
Figure 50
The toleranced axis shall be contained
between two straight lines 0.1 apart, which
are parallel to the datum axis A and lie in the
horizontal direction.
Figure 51
epiped of section t
1
t
2
and parallel to the
datum line if the tolerance is specified in
two planes perpendicular to each other.
Figure 52
The toleranced axis shall be contained in a
parallelepipedic tolerance zone having a
width of 0.2 in the horizontal and 0.1 in the
vertical direction and which is parallel to the
datum axis A (see figures 53 and 54).
Figure 53 Figure 54
32
Technical Drawings
Parallelism tolerance of a line with reference to a datum line
of diameter t parallel to the datum line if
the tolerance value is preceded by the
sign .
Figure 55
The toleranced axis shall be contained in a
cylindrical zone of diameter 0.03 parallel to
the datum axis A (datum line).
Figure 56
Parallelism tolerance of a line with reference to a datum surface
lel planes a distance t apart and parallel
to the datum surface.
Figure 57
The toleranced axis of the hole shall be con-
tained between two planes 0.01 apart and
parallel to the datum surface B.
Figure 58
Parallelism tolerance of a surface with reference to a datum line
lel planes a distance t apart and parallel
to the datum line.
Figure 59
The toleranced surface shall be contained
between two planes 0.1 apart and parallel to
the datum axis C of the hole.
Figure 60
Parallelism tolerance of a surface with reference to a datum surface
parallel planes a distance t apart and
parallel to the datum surface.
Figure 61
between two parallel planes 0.01 apart and
parallel to the datum surface D (figure 62).
Figure 62 Figure 63
All the points of the toleranced surface in a
length of 100, placed anywhere on this
surface, shall be contained between two
parallel planes 0.01 apart and parallel to the
datum surface A (figure 63).
33
Technical Drawings
5.13.6 Perpendicularity tolerance
Perpendicularity tolerance of a line with reference to a datum line
lines a distance t apart and perpendicular
to the datum line.
Figure 64
The toleranced axis of the inclined hole shall
be contained between two parallel planes
0.06 apart and perpendicular to the axis of
the horizontal hole A (datum line).
Figure 65
Perpendicularity tolerance of a line with reference to a datum surface
lines a distance t apart and perpendicular
to the datum plane if the tolerance is spec-
ified only in one direction.
Figure 66
The toleranced axis of the cylinder, to which
the tolerance frame is connected, shall be
contained between two parallel planes 0.1
apart, perpendicular to the datum surface.
Figure 67
epiped of section t
1
t
2
and perpendicular
to the datum surface if the tolerance is
specified in two directions perpendicular
to each other.
Figure 68
The toleranced axis of the cylinder shall be
contained in a parallelepipedic tolerance
zone of 0.1 0.2 which is perpendicular to the
datum surface.
Figure 69
of diameter t perpendicular to the datum
surface if the tolerance value is preceded
by the sign .
Figure 70
The toleranced axis of the cylinder to which
the tolerance frame is connected shall be
contained in a cylindrical zone of diameter
0.01 perpendicular to the datum surface A.
Figure 71
34
Technical Drawings
Perpendicularity tolerance of a surface with reference to a datum line
perpendicular to the datum line.
Figure 72
The toleranced face of the workpiece shall
be contained between two parallel planes
0.08 apart and perpendicular to the axis A
(datum line).
Figure 73
Perpendicularity tolerance of a surface with reference to a datum surface
perpendicular to the datum surface.
Figure 74
between two parallel planes 0.08 apart and
perpendicular to the horizontal datum sur-
face A.
Figure 75
5.13.7 Angularity tolerance
Angularity tolerance of a line with reference to a datum line
Line and datum line in the same plane.
lines a distance t apart and inclined at the
specified angle to the datum line.
Figure 76
The toleranced axis of the hole shall be con-
tained between two parallel straight lines
0.08 apart which are inclined at 60 to the
horizontal axis A-B (datum line).
Figure 77
Angularity tolerance of a surface with reference to a datum surface
lel planes a distance t apart and inclined
at the specified angle to the datum
surface.
Figure 78
between two parallel planes 0.08 apart which
are inclined at 40 to the datum surface A.
Figure 79
35
Technical Drawings
5.13.8 Positional tolerance
Positional tolerance of a line
lines a distance t apart and disposed sym-
metrically with respect to the theoretically
exact position of the considered line if the
tolerance is specified only in one direc-
tion.
Each of the toleranced lines shall be
contained between two parallel straight lines
0.05 apart which are symmetrically disposed
about the theoretically exact position of the
considered line, with reference to the surface
A (datum surface).
Figure 81
of diameter t the axis of which is in the
Figure 80
The axis of the hole shall be contained within
a cylindrical zone of diameter 0.08 the axis of
which is in the theoretically exact position of
the considered line, with reference to the sur-
faces A and B (datum surfaces).
Figure 83
of diameter t the axis of which is in the
theoretically exact position of the
considered line if the tolerance value is
preceded by the sign .
Figure 82
Each of the axes of the eight holes shall be
contained within a cylindrical zone of diame-
ter 0.1 the axis of which is in the theoretically
exact position of the considered hole, with
reference to the surfaces A and B (datum
surfaces).
Figure 84
Positional tolerance of a flat surface or a median plane
lel planes a distance t apart and disposed
symmetrically with respect to the theoreti-
cally exact position of the considered sur-
face.
Figure 85
The inclined surface shall be contained
between two parallel planes which are 0.05
apart and which are symmetrically disposed
with respect to the theoretically exact posi-
tion of the considered surface with reference
to the datum surface A and the axis of the
datum cylinder B (datum line).
Figure 86
36
Technical Drawings
5.13.9 Concentricity and coaxiality tolerance
Concentricity tolerance of a point
The tolerance zone is limited by a circle of
diameter t the centre of which coincides
with the datum point.
Figure 87
The centre of the circle, to which the toler-
ance frame is connected, shall be contained
in a circle of diameter 0.01 concentric with
the centre of the datum circle A.
Figure 88
Coaxiality tolerance of an axis
of diameter t, the axis of which coincides
with the datum axis if the tolerance value
is preceded by the sign .
Figure 89
The axis of the cylinder, to which the toler-
ance frame is connected, shall be contained
in a cylindrical zone of diameter 0.08 coaxial
with the datum axis A-B.
Figure 90
5.13.10 Symmetry tolerance
Symmetry tolerance of a median plane
lel planes a distance t apart and disposed
symmetrically to the median plane with
respect to the datum axis or datum plane.
Figure 91
The median plane of the slot shall be contain-
ed between two parallel planes, which are
0.08 apart and symmetrically disposed about
the median plane with respect to the datum
feature A.
Figure 92
Symmetry tolerance of a line or an axis
lines a distance t apart and disposed sym-
metrically with respect to the datum axis
(or datum plane) if the tolerance is speci-
fied only in one direction.
Figure 93
The axis of the hole shall be contained be-
tween two parallel planes which are 0.08
apart and symmetrically disposed with
respect to the actual common median plane
of the datum slots A and B.
Figure 94
37
Technical Drawings
Symmetry tolerance of a line or an axis
epiped of section t
1

.
t
2
, the axis of which
coincides with the datum axis if the toler-
ance is specified in two directions perpen-
dicular to each other.
Figure 95
The axis of the hole shall be contained in a
parallelepipedic zone of width 0.1 in the hori-
zontal and 0.05 in the vertical direction and
the axis of which coincides with the datum
axis formed by the intersection of the two me-
dian planes of the datum slots A-B and C-D.
Figure 96
5.13.11 Circular runout tolerance
Circular runout tolerance - radial
The tolerance zone is limited within any
plane of measurement perpendicular to
the axis by two concentric circles a
distance t apart, the centre of which coin-
cides with the datum axis.
Figure 97
Toleranced surface
Plane of
measurement
Runout normally applies to complete rev-
olutions about the axis but could be limit-
ed to apply to a part of a revolution.
The radial runout shall not be greater than
0.1 in any plane of measurement during one
revolution about the datum axis A-B.
Figure 98
Figure 100 Figure 99
The radial runout shall not be greater than
0.2 in any plane of measurement when
measuring the toleranced part of a revolution
about the centre line of hole A (datum axis).
Circular runout tolerance - axial
The tolerance zone is limited at any radial
position by two circles a distance t apart
lying in a cylinder of measurement, the
axis of which coincides with the datum
axis.
Figure 101
Cylinder of measurement
The axial runout shall not be greater than 0.1
at any position of measurement during one
revolution about the datum axis D.
Figure 102
38
Technical Drawings
Circular runout tolerance in any direction
cone of measurement, the axis of which
coincides with the datum axis by two cir-
cles a distance t apart. Unless otherwise
specified the measuring direction is nor-
mal to the surface.
Figure 103
Cone of measurement
The runout in the direction perpendicular to
the tangent of a curved surface shall not be
greater than 0.1 in any cone of measurement
during one revolution about the datum axis
C.
Figure 105
Figure 104
The runout in the direction indicated by the
arrow shall not be greater than 0.1 in any
cone of measurement during one revolution
about the datum axis C.
Circular runout tolerance in a specified direction
cone of measurement of the specified
angle, the axis of which coincides with the
datum axis by two circles a distance t
apart.
The runout in the specified direction shall not
be greater than 0.1 in any cone of measure-
ment during one revolution about the datum
axis C.
Figure 106
39
Technical Drawings
Sheet Sizes, Title Block,
Non-standard Formats
Technical drawings [extract from DIN 476
(10.76) and DIN 6671 Part 6 (04.88)]
6. Sheet sizes
The DIN 6771 standard Part 6 applies to the pre-
sentation of drawing forms even if they are
created by CAD. This standard may also be used
for other technical documents. The sheet sizes
listed below have been taken from DIN 476 and
DIN 6771 Part 6.
Table 3
Sheet sizes acc. to
DIN 476, A series
Trimmed sheet
a x b
Drawing area
1)
a
1
x b
1
Untrimmed sheet
a
2
x b
2
A0 841 x 1189 831 x 1179 880 x 1230
A1 594 x 841 584 x 831 625 x 880
A2 420 x 594 410 x 584 450 x 625
A3 297 x 420 287 x 410 330 x 450
A4 210 x 297 200 x 287 240 x 330
1) The actually available drawing area is redu-
ced by the title block, the filing margin, the
possible sectioning margin, etc.
6.1 Title block
Formats w A3 are produced in broadside. The
title block area is in the bottom right corner of the
trimmed sheet. For the A4 format the title block
area is at the bottom of the short side (upright
format).
Drawing area Trimmed drawing sheet
Title block
6.2 Non-standard formats
Non-standard formats should be avoided. When
necessary they should be created using the

dimensions of the short side of an A-format with
the long side of a greater A-format.
40
Technical Drawings
Drawings Suitable for
Microfilming
7. General
In order to obtain perfect microfilm prints the fol-
lowing recommendations should be adhered to:
7.1 Indian ink drawings and CAD drawings
show the best contrasts and should be preferred
for this reason.
7.2 Pencil drawings should be made in special
cases only, for example for drafts.
Recommendation:
2H-lead pencils for visible edges, letters and
dimensions;
3H-lead pencils for hatching, dimension lines
and hidden edges.
8. Lettering
For the lettering - especially with stencil - the ver-
tical style standard lettering has to be used acc.
to DIN 6776 Part 1, lettering style B, vertical (ISO
3098). In case of manual lettering the vertical
style or sloping style standard lettering may be
used according to DIN 6776 Part 1, lettering style
B (ISO 3098).
8.1 The minimum space between two lines in a
drawing as well as for lettering should be at least
once, but better twice the width of a line in order
to avoid merging of letters and lines in case of
reductions.
9. Type sizes
Table 4: Type sizes for drawing formats (h = type height, b = line width)
Paper sizes
Application range for lettering A0 and A1 A2, A3 and A4 g g
h b h b
Type, drawing no. 10 1 7 0.7
Texts and nominal dimensions 5 0.5 3.5 0.35
Tolerances, roughness values,
symbols
3.5 0.35 2.5 0.25
9.1 The type sizes as assigned to the paper si-
zes in table 4 must be adhered to with regard to
their application range. Larger type heights are
also permissible. Type heights smaller by ap-
prox. 20% will be accepted if this is required in a
drawing because of restricted circumstances.
10. Lines according to DIN 15 Part 1 and Part 2
Table 5: Line groups, line types and line widths
Line group 0.5 0.7
Drawing format A4, A3, A2 A1, A0
Line type Line width
Solid line (thick) 0.5 0.7
Solid line (thin) 0.25 0.35
Short dashes (thin) 0.25 0.35
Dot-dash line (thick) 0.5 0.7
Dot-dash line (thin) 0.25 0.35
Dash/double-dot line (thin) 0.25 0.35
Freehand (thin) 0.25 0.35
41
Technical Drawings
Drawings Suitable for
Microfilming
10.1 Line groups 0.5 and 0.7 with the pertaining
line width according to table 5 may only be used.
Assignment to the drawing formats A1 and A0 is
prescribed. For the A4, A3 and A2 formats, line
group 0.7 may be used as well.
11. Indian ink fountain pen
The use of the type sizes according to table 4 and
the lines according to table 5 permits a restricted
number of 5 different fountain pens (line widths
0.25; 0.35; 0.5; 0.7; 1 mm).
12. Lettering examples for stenciling and
handwritten entries
12.1 Example for formats A4 to A2
42
Standardization Page
ISO Metric Screw Threads (Coarse Pitch Threads) 43
ISO Metric Screw Threads (Coarse and Fine Pitch Threads) 44
Cylindrical Shaft Ends 45
ISO Tolerance Zones, Allowances, Fit Tolerances; Inside Dimensions (Holes) 46
ISO Tolerance Zones, Allowances, Fit Tolerances; Outside Dimensions (Shafts) 47
Parallel Keys, Taper Keys, and Centre Holes 48
43
Standardization
ISO Metric Screw Threads
(Coarse Pitch Threads)
ISO metric screw threads (coarse pitch threads) following DIN 13 Part 1, 12.86 edition
Bolt
Nut
Nut thread diameter Bolt thread diameter
D
1
d +2 H
1
d
2
D
2
d +0.64952 P
d
3
d +1.22687 P
H 0.86603 P
H
1
0.54127 P
h
3
0.61343 P
R
H
6
0.14434 P
Diameters of series 1 should be preferred to those of series 2, and these again to those of series 3.
Nominal thread
diameter
Pitch
Pitch
diameter
Core diameter Depth of thread Round
Tensile
stress
cross-
section
d = D P d
2
= D
2
d
3
D
1
h
3
H
1
R A
s

1)
Series 1 Series 2 Series 3 mm mm mm mm mm mm mm mm
2
3 0.5 2.675 2.387 2.459 0.307 0.271 0.072 5.03
3.5 0.6 3.110 2.764 2.850 0.368 0.325 0.087 6.78
4 0.7 3.545 3.141 3.242 0.429 0.379 0.101 8.78
4.5 0.75 4.013 3.580 3.688 0.460 0.406 0.108 11.3
5 0.8 4.480 4.019 4.134 0.491 0.433 0.115 14.2
6 1 5.350 4.773 4.917 0.613 0.541 0.144 20.1
7 1 6.350 5.773 5.917 0.613 0.541 0.144 28.9
8 1.25 7.188 6.466 6.647 0.767 0.677 0.180 36.6
9 1.25 8.188 7.466 7.647 0.767 0.677 0.180 48.1
10 1.5 9.026 8.160 8.376 0.920 0.812 0.217 58.0
11 1.5 10.026 9.160 9.376 0.920 0.812 0.217 72.3
12 1.75 10.863 9.853 10.106 1.074 0.947 0.253 84.3
14 2 12.701 11.546 11.835 1.227 1.083 0.289 115
16 2 14.701 13.546 13.835 1.227 1.083 0.289 157
18 2.5 16.376 14.933 15.294 1.534 1.353 0.361 193
20 2.5 18.376 16.933 17.294 1.534 1.353 0.361 245
22 2.5 20.376 18.933 19.294 1.534 1.353 0.361 303
24 3 22.051 20.319 20.752 1.840 1.624 0.433 353
27 3 25.051 23.319 23.752 1.840 1.624 0.433 459
30 3.5 27.727 25.706 26.211 2.147 1.894 0.505 561
33 3.5 30.727 28.706 29.211 2.147 1.894 0.505 694
36 4 33.402 31.093 31.670 2.454 2.165 0.577 817
39 4 36.402 34.093 34.670 2.454 2.165 0.577 976
42 4.5 39.077 36.479 37.129 2.760 2.436 0.650 1121
45 4.5 42.077 39.479 40.129 2.760 2.436 0.650 1306
48 5 44.752 41.866 42.587 3.067 2.706 0.722 1473
52 5 48.752 45.866 46.587 3.067 2.706 0.722 1758
56 5.5 52.428 49.252 50.046 3.374 2.977 0.794 2030
60 5.5 56.428 53.252 54.046 3.374 2.977 0.794 2362
64 6 60.103 56.639 57.505 3.681 3.248 0.866 2676
68 6 64.103 60.639 61.505 3.681 3.248 0.866 3055
1) The tensile stress cross-section is calculated
acc. to DIN 13 Part 28 with formula
As
p
4
d
2
)d
3
2
2
44
Standardization
ISO Metric Screw Threads
(Coarse and Fine Pitch Threads)
Selection of nominal thread diameters and pitches for coarse and fine pitch threads from
1 mm to 68 mm diameter, following DIN 13 Part 12, 10.88 edition
Nominal thread
diameter
d = D
Coarse
pitch
Pitches P for fine pitch threads
Series
1
Series
2
Series
3
itch
thread
4 3 2 1.5 1.25 1 0.75 0.5
1
1.2
1.4
0.25
0.25
0.3
1.6
2
1.8
0.35
0.35
0.4
2.5
3
2.2 0.45
0.45
0.5
4
5
3.5 0.6
0.7
0.8
0.5
0.5
6
8
10
1
1.25
1.5 1.25
1
1
0.75
0.75
0.75
0.5
0.5
12
14
15
1.75
2
1.5
1.5
1.5
1.25
1.25
1
1
1
16
18
17
2
2.5 2
1.5
1.5
1
1
1
20
24
22
2.5
2.5
3
2
2
2
1.5
1.5
1.5
1
1
1
27
25
26
3 2
1.5
1.5
1.5
30
28
32
3.5 2
1.5
1.5
1.5
36
33
35
3.5
4 3
2
2
1.5
1.5
1.5
39
38
40
4 3 2
1.5
1.5
42
48
45
4.5
4.5
5
3
3
3
2
2
2
1.5
1.5
1.5
52
50
55
5 3 2
2
1.5
1.5
1.5
56
60
58
5.5
5.5
4
4
3
3
2
2
1.5
1.5
1.5
64
68
65
6
6
4
4
3
3
2
2
2
45
Standardization
Cylindrical Shaft Ends
Cylindrical shaft ends
Acc. to DIN 748/1,
1.70 edition
FLENDER
works standard
W 0470,
5.82 edition
Diameter
Series
ISO
toler-
Length
Dia-
ISO
toler-
Series
toler-
ance
Dia-
meter
Length
toler-
ance
1 2
ance
zone
Long Short
meter
Length
ance
zone
mm mm mm mm mm mm
6 16
7 16
8 20
9 20
10 23 15
11 23 15
12 30 18
14
16
30
40
18
28
14
16
30
19
20
22 k6
40
50
50
28
36
36
19
20
22
35 k6
24
25
50
60
36
42
24
25
40
28
30
60
80
42
58
28
30
50
32
35
38
80
80
80
58
58
58
32
35
38
60
40
42
110
110
82
82
40
42
70
45
48
50
110
110
110
82
82
82
45
48
50
80
m6
55 110 82 55 90
m6
60
65
140
140
105
105
60
65
105
70
75 m6
140
140
105
105
70
75
120
80
85
170
170
130
130
80
85
140
90
95
170
170
130
130
90
95
160
Cylindrical shaft ends
Acc. to DIN 748/1,
1.70 edition
FLENDER
works standard
W 0470,
5.82 edition
Diameter
Series
ISO
toler-
Length
Dia-
ISO
toler-
Series
toler-
ance
Dia-
meter
Length
toler-
ance
1 2
ance
zone
Long Short
meter
Length
ance
zone
mm mm mm mm mm mm
100 210 165 100
180
m6
110 210 165 110
180
120
130
210
250
165
200
120
130
210
140
150
250
250
200
200
140
150
240
160
170
300
300
240
240
160
170
270
180
200
190
300
350
350
240
280
280
180
190
200
310
220 350 280 220 350
250
240
260
410
410
410
330
330
330
240
250
260
400
n6
280
m6
470 380 280 450
n6
320
300
m6
470
470
380
380
300
320
500
340 550 450 340 550
360
380
550
550
450
450
360
380
590
400
420
650
650
540
540
400
420
650
440 650 540 440 690
450
460
650
650
540
540
450
460
750
500
480 650
650
540
540
480
500
790
560
630
530
600
800
800
800
800
680
680
680
680
N
o
m
in
a
l
d
im
e
n
s
io
n
s

in

m
m
+ 300
+ 100
+ 200
+ 500
+ 400
500
400
300
200
100
0
m
46
Standardization
ISO Tolerance Zones, Allowances, Fit Tolerances
Inside Dimensions (Holes)
ISO tolerance zones, allowances, fit tolerances; Inside dimensions (holes)
acc. to DIN 7157, 1.66 edition; DIN ISO 286 Part 2, 11.90 edition
Tolerance zones shown for Tolerance zones shown for
nominal dimension 60 mm
ISO
abbrev.
Series 1
Series 2 P7 N7 N9 M7 K7 J6 J7
H7 H8
H11 G7
F8 E9
D9
D10 C11
A11
from
to
1
3
6
16
4
14
4
29
2
12
0
10
+ 2
4
+ 4
6
+10
0
+14
0
+ 60
0
+12
+ 2
+ 20
+ 6
+ 39
+ 14
+ 45
+ 20
+ 60
+ 20
+120
+ 60
+330
+270
above
to
3
6
8
20
4
16
0
30
0
12
+ 3
9
+ 5
3
+ 6
6
+12
0
+18
0
+ 75
0
+16
4
+ 28
+ 10
+ 50
+ 20
+ 60
+ 30
+ 78
+ 30
+145
+ 70
+345
+270
above
to
6
10
9
24
4
19
0
36
0
15
+ 5
10
+ 5
4
+ 8
7
+15
0
+22
0
+ 90
0
+20
+ 5
+ 35
+ 13
+ 61
+ 25
+ 76
+ 40
+ 98
+ 40
+170
+ 80
+370
+280
above
to
10
14 11 5 0 0 + 6 + 6 +10 +18 +27 +110 +24 + 43 + 75 + 93 +120 +205 +400
above
to
14
18
11
29
5
23
0
43
0
18
+ 6
12
+ 6
5
+10
8
+18
0
+27
0
+110
0
+24
+ 6
+ 43
+ 16
+ 75
+ 32
+ 93
+ 50
+120
+ 50
+205
+ 95
+400
+290
above
to
18
24 14 7 0 0 + 6 + 8 +12 +21 +33 +130 +28 + 53 + 92 +117 +149 +240 +430
above
to
24
30
14
35
7
28
0
52
0
21
+ 6
15
+ 8
5
+12
9
+21
0
+33
0
+130
0
+28
+ 7
+ 53
+ 20
+ 92
+ 40
+117
+ 65
+149
+ 65
+240
+110
+430
+300
above
to
30
40 17 8 0 0 + 7 +10 +14 +25 +39 +160 +34 + 64 +112 +142 +180
+280
+120
+470
+310
above
to
40
50
17
42
8
33
0
62
0
25
+ 7
18
+10
6
+14
11
+25
0
+39
0
+160
0
+34
+ 9
+ 64
+ 25
+112
+ 50
+142
+ 80
+180
+ 80 +290
+130
+480
+320
above
to
50
65 21 9 0 0 + 9 +13 +18 +30 +46 +190 +40 + 76 +134 +174 +220
+330
+140
+530
+340
above
to
65
80
21
51
9
39
0
74
0
30
+ 9
21
+13
6
+18
12
+30
0
+46
0
+190
0
+40
+10
+ 76
+ 30
+134
+ 60
+174
+100
+220
+100 +340
+150
+550
+360
above
to
80
100 24 10 0 0 +10 +16 +22 +35 +54 +220 +47 + 90 +159 +207 +260
+390
+170
+600
+380
above
to
100
120
24
59
10
45
0
87
0
35
+10
25
+16
6
+22
13
+35
0
+54
0
+220
0
+47
+12
+ 90
+ 36
+159
+ 72
+207
+120
+260
+120 +400
+180
+630
+410
above
to
120
140
+450
+200
+710
+460
above
to
140
160
28
68
12
52
0
100
0
40
+12
28
+18
7
+26
14
+40
0
+63
0
+250
0
+54
+14
+106
+ 43
+185
+ 85
+245
+145
+305
+145
+460
+210
+770
+520
above
to
160
180
68 52 100 40 28 7 14 0 0 0 +14 + 43 + 85 +145 +145
+480
+230
+830
+580
above
to
180
200
+530
+240
+950
+660
above
to
200
225
33
79
14
60
0
115
0
46
+13
33
+22
7
+30
16
+46
0
+72
0
+290
0
+61
+15
+122
+ 50
+215
+100
+285
+170
+355
+170
+550
+260
+1030
+ 740
above
to
225
250
79 60 115 46 33 7 16 0 0 0 +15 + 50 +100 +170 +170
+570
+280
+1110
+ 820
above
to
250
280 36 14 0 0 +16 +25 +36 +52 +81 +320 +69 +137 +240 +320 +400
+620
+300
+1240
+ 920
above
to
280
315
36
88
14
66
0
130
0
52
+16
36
+25
7
+36
16
+52
0
+81
0
+320
0
+69
+17
+137
+ 56
+240
+110
+320
+190
+400
+190 +650
+330
+1370
+1050
above
to
315
355 41 16 0 0 +17 +29 +39 +57 +89 +360 +75 +151 +265 +350 +440
+720
+360
+1560
+1200
above
to
355
400
41
98
16
73
0
140
0
57
+17
40
+29
7
+39
18
+57
0
+89
0
+360
0
+75
+18
+151
+ 62
+265
+125
+350
+210
+440
+210 +760
+400
+1710
+1350
above
to
400
450 45 17 0 0 +18 +33 +43 +63 +97 +400 +83 +165 +290 +385 +480
+840
+440
+1900
+1500
above
to
450
500
45
108
17
80
0
155
0
63
+18
45
+33
7
+43
20
+63
0
+97
0
+400
0
+83
+20
+165
+ 68
+290
+135
+385
+230
+480
+230 +880
+480
+2050
+1650
ISO
abbrev.
Series 1
Series 2 P7 N7 N9 M7 K7 J6 J7
H7 H8
H11 G7
F8 E9
D9
D10 C11
A11
N
o
m
in
a
l
d
im
e
n
s
io
n
s

in

m
m
+ 300
+ 100
+ 200
+ 500
+ 400
500
400
300
200
100
0
m
47
Standardization
ISO Tolerance Zones, Allowances, Fit Tolerances
Outside Dimensions (Shafts)
ISO tolerance zones, allowances, fit tolerances; Outside dimensions (shafts)
acc. to DIN 7157, 1.66 edition; DIN ISO 286 Part 2, 11.90 edition
Tolerance zones shown for Tolerance zones shown for
nominal dimension 60 mm
ISO
abbrev.
Series 1
Series 2
x8/u8
1) s6 r5
r6 n6
m5 m6 k5 k6 j6 js6
h6
h7 h8
h9
h11 g6
f7
e8 d9 c11 a11
from
to
1
3
+ 34
+ 20
+ 20
+ 14
+ 14
+ 10
+ 16
+ 10
+10
+ 4
+ 6
+ 2
+ 8
+ 2
+ 4
0
+ 6
0
+ 4
2
+ 3
3
0
6
0
10
0
14
0
25
0
60
2
8
6
16
14
28
20
45
60
120
270
330
above
to
3
6
+ 46
+ 28
+ 27
+ 19
+ 20
+ 15
+ 23
+ 15
+16
+ 8
+ 9
+ 4
+12
+ 4
+ 6
+ 1
+ 9
+ 1
+ 6
2
+ 4
4
0
8
0
12
0
18
0
30
0
75
4
12
10
22
20
38
30
60
70
145
270
345
above
to
6
10
+ 56
+ 34
+ 32
+ 23
+ 25
+ 19
+ 28
+ 19
+19
+10
+12
+ 6
+15
+ 6
+ 7
+ 1
+10
+ 1
+ 7
2
+4.5
4.5
0
9
0
15
0
22
0
36
0
90
5
14
13
28
25
47
40
76
80
170
280
370
above
to
10
14
+ 67
+ 40 + 39 + 31 + 34 +23 +15 +18 + 9 +12 + 8 +5.5 0 0 0 0 0 6 16 32 50 95 290
above
to
14
18
+ 72
+ 45
+ 39
+ 28
+ 31
+ 23
+ 34
+ 23
+23
+12
+15
+ 7
+18
+ 7
+ 9
+ 1
+12
+ 1
+ 8
3
+5.5
5.5
0
11
0
18
0
27
0
43
0
110
6
17
16
34
32
59
50
93
95
205
290
400
above
to
18
24
+ 87
+ 54 + 48 + 37 + 41 +28 +17 +21 +11 +15 + 9 +6.5 0 0 0 0 0 7 20 40 65 110 300
above
to
24
30
+ 81
+ 48
+ 48
+ 35
+ 37
+ 28
+ 41
+ 28
+28
+15
+17
+ 8
+21
+ 8
+11
+ 2
+15
+ 2
+ 9
4
+6.5
6.5
0
13
0
21
0
33
0
52
0
130
7
20
20
41
40
73
65
117
110
240
300
430
above
to
30
40
+ 99
+ 60 + 59 + 45 + 50 +33 +20 +25 +13 +18 +11 +8 0 0 0 0 0 9 25 50 80
120
280
310
470
above
to
40
50
+109
+ 70
+ 59
+ 43
+ 45
+ 34
+ 50
+ 34
+33
+17
+20
+ 9
+25
+ 9
+13
+ 2
+18
+ 2
+11
5
+8
8
0
16
0
25
0
39
0
62
0
160
9
25
25
50
50
89
80
142 130
290
320
480
above
to
50
65
+133
+ 87
+ 72
+ 53
+ 54
+ 41
+ 60
+ 41 +39 +24 +30 +15 +21 +12 +9.5 0 0 0 0 0 10 30 60 100
140
330
340
530
above
to
65
80
+148
+102
+ 78
+ 59
+ 56
+ 43
+ 62
+ 43
+39
+20
+24
+11
+30
+11
+15
+ 2
+21
+ 2
+12
7
+9.5
9.5
0
19
0
30
0
46
0
74
0
190
10
29
30
60
60
106
100
174 150
340
360
550
above
to
80
100
+178
+124
+ 93
+ 71
+ 66
+ 51
+ 73
+ 51 +45 +28 +35 +18 +25 +13 +11 0 0 0 0 0 12 36 72 120
170
390
380
600
above
to
100
120
+198
+144
+101
+ 79
+ 69
+ 54
+ 76
+ 54
+45
+23
+28
+13
+35
+13
+18
+ 3
+25
+ 3
+13
9
+11
11
0
22
0
35
0
54
0
87
0
220
12
34
36
71
72
126
120
207 180
400
410
630
above
to
120
140
+233
+170
+117
+ 92
+ 81
+ 63
+ 88
+ 63
200
450
460
710
above
to
140
160
+253
+190
+125
+100
+ 83
+ 65
+ 90
+ 65
+52
+27
+33
+15
+40
+15
+21
+ 3
+28
+ 3
+14
11
+12.5
12.5
0
25
0
40
0
63
0
100
0
250
14
39
43
83
85
148
145
245
210
460
520
770
above
to
160
180
+273
+210
+133
+108
+ 86
+ 68
+ 93
+ 68
+27 +15 +15 + 3 + 3 11 12.5 25 40 63 100 250 39 83 148 245
230
480
580
830
above
to
180
200
+308
+236
+151
+122
+ 97
+ 77
+106
+ 77
240
530
660
950
above
to
200
225
+330
+258
+159
+130
+100
+ 80
+109
+ 80
+60
+31
+37
+17
+46
+17
+24
+ 4
+33
+ 4
+16
13
+14.5
14.5
0
29
0
46
0
72
0
115
0
290
15
44
50
96
100
172
170
285
260
550
740
1030
above
to
225
250
+356
+284
+169
+140
+104
+ 84
+113
+ 84
+31 +17 +17 + 4 + 4 13 14.5 29 46 72 115 290 44 96 172 285
280
570
820
1100
above
to
250
280
+396
+315
+190
+158
+117
+ 94
+126
+ 94 +66 +43 +52 +27 +36 +16 +16 0 0 0 0 0 17 56 110 190
300
620
920
1240
above
to
280
315
+431
+350
+202
+170
+121
+ 98
+130
+ 98
+66
+34
+43
+20
+52
+20
+27
+ 4
+36
+ 4
+16
16
+16
16
0
32
0
52
0
81
0
130
0
320
17
49
56
108
110
191
190
320 330
650
1050
1370
above
to
315
355
+479
+390
+226
+190
+133
+108
+144
+108 +73 +46 +57 +29 +40 +18 +18 0 0 0 0 0 18 62 125 210
360
720
1200
1560
above
to
355
400
+524
+435
+244
+208
+139
+114
+150
+114
+73
+37
+46
+21
+57
+21
+29
+ 4
+40
+ 4
+18
18
+18
18
0
36
0
57
0
89
0
140
0
360
18
54
62
119
125
214
210
350 400
760
1350
1710
above
to
400
450
+587
+490
+272
+232
+153
+126
+166
+126 +80 +50 +63 +32 +45 +20 +20 0 0 0 0 0 20 68 135 230
440
840
1500
1900
above
to
450
500
+637
+540
+292
+252
+159
+132
+172
+132
+80
+40
+50
+23
+63
+23
+32
+ 5
+45
+ 5
+20
20
+20
20
0
40
0
63
0
97
0
155
0
400
20
60
68
131
135
232
230
385 480
880
1650
2050
ISO
abbrev.
Series 1
Series 2
x8/u8
1) s6 r5
r6 n6
m5 m6 k5 k6 j6 js6
h6
h7 h8
h9
h11 g6
f7
e8 d9 c11 a11
1) Up to nominal dimension 24 mm: x8; above nominal dimension 24 mm: u8
48
Standardization
Parallel Keys, Taper Keys,
and Centre Holes
Dimensions of parallel keys and taper keys Parallel keys and taper keys
acc to DIN 6885 Part 1 6886 and 6887
Diameter Width Height
Depth
of key-
way in
shaft
Depth of
keyway in
hub
Lengths, see
below
y p y
acc. to DIN 6885 Part 1, 6886 and 6887
Editions: 08.68 12.67 4.68
Side fitting square and rectangular keys
d b h t1 t2 l1 l
DIN DIN
above to
1) 2)
6885/1
6886/
6887
6885/1 6886
2)
from to from to
mm mm mm mm mm mm mm mm mm mm mm
6
8
10
8
10
12
2
3
4
2
3
4
1.2
1.8
2.5
1.0
1.4
1.8
0.5
0.9
1.2
6
6
8
20
36
45
6
8
10
20
36
45
Parallel key and keyway acc. to DIN 6885 Part 1
Square and rectangular taper keys
12
17
22
17
22
30
5
6
8
5
6
7
3
3.5
4
2.3
2.8
3.3
1.7
2.2
2.4
10
14
18
56
70
90
12
16
20
56
70
90
Square and rectangular taper keys
30
38
44
38
44
50
10
12
14
8
8
9
5
5
5.5
3.3
3.3
3.8
2.4
2.4
2.9
22
28
36
110
140
160
25
32
40
110
140
160
50
58
65
58
65
75
16
18
20
10
11
12
6
7
7.5
4.3
4.4
4.9
3.4
3.4
3.9
45
50
56
180
200
220
45
50
56
180
200
220 Taper and round-ended sunk key and
k t DIN 6886
75
85
95
85
95
110
22
25
28
14
14
16
9
9
10
5.4
5.4
6.4
4.4
4.4
5.4
63
70
80
250
280
320
63
70
80
250
280
320
y
keyway acc. to DIN 6886
1) The tolerance zone for hub keyway width b for
parallel keys with normal fit is ISO JS9 and
110
130
150
130
150
170
32
36
40
18
20
22
11
12
13
7.4
8.4
9.4
6.4
7.1
8.1
90
100
110
360
400
400
90
100
110
360
400
400
) y y
parallel keys with normal fit is ISO JS9 and
with close fit ISO P9. The tolerance zone for
shaft keyway width b with normal fit is ISO N9
and with close fit ISO P9
170
200
230
200
230
260
45
50
56
25
28
32
15
17
20
10.4
11.4
12.4
9.1
10.1
11.1
125
140
160
400
400
400
125
140
400
400
and with close fit ISO P9.
2) Dimension h of the taper key names the
largest height of the key, and dimension tz the
largest depth of the hub keyway The shaft
260
290
330
290
330
380
63
70
80
32
36
40
20
22
25
12.4
14.4
15.4
11.1
13.1
14.1
180
200
220
400
400
400
Lengths
not
deter-
g g y, z
largest depth of the hub keyway. The shaft
keyway and hub keyway dimensions
according to DIN 6887 - taper keys with gib
head - are equal to those of DIN 6886
380
440
440
500
90
100
45
50
28
31
17.4
19.5
16.1
18.1
250
280
400
400
deter-
mined
head - are equal to those of DIN 6886.
Lengths mm
I1 or I
6 8 10 12 14 16 18 20 22 25 28 32 36 40 45 50 56 63 70 80
90 100 110 125 140 160 180 200 220 250 280 320 360 400
Dimensions of 60 centre holes Centre holes
i h f d ( i ) DIN 332 P 1
Recommended
diameters
Bore
diameter
Form B
Minimum
dimensions
Centre holes
in shaft ends (centerings) acc. to DIN 332 Part 1
d
2)
d1 a
1)
b d2 d3 t
above to
mm mm mm mm mm mm mm mm
6
10
25
63
10
25
63
100
1.6
2
2.5
3.15
4
5
6.3
5.5
6.6
8.3
10
12.7
15.6
20
0.5
0.6
0.8
0.9
1.2
1.6
1.4
3.35
4.25
5.3
6.7
8.5
10.6
13.2
5
6.3
8
10
12.5
16
18
3.4
4.3
5.4
6.8
8.6
10.8
12.9
Form B
DIN 332/1 4.80
Recommended
diameters
Form DS
d6
2)
d1 d2 d3 d4 d5 t1 t2 t3 t4 t5
above to
3)
+2 min. +1 Keyway
mm mm mm mm mm mm mm mm mm mm mm mm
Keyway
7
10
13
10
13
16
M3
M4
M5
2.5
3.3
4.2
3.2
4.3
5.3
5.3
6.7
8.1
5.8
7.4
8.8
9
10
12.5
12
14
17
2.6
3.2
4
1.8
2.1
2.4
0.2
0.3
0.3
16
21
24
21
24
30
M6
M8
M10
5
6.8
8.5
6.4
8.4
10.5
9.6
12.2
14.9
10.5
13.2
16.3
16
19
22
21
25
30
5
6
7.5
2.8
3.3
3.8
0.4
0.4
0.6
Form DS (with thread)
30
38
50
85
38
50
85
130
M12
M16
M20
M24
10.2
14
17.5
21
13
17
21
25
18.1
23
28.4
34.2
19.8
25.3
31.3
38
28
36
42
50
37
45
53
63
9.5
12
15
18
4.4
5.2
6.4
8
0.7
1.0
1.3
1.6
Form DS (with thread)
DIN 332/1 5.83
1) Cutting-off dimension in case of no centering
2) Diameter applies to finished workpiece
* Dimensions not acc to DIN 332 Part 2
130
225
320
225
320
500
M30*
M36*
M42*
26
31.5
37
31
37
43
44
55
65
48
60
71
60
74
84
77
93
105
17
22
26
11
15
19
1.9
2.3
2.7
)
* Dimensions not acc. to DIN 332 Part 2
3) Drill diameter for tapping-size holes acc. to
DIN 336 Part 1
49
Physics Page
Internationally Determined Prefixes 50
Basic SI Units 50
Derived SI Units 51
Legal Units Outside the SI 51
Physical Quantities and Units of Lengths and Their Powers 52
Physical Quantities and Units of Time 53
Physical Quantities and Units of Mechanics 53/55
Physical Quantities and Units of Thermodynamics and Heat Transfer 55/56
Physical Quantities and Units of Electrical Engineering 56
Physical Quantities and Units of Lighting Engineering 57
Different Measuring Units of Temperature 57
Measures of Length and Square Measures 58
Cubic Measures and Weights 59
Energy, Work, Quantity of Heat 59
Power, Energy Flow, Heat Flow 60
Pressure and Tension 60
Velocity 60
Equations for Linear Motion and Rotary Motion 61
50
Physics
Internationally Determined Prefixes
Basic SI Units
Internationally determined prefixes
Decimal multiples and sub-multiples of units are represented with prefixes and symbols.
Prefixes and symbols are used only in combination with unit names and unit symbols.
Factor by which the unit
is multiplied
Prefix Symbol
Factor by which the unit
is multiplied
Prefix Symbol
10
18
Atto a 10
1
Deka da
10
15
Femto f 10
2
Hecto h
10
12
Pico p 10
3
Kilo k
10
9
Nano n 10
6
Mega M
10
6
Micro 10
9
Giga G
10
3
Milli m 10
12
Tera T
10
2
Centi c 10
15
Peta P
10
1
Deci d 10
18
Exa E
Prefix symbols and unit symbols are written
without blanks and together they form the
symbol for a new unit. An exponent on the unit
symbol also applies to the prefix symbol.
Example:
1 cm
3
= 1
.
(10
2
m)
3
= 1
.
10
6
m
3
1 s = 1
.
10
6
s
10
6
s
1
= 10
6
Hz = 1 MHz
Prefixes are not used with the basic SI unit kilo-
gram (kg) but with the unit gram (g).
Example:
Milligram (mg), NOT microkilogram (kg).
When giving sizes by using prefix symbols and
unit symbols, the prefixes should be chosen in
such a way that the numerical values are
between 0.1 and 1000.
Example:
12 kN instead of 1.2 10
4
N
3.94 mm instead of 0.00394 m
1.401 kPa instead of 1401 Pa
31 ns instead of 3.1
.
10
8
s
Combinations of prefixes and the following
units are not allowed:
Units of angularity: degree, minute, second
Units of time: minute, hour, year, day
Unit of temperature: degree Celsius
Basic SI units
Physical quantity
Basic SI unit
Physical quantity
Basic SI unit
Physical quantity
Name Symbol
Physical quantity
Name Symbol
Length Metre m
Thermodynamic
Mass
Kilo-
gram
kg
Thermodynamic
temperature
Kelvin K
Time Second s Amount of substance Mole mol
Electric current Ampere A Luminous intensity Candela cd
51
Physics
Derived SI Units
Legal Units Outside the SI
Derived SI units having special names and special unit symbols
Physical quantity
SI unit
Relation Physical quantity
Name Symbol
Relation
Plane angle Radian rad 1 rad = 1 m/m
Solid angle Steradian sr 1 sr = 1 m
2
/m
2
Frequency, cycles per
second
Hertz Hz 1 Hz = 1 s
1
Force Newton N 1 N = 1 kg
.
m/s
2
Pressure, mechanical
stress
Pascal Pa 1 Pa = 1 N/m
2
= 1 kg/ (m
.
s
2
)
Energy; work; quantity
of heat
Joule J 1 J = 1 N
.
m = 1 W
.
s = 1 kg
.
m
2
/m
2
Power, heat flow Watt W 1 W = 1 J/s = 1 kg
.
m
2
/s
3
Electric charge Coulomb C 1 C = 1 A
.
s
Electric potential Volt V 1 V = 1 J/C = 1 (kg
.
m
2
)/(A
.
s
3
)
Electric capacitance Farad F 1 F = 1 C/V = 1 (A
2

.
s
4
)/(kg
.
m
2
)
Electric resistance Ohm 1 = 1 V/A = 1 (kg
.
m
2
)/A
2

.
s
3
)
Electric conductance Siemens S 1 S = 1
1
= 1 (A
2

.
s
3
)/(kg
.
m
2
)
Celsius temperature
degrees
Celsius
C 1 C = 1 K
Inductance Henry H 1 H = 1 V
.
s/A
Legal units outside the SI
Physical quantity Unit name Unit symbol Definition
Plane angle
Round angle
Gon
Degree
Minute
Second
1)
gon
2)
2)
2)
1 perigon = 2 rad
1 gon = (/200)rad
1 = (/180)rad
1 = (1/60)
1 = (1/60)
Volume Litre l 1 l = 1 dm
3
= (1/1000) m
3
Time
Minute
Hour
Day
Year
min 2)
h 2)
d 2)
a 2)
1 min = 60 s
1 h = 60 min = 3600 s
1 d = 24 h = 86 400 s
1 a = 365 d = 8 760 h
Mass Ton t 1 t = 10
3
kg = 1 Mg
Pressure Bar bar 1 bar = 10
5
Pa
1) A symbol for the round angle has not yet been internationally determined
2) Do not use with prefixes
52
Physics
Physical Quantities and Units of
Lengths and Their Powers
Physical quantities and units of lengths and their powers
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
L.U.: Further legal units
N.A.: Units no longer allowed
l Length
m
(metre)
N.: Basic unit
L.U.: m; mm; cm; dm; km; etc.
N.A.: micron (): 1 = 1 m
ngstrm unit (): 1 = 10
10
m
A Area
m
2
(square metre)
L.U.: mm
2
; cm
2
; dm
2
; km
2
are (a): 1 a = 10
2
m
2
hectare (ha): 1 ha = 10
4
m
2
V Volume
m
3
(cubic metre)
L.U.: mm
3
; cm
3
; dm
3
litre (l): 1 l = dm
3
H
Moment of
area
m
3
N.: moment of a force; moment of resistance
L.U.: mm
3
; cm
3
Second mo-
ment of area
m
4
N.: formerly: geometrical moment of inertia
L.U.: mm
4
; cm
4
,. Plane angle
rad
(radian)
N. : 1 rad )
1 m (arc)
1 m (radius)
)
1 m
1 m
)1m m
1 rad
1 degree )1
o
)
p
180
rad
90
o
)
p
2
rad
Degree (
o
) : 1
o
)
p
180
rad
Minute ( ) : 1 )
1
o
60
Second ( ) : 1 )
1
60
Gon (gon) : 1 gon )
p
200
rad
N.A. : Right angle +(L) : 1L )
p
2
rad
Centesimal degree (g) : 1g )1 gon
Centesimal minute (
c
) : 1
c
)
1
100
gon
Centesimal second (
cc
) : 1
cc
)
1
c
100
L.U. : mrad, mrad
, Solid angle
sr
(steradian)
N. : 1 sr )
1 m
2
(spherical surface)
1 m
2
(square of spherical radius)
)1
m
2
m
2
53
Physics
Physical Quantities and Units
of Time and of Mechanics
Physical quantities and units of time
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
t
Time,
Period,
Duration
s
(second)
N.: Basic unit
L.U.: ns; s; ms; ks
Minute (min): 1 min = 60 s
Hour (h): 1 h = 60 min
Day (d): 1 d = 24 h
Year (a): 1 a = 365 d
(Do not use prefixes for decimal multiples
and sub-multiples of min, h, d, a)
f
Frequency,
Periodic
frequency
Hz
(Hertz)
L.U.: kHz; MHz; GHz; THz
Hertz (Hz): 1 Hz = 1/s
n
Rotational
frequency
(speed)
s
1
N.: Reciprocal value of the duration of one
revolution
L.U.: min
1
= 1/min
v Velocity m/s
1 km h )
1
3.6
m s
L.U.: cm/s; m/h; km/s; km/h
a
Accelera-
tion, linear
m/s
2
N.: Time-related velocity
L.U.: cm/s
2
g Gravity m/s
2
N.: Gravity varies locally.
Normal gravity (g
n
):
g
n
= 9.80665 m/s
2
9.81 m/s
2
Angular
velocity
rad/s L.U.: rad/min
Angular
acceleration
rad/s
2
L.U.: /s
2
V
.
Volume
flow rate
m
3
/s L.U.: l/s; l/min; dm
3
/s; l/h; m
3
/h; etc.
Physical quantities and units of mechanics
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
m Mass
kg
(kilogram)
N.: Basic unit
L.U.: g; mg; g; Mg
ton (t): 1 t = 1000 kg
m
Mass per
unit length
kg/m
N.: m = m/l
L.U.: mg/m; g/km;
In the textile industry:
Tex (tex):1 tex = 10
-6
kg/m = 1 g/km
m
Mass in
relation to
the surface
kg/m
2
N.: m = m/A
L.U.: g/mm
2
; g/m
2
; t/m
2
r Density
kg/m
3
N.: r = m/V
L.U.: g/cm
3
, kg/dm
3
, Mg/m
3
, t/m
3
, kg/l
1g/cm
3
= 1 kg/dm
3
= 1 Mg/m
3
=
1 t/m
3
= 1 kg/l
54
Physics
Physical Quantities and
Units of Mechanics
Physical quantities and units of mechanics (continued)
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
J
Mass
moment of
inertia; sec-
ond mass
moment
kg
.
m
2
N.: Instead of the former flywheel effect GD
2
L.U.: g m
2
; t m
2
GD
2
in kpm
2
now : J )
GD
2
4
m
.
Rate of
mass flow
kg/s L.U.: kg/h; t/h
F Force
N
(Newton)
L.U.: N; mN; kN; MN; etc.; 1 N = 1 kg m/s
2
N.A.: kp (1 kp = 9.80665 N)
G Weight
N
(Newton)
N.: Weight = mass acceleration due to gravity
L.U.: kN; MN; GN; etc.
M, T Torque Nm
L.U.: Nm; mNm; kNm; MNm; etc.
N.A.: kpm; pcm; pmm; etc.
M
b
Bending
moment
Nm
L.U.: Nmm; Ncm; kNm etc.
N.A.: kpm; kpcm; kpmm etc.
p Pressure
Pa
(Pascal)
N.: 1 Pa = 1 N/m
2
L.U.: Bar (bar): 1 bar = 100 000 Pa = 10
5
Pa
bar, mbar
N.A.: kp/cm
2
; at; ata; at; mmWS; mmHg; Torr
1kp/cm
2
= 1 at = 0.980665 bar
1 atm = 101 325 Pa = 1.01325 bar
1 mWS = 9806.65 Pa = 9806.65 N/m
2
1 mmHg = 133.322 Pa = 133.322 N/m
2
1 Torr )
101325
760
Pa )133.322 Pa
p
abs
Absolute
pressure
Pa
(Pascal)
p
amb
Ambient
atmospher-
ic pressure
Pa
(Pascal)
p
e
Pressure
above
atmos-
pheric
Pa
(Pascal)
p
e
= p
abs
- p
amb
Direct
stress
(tensile and
compres-
sive stress)
N/m
2
L.U.: N/mm
2
1 N/mm
2
= 10
6
N/m
2
Shearing
stress
N/m
2
L.U.: N/mm
2
Extension m/m
N.: l / l
L.U.: m/m; cm/m; mm/m
W, A Work
J
N.: 1 J = 1 Nm = 1 Ws
L.U.: mJ; kJ; MJ; GJ; TJ; kWh
1 kWh = 3 6 MJ
E, W Energy
J
(Joule)
1 kWh = 3.6 MJ
N.A.: kpm; cal; kcal
1 cal = 4.1868 J; 860 kcal = 1 kWh
55
Physics
Physical Quantities and Units of Mechanics,
Thermodynamics and Heat Transfer
Physical quantities and units of mechanics (continued)
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
P
.
Power
W
N.: 1 W = 1 J/s = 1 Nm/s
L.U.: W; mW; kW; MW; etc.
kJ/s; kJ/h; MJ/h, etc.
N.A.: PS; kpm/s; kcal/h
Q
.
Heat flow
W
Watt)
N.A.: PS k m/s kcal/h
1 PS = 735.49875 W
1 kpm/s = 9.81 W
1 kcal/h = 1.16 W
1 hp = 745.70 W
Dynamic
viscosity
Pa
.
s
N.: 1 Pa
.
s = 1 Ns/m
2
L.U.: dPa
.
s, mPa
.
s
N.A.: Poise (P): 1 P = 0.1 Pa
.
s
Kinematic
viscosity
m
2
/s
L.U.: mm
2
/s; cm
2
/s
N.A.: Stokes (St):
1 St = 1/10000 m
2
/s
1cSt = 1 mm
2
/s
Physical quantities and units of thermodynamics and heat transfer
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
T
Thermody-
namic
temperature
K
(Kelvin)
N.: Basic unit
273.15 K = 0 C
373.15 K = 100 C
L.U.: mK
t
Celsius
temperature
C
N.: The degrees Celsius (C) is a special name for
the degrees Kelvin (K) when stating Celsius
temperatures. The temperature interval of
1 K equals that of 1 C.
Q
Heat
Quantity of
heat
J
1 J = 1 Nm = 1 Ws
L.U.: mJ; kJ; MJ; GJ; TJ
N.A.: cal; kcal
a
Tempera-
ture
conductivity
m
2
/s
[ W/(m
.
K)] = thermal conductivity
a )
m +c
p
m [kg/m
3
] = density of the body
c
p
[J/(kg K)] = specific heat capacity
at constant pressure
H
Enthalpy
(Heat con-
tent)
J
N.: Quantity of heat absorbed under certain
conditions
L.U.: kJ; MJ; etc.
N.A.: kcal; Mcal; etc.
s Entropy J/K
1 J/K = 1 Ws/K = 1 Nm/K
L.U.: kJ/K
N.A.: kcal/deg; kcal/K
,h
Heat
transfer
coefficient
W/(m
2

.
K)
L.U.: W/(cm
2

.
K); kJ/(m
2

.
h
.
K)
N.A.: cal/(cm
2

.
s
.
grd)
kal/(m
2

.
h
.
grd) 4.2 kJ/(m
2

.
h
.
K)
56
Physics
Physical Quantities and Units of Thermodynamics,
Heat Transfer and Electrical Engineering
Physical quantities and units of thermodynamics and heat transfer (continued)
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
c
Specific
heat
capacity
J/(K
.
kg)
1 J/(K
.
kg) = W
.
s / (kg
.
K)
N.: Heat capacity referred to mass
N.A.: cal / (g
.
deg); kcal / (kg
.
deg); etc.
l
Coefficient
of linear
thermal
expansion
K
1
m / (m
.
K) = K
1
N.: Temperature unit/length unit ratio
L.U.: m / (m
.
K); cm / (m
.
K); mm / (m
.
K)
v
,
Coefficient
of
volumetric
expansion
K
1
m
3
/ (m
3

.
K) = K
1
N.: Temperature unit/volume ratio
N.A.: m
3
/ (m
3

.
deg)
Physical quantities and units of electrical engineering
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
I
Current
strength
A
(Ampere)
N.: Basic unit
L.U.: pA; nA; A; mA; kA; etc.
Q
Electric-
charge;
Quantity of
electricity
C
(Coloumb)
1 C = 1 A
.
s
1 Ah = 3600 As
L.U.: pC; nC; C; kC
U
Electric
voltage
V
(Volt)
1 V = 1 W / A = 1 J / (s
.
A)
= 1 A
.
= 1 N
.
m / (s
.
A)
L.U.: V; mV; kV; MV; etc.
R
Electric
resistance
(Ohm)
1 = 1 V / A = 1 W / A
2
1 J / (s
.
A
2
) = 1 N
.
m / (s
.
A
2
)
L.U.: ; m; k; etc.
G
Electric
conductance
S
(Siemens)
N.: Reciprocal of electric resistance
1 S = 1
1
= 1 / ; G = 1 / R
L.U.: S; mS; kS
C
Electrostatic
capacitance
F
(Farad)
1 F = 1 C / V = 1 A
.
s / V
= 1 A
2

.
s / W = 1 A
2

.
s
2
/ J
= 1 A
2

.
s
2
/ (N
.
m)
L.U.: pF; F; etc.
57
Physics
Physical Quantities and Units of Lighting Engineering,
Different Measuring Units of Temperature
Physical quantities and units of lighting engineering
Symbol
Physical
quantity
SI unit
Symbol
Name
N.: Note
I
Luminous
intensity
cd
(Candela)
N.: Basic unit
1 cd = 1 lm (lumen)/sr (Steradian)
L.U.: mcd; kcd
L
Luminous
density;
Luminance
cd / m
2
L.U.: cd / cm
2
; mcd/m
2
; etc.
N.A.: Apostilb (asb); 1 asb
1
p
cd m
2
Nit (nt): 1 nt = 1 cd / m
2
Stilb (sb): 1 sb = 10
4
cd / m
2
Luminous
flux
lm
(Lumen)
1 Im = 1 cd
.
sr
L.U.: klm
E Illuminance
lx
(Lux)
1 lx = 1 lm / m
2
Different measuring units of temperature
Kelvin K
T
K
Degrees Celsius C
t
C
Degrees Fahrenheit F
t
F
Degrees Rankine R
T
R
T
K
273.15 )tc
t
C
T
K
+273.15 t
F
9
5
T
K
+459.67 T
R
9
5
T
K
T
K
255.38 )
5
9
t
F
t
C
5
9
t
F
+32 t
F
32 )
9
5
t
C
T
R
9
5
tc )273.15
T
K
5
9
T
R
t
C
5
9
T
R
+273.15 t
F
T
R
+459.67 T
R
459.67 )t
F
Comparison of some temperatures
0.00
+ 255.37
+ 273.15
+ 273.16 1)
+ 373.15
273.15
17.78
0.00
+ 0.01
1)
+ 100.00
459.67
0.00
+ 32.00
+ 32.02
+ 212.00
0.00
+ 459.67
+ 491.67
+ 491.69
+ 671.67
1) The triple point of water is +0.01 C. The triple point of pure water is the equilibrium point
between pure ice, air-free water and water vapour (at 1013.25 hPa).
Temperature
comparison
of F with C
58
Physics
Measures of Length
and Square Measures
Measures of length
Unit
Inch
in
Foot
ft
Yard
yd
Stat mile Naut mile mm m km
1 in
1 ft
1 yd
1 stat mile
1 naut mile
=
=
=
=
=
1
12
36
63 360
72 960
0.08333
1
3
5280
6080
0.02778
0.3333
1
1760
2027
1
1.152
0.8684
1
25.4
304.8
914.4
0.0254
0.3048
0.9144
1609.3
1853.2
1.609
1.853
1 mm
1 m
1 km
=
=
=
0.03937
39.37
39 370
3.281
.
10
3
3.281
3281
1.094
.
10
3
1.094
1094
0.6214
0.5396
1
1000
10
6
0.001
1
1000
10
6
0.001
1
1 German statute mile = 7500 m
1 geograph. mile = 7420.4 m = 4 arc minutes at the
equator (1 at the equator = 111.307 km)
Astronomical units of measure
1 light-second = 300 000 km
1 l.y. (light-year) = 9.46
.
10
12
km
1 parsec (parallax second, distances to the stars) =
1 internat. nautical mile
1 German nautical mile
(sm)
1 mille marin (French)
=1852 m = 1 arc
minute at the degree of
longitude (1 at the me-
ridian = 111.121 km)
}
1 parsec (parallax second, distances to the stars) =
3.26 l.y.
1 astronomical unit (mean distance of the earth from
the sun) = 1.496
.
10
8
km
Typographical unit of measure: 1 point (p) = 0.376 mm
Other measures of length of the Imperial system
1 micro-in = 10
6
in = 0.0254 m
1 mil = 1 thou = 0.001 in = 0.0254 mm
1 line = 0.1 in = 2,54 mm
1 fathom = 2 yd = 1.829 m
1 engineers chain = 100 eng link = 100 ft = 30.48 m
1 rod = 1 perch = 1 pole = 25 surv link = 5.029 m
1 surveyors chain = 100 surv link = 20.12 m
1 furlong = 1000 surv link = 201.2 m
1 stat league = 3 stat miles = 4.828 km
Other measures of length of the metric system
France:
1 toise = 1.949 m 1 myriametre = 10 000 m
Russia:
1 werschok = 44.45 mm 1 saschen = 2.1336 m
1 arschin = 0.7112 m 1 werst = 1.0668 km
Japan:
1 shaku = 0.3030 m
1 ken = 1.818 m
1 ri = 3.927 km
Square measures
Unit
sq
in
sq
ft
sq
yd
sq
mile
cm
2
dm
2
m
2
a ha km
2
1 square inch
1 square foot
1 square yard
1 square mile
=
=
=
=
1
144
1296
1
9
0.1111
1
1
6.452
929
8361
0.06452
9.29
83.61
0.0929
0.8361
259
2.59
1 cm
2
1 dm
2
1 m
2
1 a
1 ha
1 km
2
=
=
=
=
=
=
0.155
15.5
1550
0.1076
10.76
1076
0.01196
1.196
119.6
0.3861
1
100
10000
0.01
1
100
10000
0.01
1
100
10000
0.01
1
100
10000
0.01
1
100
0.01
1
Other square measures of the Imperial system
1 sq mil = 1 S 10
6
sq in = 0.0006452 mm
2
1 sq line = 0.01 sq in = 6.452 mm
2
1 sq surveyors link = 0.04047 m2
1 sq rod = 1 sq perch = 1 sq pole = 625 sq surv link
= 25.29 m
2
1 sq chain = 16 sq rod = 4.047 a
1 acre = 4 rood = 40.47 a
1 township (US) = 36 sq miles = 3.24 km
2
1 circular in +
p
4
sq in +5.067cm
2
(circular area with 1 in dia.)
1 circular mil +
p
4
sq mil +0.0005067mm
2
(circular area with 1 mil dia.)
Other square measures of the metric
system
Russia:
1 kwadr. archin = 0.5058 m
2
1 kwadr. saschen = 4.5522 m
2
1 dessjatine = 1.0925 ha
1 kwadr. werst = 1.138 km
2
Japan:
1 tsubo = 3.306 m
2
1 se = 0.9917a
1 ho-ri = 15.42 km
2
59
Physics
Cubic Measures and Weights;
Energy, Work, Quantity of Heat
Cubic measures
Unit
cu
in
cu
ft
US liquid
quart
US
gallon
Imp quart
Imp
gallon
cm
3
dm
3
(l)
m
3
1 cu in
1 cu ft
1 cu yd
=
=
=
1
1728
46656
1
27
0.01732
29.92
807.9
7.481
202
0.01442
24.92
672.8
6.229
168.2
16.39
0.01639
28.32
764.6
0.02832
0.7646
1 US liquid quart
1 US gallon
=
=
57.75
231
0.03342
0.1337
1
4
0.25
1
0.8326
3.331
0.2082
0.8326
946.4
3785
0.9464
3.785
1 imp quart
1 imp gallon
=
=
69.36
277.4
0.04014
0.1605
1.201
4.804
0.3002
1.201
1
4
0.25
1
1136
4546
1.136
4.546
1 cm
3
1 dm
3
(l)
1 m
3
=
=
0.06102
61.02
61023
0.03531
35.31
1.057
1057
0.2642
264.2
0.88
880
0.22
220
1
1000
10
6
0.001
1
1000
10
6
0.001
1
1 US minim = 0.0616 cm
3
(USA)
1 US fl dram = 60 minims = 3.696 cm
3
1 US fl oz = 8 fl drams = 0,02957 l
1 US gill = 4 fl oz = 0.1183 l
1 US liquid pint = 4 gills = 0.4732 l
1 US liquid quart = 2 liquid pints = 0.9464 l
1 US gallon = 4 liquid quarts = 3.785 l
1 US dry pint = 0.5506 l
1 US dry quart = 2 dry pints = 1.101 l
1 US peck = 8 dry quarts = 8.811 l
1 US bushel = 4 pecks = 35.24 l
1 US liquid barrel = 31.5 gallons = 119.2 l
1 US barrel = 42 gallons = 158.8 l (for crude oil)
1 US cord = 128 cu ft = 3.625 m
2
1 Imp minim = 0.0592 cm
3
(GB)
1 Imp ft drachm = 60 minims = 3.552 cm
3
1 Imp ft oz = 8 ft drachm = 0,02841 l
1 Imp gill = 5 ft oz = 0.142 l
1 Imp pint = 4 gills = 0.5682 l
1 Imp quart = 2 pints = 1.1365 l
1 imp gallon = 4 quarts = 4.5461 l
1 iImp pottle = 2 quarts = 2.273 l
1 Imp peck = 4 pottles = 9.092 l
1 Imp bushel = 4 pecks = 36.37 l
1 Imp quarter = 8 bushels = 64 gallons = 290.94 l
Weights
Unit dram oz lb
short
cwt
long cwt
short
ton
long ton g kg t
1 dram
1 oz (ounze)
1 lb (pound)
=
=
=
1
16
256
0.0625
1
16
0.003906
0.0625
1
0.01
0.008929
1.772
28.35
453.6
0.00177
0.02835
0.4536
1 short cwt (US)

1 long cwt (GB/US)
=
=
25600
28672
1600
1792
100
112
1
1.12
0.8929
1
0.05
0.056
0.04464
0.05
45359
50802
45.36
50.8
0.04536
0.0508
1 short ton (US)
1 long ton (GB/US)
=
=
32000
35840
2000
2240
20
22.4
17.87
20
1
1.12
0.8929
1
907.2
1016
0.9072
1.016
1g
1kg
1t
=
=
=
0.5643
564.3
0.03527
35.27
35270
0.002205
2.205
2205
0.02205
22.05
0.01968
19.68
1.102
0.9842
1
1000
10
6
0.001
1
1000
10
6
0.001
1
1 grain = 1 / 7000 lb = 0.0648 g (GB)
1 stone = 14 lb = 6.35 kg (GB)
1 short quarter = 1/4 short cwt = 11.34 kg (USA)
1 long quarter = 1/4 long cwt = 12.7 kg (GB / USA)
1 quintal or 1 cental = 100 lb = 45.36 kg (USA)
1 quintal = 100 livres = 48.95 kg (F)
1 kilopound = 1kp = 1000 lb = 453.6 kg (USA)
1 solotnik = 96 dol = 4.2659 g (CIS)
1 lot = 3 solotnik = 12.7978 g (CIS)
1 funt = 32 lot = 0.409 kg (CIS)
1 pud = 40 funt = 16.38 kg (CIS)
1 berkowetz = 163.8 kg (CIS)
1 kwan = 100 tael = 1000 momme = 10000 fun =
3.75 kg (J) (J)
1 hyaku kin = 1 picul = 16 kwan = 60 kg (J)
tdw = tons dead weight = lading capacity of a cargo vessel (cargo + ballast + fuel + stores), mostly given in
long tons, i.e. 1 tdw = 1016 kg
Energy, work, quantity of heat
Work ft lb erg
J = Nm
= Ws
kpm PSh hph kWh kcal Btu
1 ft lb
1 erg
1 Joule (WS)
1 kpm
1 PSh
1 hph
1 kWh
1 kcal
1 Btu
=
=
=
=
=
=
=
=
=
1
0.7376
.
10
7
0.7376
7.233
1.953
.
10
6
1.98
.
10
6
2.655
.
10
6
3.087
.
10
3
778.6
1.356
.
10
7
1
10
7
9.807
.
10
7
26.48
.
10
12
26.85
.
10
12
36
.
10
12
41.87
.
10
9
10.55
.
10
9
1.356
10
7
1
9.807
2.648
.
10
6
2.685
.
10
6
3.6
.
10
6
4186.8
1055
0.1383
0.102
.
10
7
0.102
1
270
.
10
3
273.8
.
10
3
367.1
.
10
3
426.9
107.6
0.5121
.
10
6
37.77
.
10
15
377.7
.
10
9
3.704
.
10
6
1
1.014
1.36
1.581
.
10
3
398.4
.
10
6
0.505
.
106
37.25
.
10
15
372.5
.
10
9
3.653
.
10
6
0.9863
1
1.341
1.559
.
10
3
392.9
.
10
6
0.3768
.
10
6
27.78
.
10
15
277.8
.
10
9
2.725
.
10
6
0.7355
0.7457
1
1.163
.
10
3
293
.
10
6
0.324
.
10
3
23.9
.
10
12
238
.
10
6
2.344
.
10
3
632.5
641.3
860
1
0.252
1.286
.
10
3
94.84
.
10
12
948.4
.
10
6
9.301
.
10
3
2510
2545
3413
3.968
1
1 in oz = 0.072 kpcm; 1 in lb = 0.0833ft lb = 0.113 Nm, 1 thermi (French) = 4.1855
.
10
6
J; 1 therm (English) = 105.51
.
10
6
J
Common in case of piston engines: 1 litre-atmosphere (litre
.
atmosphere ) = 98.067 J
60
Physics
Power, Energy Flow, Heat Flow,
Pressure and Tension, Velocity
Power, energy flow, heat flow
Power erg/s W kpm/s PS hp kW kcal/s Btu/s
1 erg/s
1W
1kpm/s
1 PS (ch)
2)
1hp
1 kW
1 kcal/s
1 Btu/s
=
=
=
=
=
=
=
=
1
10
7
9.807
.
10
7
7.355
.
10
9
7.457
.
10
9
10
10
41.87
.
10
8
10.55
.
10
9
10
7
1
9.807
735.5
745.7
1000
4187
1055
0.102
.
10
7
0.102
1
75
76.04
102
426.9
107.6
0.136
.
10
9
1.36
.
10
3
13.33
.
10
3
1
1.014
1.36
5.692
1.434
0.1341
.
10
9
1.341
.
10
3
13.15
.
10
3
0.9863
1
1.341
5.614
1.415
10
10
10
3
9.804
.
10
3
0.7355
0.7457
1
4.187
1.055
23.9
.
10
12
239
.
10
6
2.344
.
10
3
0.1758
0.1782
0.239
1
0.252
94.84
.
10
12
948.4
.
10
6
9.296
.
10
3
0.6972
0.7068
0.9484
3.968
1
1 poncelet (French) = 980.665 W; flywheel effect: 1 kgm
2
= 3418 lb in
2
Pressure and tension
Unit
bar =
dN/m
2
mbar
= cN/
cm
2
bar =
daN/
cm
2
kp/m
2
mm
WS
p/cm
2
kp/cm
2
=
at
kp/mm
2
Torr=
mm
QS
atm
lb
sq ft
lb
sq in
long ton
sq in
{sh ton}
sq in
1 b=daN
1mbar=cN/cm
2
1 bar
= daN/cm
2
=
=
=
1
1000
10
6
0.001
1
1000
0.001
1
0.0102
10.2
10197
1.02
1020
1.02
0.0102
0.7501
750.1
0.9869
2.089
2089
0.0145
14.5
0.0064
0.0072
1 kp/m
2
=1mm
WS at 4 C
= 98.07 1 0.1 0.0001 0.2048
1 p/cm
2
= 980.7 0.9807 10 1 0.001 0.7356 2.048 0.0142
1 kp/cm
2
=1at
(techn.
atmosph.)
= 980.7 0.9807 10000 1000 1 0.01 735.6 0.9678 2048 14.22
1 kp/mm
2
= 98067 98.07 10
6
10
5
100 1 73556 96.78 1422 0.635 0.7112
1 Torr = 1 mm
QS at 0 C
= 1333 1.333 0.00133 13.6 1.36 0.00136 1 2.785 0.01934
1 atm
(pressure of
the
atmosphere)
= 1013 1.013 10332 1033 1.033 760 1 2116 14.7
1 lb/sq ft = 478.8 0.4788 4.882 0.4882 0.3591 1
1 lb/sq in=1 psi = 68948 68.95 0.0689 703.1 70.31 0.0703 51.71 0.068 144 1 0.0005
1 long ton/sq
in (GB)
= 154.4 157.5 1.575 152.4 2240 1 1.12
1 short ton/sq
in (US)
= 137.9 140.6 1.406 136.1 2000 0.8929 1
1 psi = 0.00689 N / mm
2
1 N/m
2
(Newton/m
2
) = 10 b, 1 barye (French) = 1 b, 1 piece (pz) (French) = 1 sn/m
2
102 kp/m
2
. 1 hpz =
100 pz = 1.02 kp/m
2.
In the USA, inches Hg are calculated from the top, i.e. 0 inches Hg = 760 mm QS and 29.92 inches Hg = 0
mm QS = absolute vacuum.
The specific gravity of mercury is assumed to be 13.595 kg/dm
3
.
Velocity
Unit m/s m/min km/h ft/min mile/h
m/s
m/min
km/h
ft/min
mile/h
=
=
=
=
=
1
0.0167
0.278
0.0051
0.447
60
1
16.67
0.305
26.82
3.6
0.06
1
0.0183
1.609
196.72
3.279
54.645
1
87.92
2.237
0.0373
0.622
0.0114
1
61
Physics
Equations for Linear Motion
and Rotary Motion
Definition
SI Sym-
Basic formulae
Definition
SI
unit
Sym
bol
Linear motion Rotary motion
Uniform
motion
distance moved divided by time
angular velocity = angle of
rotation in radian measure/time
Velocity m/s v v +
s
2
)s
1
t
2
)t
1
+
s
t
+const. p +
r
2
)r
1
t
2
)t
1
+
r
t
+const.
Angular
velocity
rad/s motion accelerated from rest:
Angle of
rotation
rad
m/s
r
v
v +
s
t
r +
r
t
Distance
moved
m s s = v
.
t angle of rotation =
.
t
Uniformly
accelerated
motion
acceleration equals change of
velocity divided by time
angular acceleration equals
change of angular velocity
divided by time
Acceleration m/s
2
a a +
v
2
)v
1
t
2
)t
1
+
v
t
+const. m +
p
2
)p
1
t
2
)t
1
+
p
t
+const.
Angular
acceleration
rad/s
2
motion accelerated from rest:
m/s
2
a
a +
v
t
+
v
2
2s
+
2s
t
2
m +
p
t
+
p
2
2r
+
2r
t
2
Velocity m/s v
v +a t + 2 a s
p +m t
Circumferential
speed
m/s v v +r p +r m t
Distance moved m s s +
v
2
t +
a
2
t
2
+
v
2
2a
angle of rotation
r +
p
2
t +
m
2
t
2
+
p
2
2m
Uniform motion
and constant
force or constant
torque
force
.
distance moved
torque
.
angle of rotation in
radian measure
Work J W W = F
.
s W = M
.

work in unit of time =
force
.
velocity
work in unit of time =
torque
.
angular velocity
Power W P P +
W
t
+F v P +
W
t
+M p
Non-uniform
(accelerated)
motion
accelerating force =
mass
.
acceleration
accel. torque = second mass
moment
.
angular acceleration
Force N F F = m
.
a M = J
.

In case of any
motion
*) * *)
Energy J E
k
E
k
m
2
v
2
E
k
+
J
2
p
2
Potential energy
(due to force of
gravity)
J E
p
weight
.
height
E
p
= G
.
h = m
.
g
.
h
Centrifugal force N F
F
F
F
= m
.
r
s

.

2
(r
s
= centre-of-gravity radius)
*) Momentum (kinetic energy) equals half the mass
.
second power of velocity.
**) Kinetic energy due to rotation equals half the mass moment of inertia
.
second power of the angular
velocity.
62
Mathematics / Geometry Page
Calculation of Areas 63
Calculation of Volumes 64
63
Mathematics/Geometry
Calculation of Areas
A = area U = circumference
Square
Rectangle
Parallelogram
Trapezium
Triangle
Equilateral triangle
Hexagon
Octagon
Polygon
Formed area
Circle
Circular ring
Circular sector
Ellipse
Circular segment
A = a
2
a A
d a 2
A a b
d a
2
)b
2
A a h
a
A
h
A m h
m
{a )b}
2
A
{a h}
2
a
{2 A}
h
A
a
2
4
3
d
a
2
3
A
3 a
2
3
2
d 2 a
s 3 a
A 2a
2
( 2 )1)
s a( 2 )1)
A A
1
)A
2
)A
3
A
r
2
2
{
o
m}
180
+sin
a h
1
)b h
2
)b h
3
2
A
r
2
2
(2 3 +m)
0.785 d
2
A
d
2
m
4
r
2
m
U 2rm d m
A
m
4
(D
2
+d
2
)
A
r
2
m
o
360
o
{b r}
2
A
{D d m}
4
0.16 r
2
(d )b) b m
b
{D +d}
2
b
{r m
o}
180
o
1
2
[ r(b +s) )sh]
s 2 r sin
^
{
o
m}
180
s
2
tan
4
h r (1 +cos
a
2
)
b r
^
1
64
{a +b}
{a )b}
4
1
4
{a +b}
{a )b}
2
)
U m (a )b) [ 1 )
U
{D )d}
2
m
a b m
)
1
256
{a +b}
{a )b}
6
.. ]
d a 4 )2 2
64
Mathematics / Geometry
Calculation of Volumes
O = surface
V a
3
d a 3
V a b c
O 2 (ab )ac )bc )
V A h
V
{A h}
3
V
h
3
(A
1
)A
2
) A
1
A
2
)
h
A
1
)A
2
2
V
d
2
p
4
h
M 2 r p h
V
{h p}
4
(D
2
+d
2
)
V
r
2
p h
3
M r p m
m h
2
)
d
2
2
V
{p h}
12
( D
2
)Dd )d
2
)
M
{p m}
2
( D )d )
V
4
3
r
3
p
1
6
d
3
p
V
{p h}
6
(3a
2
)3b
2
)h
2
)
M 2 r p h
V
{p h}
6
3
4
s
2
)h
2
V
2
3
h r
2
p
O
{p r}
2
(4h )s)
4.189 r
3
p h
2
r +
h
3
M 2 r p h
V
D p
2
d
2
4
M = generated surface V = volume
Cube Frustum of cone
Prismatoid Cone
Cylindrical barrel Hollow cylinder
Cylinder Cylindrical ring
Frustum of pyramid Spherical sector
Spherical segment Pyramid
Spherical zone
Parallelepiped
Rectangular block
Sphere
(Cavalier principle)
O 6 a
2
d a
2
)b
2
)c
2
O 2 r p (r )h)
2p p h
m
{D +d}
2
2
)h
2
O 4 p r
2
p d
2
p
4
( s
2
)4h
2
)
O D d p
2
V
{h p}
12
( 2D
2
)d
2
)
V
h
6
( A
1
)A
2
)4A )
O r p ( r )m)
65
Mechanics / Strength of Materials Page
(Moments of Inertia) of Different Profiles 66
Deflections in Beams 67
Values for Circular Sections 68
Stresses on Structural Members and Fatigue Strength of Structures 69
66
Mechanics / Strength of Materials
(Moments of Inertia) of Different Profiles
Cross-sectional area Second moment of area Section modulus
W
1
bh
2
6
W
2
hb
2
6
1
bh
3
12
W
2
rb
2
a 4
W
1
W
2
r
32
D
4
+d
4
D
W
1
W
2
r D
3
32 D
3
10
for e
1
3
3b )2b
1
2b )b
1
h
W
1
6b
2
)6bb
1
)b
2
1
12( 3b )2b
1
)
h
2
W
1
bh
2
24 for e
2
3
h
W
1
W
2
a
3
6
W
2
hb
2
24
W
1
5
8
R
3
0.625 R
3
2
r
64
( D
4
+d
4
)
2
rD
4
64 D
4
20
W
1
BH
3
+bh
3
6H
W
2
0.5413 R
3
W
1
W
2
(r )s 2) rsr
2
W
1
ra
2
b 4
W
1
1
a
1
W
1
1
e 0.1908 r
3
with e r 1 +
4
{3r}
0.5756 r
2
hb
3
12
2
a
4
12
1
bh
3
36
2
5
16
3 R
4
0.5413 R
4
1
6b
2
)6bb
1
)b
2
1
36 (2b )b
1
)
h
3
1
BH
3
+bh
3
12
2
rsr
3
1 )(s 2r)
2
rsr
3
1
ra
3
b 4
2
rb
3
a 4
1
r
4
(a
3
1b
1
+a
3
2b
2
)
s a
1
+a
2
b
1
+b
2
2 (a +a
2
) 2 (b +b
2
) thin
1
r
4
a
2
(a )3b) s
1
[ r 8 +8 (9 r) r
4
0.1098 r
4
or in case of thin wall thickness s:
or if the wall thickness is
axis 1-1 = axis of centre of gravity
2
hb
3
48
W
1
r
4
a (a )3b) s
67
Deflections in Beams
f, f
max
, f
m
, w, w
1
, w
2
a, b, l, x
1
, x
1max
, x
2
E
q, q
o
w(x)
F
3
{3E }
1 +
3
2
x
)
1
2
x
3
Deflection (mm)
Lengths (mm)
Modulus of elasticity (N/mm
2
)
Line load (N/mm)
Second moment of area (mm
4
)
(moment of inertia)
Angle ()
Forces (N)
,
1,

2
,
A
,
B
,
F, F
A
, F
B

f
F
3
{3E }
w(x)
F
3
{2E }
x a
1 +
a
+
1
3
x
2
w
1
(x
1
)
F
3
{6E }
a b
2 x
1
1 )
l
b
+
x
2
1
ab
w(x)
F
3
{16E }
x
1 +
4
3
x
l
2
w(x)
q
4
{8E }
1 +
4
3
x
)
1
3
x
4
tanm
F
2
{2 E }
F
p
F
f
q
4
{8E }
tanm
q
3
{6 E }
F
p
q
w(x)
q
o
4
{120E }
4 +5
x
)
x
5
f
q
o
4
{30E }
tanm
q
o
3
{24 E }
F
p
q
o
2
x
2
f
F
3
{48 E }
tanm
F
2
{16 E }
F
A
F
B
F
2
x
1
a f
F
3
{3E }
a
2
b
2
tanm
1
f
2a
1 )
b
x
2
b tanm
2
f
2b
1 )
a w
2
(x
2
)
F
3
{6E }
b a
2 x
2
1 )
a
+
x
2
2
ab
F
A
F
b
F
B
F
a
f
F
3
{2E }
a
l
2
1 +
4
3
a
tanm
1
F
2
{2E }
a
1 +
a
x a 2
w(x)
F
3
{2E }
a x
1 +
x
+
1
3
a
2
f
m
F
3
{8E }
a
1 +
4
3
a
2
tanm
2
F
2
{2E }
a
1 +2
a
a x 2
w
1
(x
1
)
F
3
{2E }
1
3
x
1
3
+
a
1 )
a
x
1
)
a
2
1 )
2
3
a
f
F
3
{2E }
a
2
1 )
2
3
a
tanm
1
F
2
{2E }
a
1 )
a
w
2
(x
2
)
F
3
{2E }
a
x
2
1 +
x
2
f
m
F
3
{8E }
a
tanm
2
F
2
{2E }
a
w
1
(x
1
)
F
3
{6E }
a
x
1
1 +
x
1
2
x
1
f
F
3
{3E }
a
2
1 )
a
tan
m
A
F
2
{6E }
a
l
w
2
(x
2
)
F
3
{6E }
x
2 2a
)
3a
x
2
+
x
2
2
x
2
a f
max
F
3
9 3 E
a
tanm
B
2 tanm
A
tanm
F
2
{6E }
a
2 )3
a
F
A
F
a
F
B
F 1 )
a
w(x)
q
4
{24E }
x
1 +2
x
2
)
x
3
0 x f
m
5q
4
{384E }
tanm
q
3
{24E }
F
A
q
2
F
B
q
2
f
max
f
{ ) b}
3b
) b
3a
for a > b
change a and b for a < b
a (l )b) 3a x1max
x
2
x
1
a
FA = FB = F
FA = FB = F
68
Values for Circular Sections
Axial section modulus:
Polar section modulus:
Axial second moment of area
(axial moment of inertia):
Polar second moment of area
(polar moment of area):
Wa
p d
3
32
Wp
p d
3
16
a
p d
4
64
p
p d
4
32
Area:
Mass:
Density of steel:
Second mass moment of
inertia (mass moment of inertia):
A
p d
2
4
J
p d
4
l r
32
r 7, 85
kg
dm
3
m
p d
2
4
l r
d A Wa a Mass /I J / I d A Wa a Mass/ I J / I
mm cm
2
cm
3
cm
4
kg/m kgm
2
/m mm cm
2
cm
3
cm
4
kg/m kgm
2
/m
6.
7.
8.
9.
10.
11.
0.293
0.385
0.503
0.636
0.785
0.950
0.0212
0.0337
0.0503
0.0716
0.0982
0.1307
0.0064
0.0118
0.0201
0.0322
0.0491
0.0719
0.222
0.302
0.395
0.499
0.617
0.746
0.000001
0.000002
0.000003
0.000005
0.000008
0.000011
115.
120.
125.
130.
135.
140.
103.869
113.097
122.718
132.732
143 139
153.938
149.3116
169.6460
191.7476
215.6900
241.5468
269.3916
858.5414
1017.8760
1198.4225
1401.9848
1630.4406
1895.7410
81.537
88.781
96.334
104.195
112.364
120.841
0.134791
0.159807
0.188152
0.220112
0.255979
0.296061
12.
13.
14.
15.
16.
17.
1.131
1.327
1.539
1.767
2.011
2.270
0.1696
0.2157
0.2694
0.3313
0.4021
0.4823
0.1018
0.1402
0.1986
0.2485
0.3217
0.4100
0.888
1.042
1.208
1.387
1.578
1.782
0.000016
0.000022
0.000030
0.000039
0.000051
0.000064
145.
150.
155.
160.
165.
170.
165.130
176.715
188.692
201.062
213.825
226.980
299.2981
331.3398
365.5906
402.1239
441.0133
482.3326
2169.9109
2485.0489
2833.3269
3216.9909
3638.3601
4099.8275
129.627
138.721
148.123
157.834
167.852
178.179
0.340676
0.390153
0.444832
0.505068
0.571223
0.643673
18.
19.
20.
21.
22.
23.
2.545
2.835
3.142
3.464
3.801
4.155
0.5726
0.6734
0.7854
0.9092
1.0454
1.1945
0.5153
0.6397
0.7854
0.9547
1.1499
1.3737
1.998
2.226
2.466
2.719
2.984
3.261
0.000081
0.000100
0.000123
0.000150
0.000181
0.000216
175.
180.
185.
190.
195.
200.
240.528
254.469
268.803
283.529
298.648
314.159
526.1554
572.5553
621.6058
673.3807
727.9537
785.3982
4603.8598
5152.9973
5749.8539
6397.1171
7097.5481
7853.9816
188.815
199.758
211.010
222.570
234.438
246.615
0.722806
0.809021
0.902727
1.004347
1.114315
1.233075
24.
25.
26.
27.
28.
29.
4.524
4.909
5.309
5.726
6.158
6.605
1.3572
1.5340
1.7255
1.9324
2.1551
2.3944
1.6286
1.9175
2.2432
2.6087
3.0172
3.4719
3.551
3.853
4.168
4.495
4.834
5.185
0.000256
0.000301
0.000352
0.000410
0.000474
0.000545
210.
220.
230.
240.
250.
260.
346.361
380.133
415.476
452.389
490.874
530.929
909.1965
1045.3650
1194.4924
1357.1680
1533.9808
1725.5198
9546.5638
11499.0145
13736.6629
16286.0163
19174.7598
22431.7569
271.893
298.404
326.148
355.126
385.336
416.779
1.498811
1.805345
2.156656
2.556905
3.010437
3.521786
30.
32.
34.
36.
38.
40.
7.069
8.042
9.079
10.179
11.341
12.566
2.6507
3.2170
3.8587
4.5804
5.3870
6.2832
3.9761
5.1472
6.5597
8.2448
10.2354
12.5664
5.549
6.313
7.127
7.990
8.903
9.865
0.000624
0.000808
0.001030
0.001294
0.001607
0.001973
270.
280.
300.
320.
340.
360.
572.555
615.752
706.858
804.248
907.920
1017.876
1932.3740
2155.1326
2650.7188
3216.9909
3858.6612
4580.4421
26087.0491
30171.8558
39760.7820
51471.8540
65597.2399
82447.9575
449.456
483.365
554.884
631.334
712.717
799.033
4.095667
4.736981
6.242443
8.081081
10.298767
12.944329
42.
44.
46.
48.
50.
52.
13.854
15.205
16.619
18.096
19.635
21.237
7.2736
8.3629
9.5559
10.8573
12.2718
13.9042
15.2745
18.3984
21.9787
26.0576
30.6796
35.8908
10.876
11.936
13.046
14.205
15.413
16.671
0.002398
0.002889
0.003451
0.004091
0.004817
0.005635
380.
400.
420.
440.
460.
480.
1134.115
1256.637
1385.442
1520.531
1661.903
1809.557
5387.0460
6283.1853
7273.5724
8362.9196
9555.9364
10857.3442
102353.8739
125663.7060
152745.0200
183984.2320
219786.6072
260576.2608
890.280
986.460
1087.572
1193.617
1304.593
1420.503
16.069558
19.729202
23.980968
28.885524
34.506497
40.910473
54.
56.
58.
60.
62.
64.
22.902
24.630
26.421
28.274
30.191
32.170
15.4590
17.2411
19.1551
21.2058
23.3978
25.7359
41.7393
48.2750
55.5497
63.6173
72.5332
82.3550
17.978
19.335
20.740
22.195
23.700
25.253
0.006553
0.007579
0.008721
0.009988
0.011388
0.012930
500.
520.
540.
560.
580.
600.
1693.495
2123.717
2290.221
2463.009
2642.079
2827.433
12271.8463
13804.1581
15458.9920
17241.0605
19155.0758
21205.7504
306796.1572
358908.1107
417392.7849
482749.6930
555497.1978
636172.5116
1541.344
1667.118
1797.824
1933.462
2074.032
2219.535
48.166997
56.348573
65.530667
75.791702
87.213060
99.879084
66.
68.
70.
72.
74.
76.
34.212
36.317
38.485
40.715
43.008
45.365
28.2249
30.8693
33.6739
36.6435
39.7828
43.0964
93.1420
104.9556
117.8588
131.9167
147.1963
163.7662
26.856
28.509
30.210
31.961
33.762
35.611
0.014623
0.016478
0.018504
0.020711
0.023110
0.025711
620.
640.
660.
680.
700.
720.
3019.071
3216.991
3421.194
3631.681
3848.451
4071.504
23397.7967
25735.9270
28224.8538
30869.2894
33673.9462
36643.5367
725331.6994
823549.6636
931420.1743
1049555.8389
1178588.1176
1319167.3201
2369.970
2525.338
2685.638
2850.870
3021.034
3196.131
113.877076
129.297297
146.232967
164.780267
185.038334
207.109269
78.
80.
82.
84.
86.
88.
47.784
50.265
52.810
55.418
58.088
60.821
46.5890
50.2655
54.1304
58.1886
62.4447
66.9034
181.6972
201.0619
221.9347
244.3920
268.5120
294.3748
37.510
39.458
41.456
43.503
45.599
47.745
0.028526
0.031567
0.034844
0.038370
0.042156
0.046217
740.
760.
780.
800.
820.
840.
4300.840
4536.460
4778.362
5026.548
5281.017
5541.769
39782.7731
43096.3680
46589.0336
50265.4824
54130.4268
58188.5791
1471962.6056
1637661.9830
1816972.3105
2010619.2960
2219347.4971
2443920.3207
3376.160
3561.121
3751.015
3945.840
4145.599
4350.289
231.098129
257.112931
285.264653
315.667229
348.437557
383.695490
90.
92.
95.
100.
105.
110.
63.617
66.476
70.882
78.540
86.590
95.033
71.5694
76.4475
84.1726
98.1748
113.6496
130.6706
322.0623
351.6586
399.8198
490.8739
596.6602
718.6884
49.940
52.184
55.643
61.654
67.973
74.601
0.050564
0.055210
0.062772
0.077067
0.093676
0.112834
860.
880.
900.
920.
940.
960.
980.
1000.
5808.805
6082.123
6361.725
6647.610
6939.778
7238.229
7542.964
7853.982
62444.6517
66903.3571
71569.4076
76447.5155
81542.3934
86858.7536
92401.3084
98174.7703
2685120.0234
2943747.7113
3220623.3401
3516585.7151
3832492.4910
4169220.1722
4527664.1126
4908738.5156
4559.912
4774.467
4993.954
5218.374
5447.726
5682.010
5921.227
6165.376
421.563844
462.168391
505.637864
552.103957
601.701321
654.567567
710.843266
770.671947
69
Stresses on Structural Members
and Fatigue Strength of Structures
Yield point R
e
; R
p0.2
Diffusion of stress in structural members: loading types
static dynamic alternating oscillating
Maximum stress limit:
Mean stress:
Minimum stress limit:
Ruling coefficient of strength of material for the calculation of structural members:
m sch
2
o sch
u 0
m 0
o ) w
u + w
m v (initial stress)
o m ) a
u m + a
Resistance to
breaking R
m
Fatigue strength under
fluctuating stresses
Sch
alternating stresses
W
Resistance to
deflection
A
Coefficients of fatigue strength
D
Alternate area/Area of fluctuation
In case of stresses below the
damage curve initial damage
will not occur to the material.
Stress-number diagram
S
t
r
e
s
s

Number of cycles to failure N

Example:
Tension-Compression
Fatigue strength diagram acc. to SMITH
fluctuating stresses Sch
F
a
t
ig
u
e

s
t
r
e
n
g
t
h

u
n
d
e
r
a
lt
e
r
n
a
t
in
g

s
t
r
e
s
s
e
s

D
= ruling fatigue strength value of
the material
b
= surface number ( 1)
b
d
= size number ( 1)
k
= stress concentration factor ( 1)
S = safety (1.2 ... 2)
Reduced stress
on the member
Permissible
stress
Design strength
of the member
v perm.
D
bo b
d
S
k
Alternating bending, dynamic torsion:
0
0.7
Alternating bending, alternating torsion:
0
1.0
Static bending, alternating torsion:
0
1.6
Reduced stress
v
For the frequently occurring case of com-
bined bending and torsion, according to
the distortion energy theory:
with:
= single axis bending stress
= torsional stress
0
= constraint ratio according to Bach
v
2
)3 (mo )
2
Surfaces with
rolling skin
For bending and torsion
S
i
z
e

n
u
m
b
e
r

b
d
Diameter of component d
S
u
r
f
a
c
e

n
u
m
b
e
r

b
o
Resistance to breaking of the material Rm
S
u
r
f
a
c
e

r
o
u
g
h
n
e
s
s
R
t

i
n

m
with:
C
o
e
f
f
ic
ie
n
t

o
f

f
a
t
ig
u
e

s
t
r
e
n
g
t
h
Stress-number
curve
Damage curve
Endurance limit
Fatigue limit
Resistance to breaking Rm
Yield point Re
Resistance to
deflection A
Mean stress m
for tension
compression
bd = 1.0
70
Hydraulics Page
Hydrostatics 71
(Source: K. Gieck, Technische Formelsammlung, 29th Edition, Gieck Verlag,
D-7100 Heilbronn)
Hydrodynamics 72
(Source: K. Gieck, Technische Formelsammlung, 29th Edition, Gieck Verlag,
D-7100 Heilbronn)
71
Hydraulics
Hydrostatics
p
1
po )g h
1
For
k
density of the body applies:
>
k
the body floats
=
k
the body is suspended
<
k
the body sinks
Pressure distribution in a fluid
Linear pressure
P
2
p
1
)g (h
2
+h
1
) p
1
)g h
Hydrostatic force of pressure on planes
The hydrostatic force of pressure F is that force
which is exerted on the wall by the fluid only -
i.e. without consideration of pressure p
.
F g ys A cos p g hs A
y
D
mx
ysA
ys )
ms
ysA
; x
D
mxy
ysA
m, mm
Hydrostatic force of pressure on curved surfaces
The hydrostatic force of pressure on the curved sur-
face 1, 2 is resolved into a horizontal component F
H
and a vertical component F
V
.
F
V
is equal to the weight of the fluid having a volume
V located (a) or thought to be located (b) over the
surface 1, 2. The line of application runs through the
centre of gravity.
F
H
is equal to the hydrostatic force of pressure on the
projection of the considered surface 1, 2 on the plane
perpendicular to F
H
.
Fv g V (N, kN)
Buoyance
The buoyant force F
A
is equal to the weight of the dis-
placed fluids having densities and .
If the fluid with density is a gas, the following applies:
S = centre of gravity of plane A
D = centre of pressure
x
,
s
= moments of inertia
xy
= product of inertia of plane A referred to the x- and y-axes
in a heavy liquid
F
A
g V )g V ( N, kN )
F
A
g V ( N, kN )
}
72
Hydraulics
Hydrodynamics
v 2 g H
v: discharge velocity
g: gravity
: density
p
: excess pressure compared to external pressure

: coefficient of friction (for water = 0.97)
: coefficient of contraction ( = 0.62 for sharp-edged openings)
( = 0.97 for smooth-rounded openings)
F: force of reaction
b: width of opening
Discharge of liquids from vessels
V
.
r A 2 g H
Vessel with small lateral opening
v 2 g H
s 2 H h
(without any coefficient of friction)
V
.
r A 2 g H
F V
.
v
Vessel with wide lateral opening
V
.
2
3
r b 2 g (H
2
3 2
+H
1
3 2
)
Vessel with excess pressure on liquid level
Vessel with excess pressure on outlet
V
.
: volume flow rate
v 2 ( g H )
p
)
V
.
A 2 ( g H )
p
)
v 2
p
V
.
A 2
p
Vessel with bottom opening

73
Electrical Engineering Page
Basic Formulae 74
Speed, Power Rating and Efficiency of Electric Motors 75
Types of Construction and Mounting Arrangements of Rotating Electrical Machinery 76
Types of Protection for Electrical Equipment 77
(Protection Against Contact and Foreign Bodies)
Types of Protection for Electrical Equipment (Protection Against Water) 78
Explosion Protection of Electrical Switchgear 79
(Types of protection)
Explosion Protection of Electrical Switchgear 80
(Gases and vapours)
74
Basic Formulae
U R
U
R
R
U
36
0.83
4.84
13
6.7...10
43.5
58
22
14.5
9.35
1.04
61
7.4
18.2
16.5
8.3
30.0
48
36
18
2.0
2.32
15.9
3.33
0.92
2.32
5.0
7.7
1.85
0.046
0.015
0.014
0.0278
1.2
0.2066
0.0769
0.15..0.1
0.023
0.01724
0.045
0.069
0.107
0.962
0.0164
0.135
0.055
0.061
0.12
0.033
0.02083
0.02778
0.05556
0.50
0.43
0.063
0.30
1.09
0.43
0.20
0.13
0.54
22
65
70
a) Metals
Aluminium
Bismuth
Lead
Cadmium
Iron wire
Gold
Copper
Magnesium
Nickel
Platinum
Mercury
Silver
Tantalum
Tungsten
Zinc
Tin
b) Alloys
Aldrey (AlMgSi)
Bronze I
Bronze II
Bronze III
Constantan (WM 50)
Manganin
Brass
Nickel silver (WM 30)
Nickel chromium
Niccolite (WM 43)
Platinum rhodium
Steel wire (WM 13)
Woods metal
c) Other conductors
Graphite
Carbon, homog.
Retort graphite
R = resistance ()
l = length of conductor (m)
= electric conductivity (m/ mm
2
)
A = cross section of conductor (mm
2
)
= specific electrical resistance ( mm
2
)/m)
Ohms law:
Series connection of resistors:
R R
1
)R
2
)R
3
) ) Rn
R total resistance m
Rn individual resistance m
Shunt connection of resistors:
1
R
1
R
1
)
1
R
2
)
1
R
3
) )
1
Rn
R total resistance m
P U
Rn individual resistance m
Electric power:
P
U cos
P
U
P 1.73 U cos
P U cos
P
1.73 U cos
Power
Resistance of a conductor:
T
h
r
e
e
-
p
h
a
s
e

c
u
r
r
e
n
t
S
i
n
g
l
e
-
p
h
a
s
e
a
l
t
e
r
n
a
t
i
n
g

c
u
r
r
e
n
t
D
i
r
e
c
t

c
u
r
r
e
n
t
R
l
p A
l
A
Material
m
m mm
2
p
m mm
2
m
Current consumption
75
Speed, Power Rating and Efficiency
of Electric Motors
n
f 60
p
Speed: Power rating:
n = speed (min
-1
)
f = frequency (Hz)
p = number of pole pairs
Example:
Efficiency and power factor of a four-pole 1.1-kW motor and a 132-kW motor dependent
on the load
Example: f = 50 Hz, p = 2
n
50 60
2
1500 min
+1
Efficiency:
r
P
ab
Pzu
100 %
1)
Output power 1)
Direct current:
.
P
ab
= U
.

.

Single-phase alternating current:
P
ab
= U
.

.
cos
.
r
Three-phase current:
P
ab
= 1.73
.
U
.

.
cos
.
r
Power output P / P
N
1) P
ab
= mechanical output power on the motor shaft
P
zu
= absorbed electric power
Power factor cos Efficiency
132-kW motor
1.1-kW motor
76
Types of Construction and Mounting Arrangements
of Rotating Electrical Machinery
Types of construction and mounting arrangements of rotating electrical machinery
[Extract from DIN/IEC 34, Part 7 (4.83)]
Machines with end shields, horizontal arrangement
Design Explanation
Sym-
bol
Figure Bearings
Stator
(Housing)
Shaft
General
design
Design/Explanation
Fastening or
Installation
B3
2
end
shields
with
feet
free shaft
end
installation on
substructure
B5
2
end
shields
without
feet
free
shaft
end
mounting flange
close to bearing,
access from
housing side
flanged
B6
2
end
shields
with
feet
free
shaft
end
design B3, if
necessary end
shields turned
through -90
wall fastening, feet on
LH side when looking at
input side
B7
2
end
shields
with
feet
free
shaft
end
design B3, if
necessary end
shields turned
through 90
wall fastening, feet on
RH side when looking at
input side
B8
2
end
shields
with
feet
free
shaft
end
design B3, if
necessary end
shields turned
through 180
fastening on ceiling
B 35
2
end
shields
with
feet
free
shaft
end
mounting flange
close to bearing,
access from
housing side
installation on
substructure with
additional flange
Machines with end shields, vertical arrangement
Design Explanation
Sym-
bol
Figure Bearings
Stator
(Housing)
Shaft
General
design
Design/Explanation
Fastening or
Installation
V 1
2
end
shields
without
feet
free
shaft end
at the
bottom
mounting flange
close to bearing
on input side,
access from
housing side
flanged at the bottom
V 3
2
end
shields
without
feet
free
shaft end
at the top
mounting flange
close to bearing
on input side,
access from
housing side
flanged at the top
V 5
2
end
shields
with
feet
free
shaft end
at the
bottom
fastening to wall or
on substructure
V 6
2
end
shields
with
feet
free
shaft end
at the top
fastening to wall or
on substructure
77
Types of Protection for Electrical Equipment
(Protection Against Contact and Foreign Bodies)
1) For equipment with degrees of protection from 1 to 4, uniformly or non-uniformly shaped
foreign bodies with three dimensions perpendicular to each other and above the correspond-
ing diameter values are prevented from ingress.
2) For degrees of protection 3 and 4, the respective expert commission is responsible for the
application of this table for equipment with drain holes or cooling air slots.
3) For degree of protection 5, the respective expert commission is responsible for the applica-
tion of this table for equipment with drain holes.
Types of protection for electrical equipment
[Extract from DIN 40050 (7.80)]
Example of designation Type of protection DIN 40050 4
Designation
DIN number
Code letters
First type number
Second type number
An enclosure with this designation is protected against the ingress of solid foreign bodies
having a diameter above 1 mm and of splashing water.
Degrees of protection for protection against contact and foreign bodies
(first type number)
First type
number
Degree of protection
(Protection against contact and foreign bodies)
0 No special protection
1 Protection against the ingress of solid foreign bodies having a diameter above
50 mm (large foreign bodies) 1)
No protection against intended access, e.g. by hand, however, protection of
persons against contact with live parts
12 mm (medium-sized foreign bodies) 1)
Keeping away of fingers or similar objects
2.5 mm (small foreign bodies) 1) 2)
Keeping away tools, wires or similar objects having a thickness above 2.5 mm
1 mm (grain sized foreign bodies) 1) 2)
Keeping away tools, wires or similar objects having a thickness above 1 mm
5 Protection against harmful dust covers. The ingress of dust is not entirely
prevented, however, dust may not enter to such an amount that operation of the
equipment is impaired (dustproof). 3)
Complete protection against contact
6 Protection against the ingress of dust (dust-tight)
Complete protection against contact
4 IP
78
Types of Protection for Electrical Equipment
(Protection Against Water)
Types of protection for electrical equipment
[Extract from DIN 40050 (7.80)]
Example of designation Type of protection DIN 40050 4
Designation
DIN number
Code letters
First type number
Second type number
An enclosure with this designation is protected against the ingress of solid foreign bodies
having a diameter above 1 mm and of splashing water.
4 IP
2 Protection against dripping water falling vertically.
It may not have any harmful effect on equipment (enclosure) inclined by up to 15
relative to its normal position (diagonally falling dripping water).
Degrees of protection for protection against water (second type number)
Second type
number
Degree of protection
(Protection against water)
0 No special protection
1 Protection against dripping water falling vertically.
It may not have any harmful effect (dripping water).
3 Protection against water falling at any angle up to 60 relative to the perpendicular.
It may not have any harmful effect (spraying water).
7 Protection against water if the equipment (enclosure) is immersed under deter-
mined pressure and time conditions.
No harmful quantities of water may enter the equipment (enclosure) (immersion).
1) This degree of protection is normally for air-tight enclosed equipment. For certain equipment,
however, water may enter provided that it has no harmful effect.
8 The equipment (enclosure) is suitable for permanent submersion under condi-
tions to be described by the manufacturer (submersion). 1)
4 Protection against water spraying on the equipment (enclosure) from all
directions.
It may not have any harmful effect (splashing water).
5 Protection against a water jet from a nozzle which is directed on the equipment
(enclosure) from all directions.
It may not have any harmful effect (hose-directed water).
6 Protection against heavy sea or strong water jet.
No harmful quantities of water may enter the equipment (enclosure) (flooding).
79
Explosion Protection of Electrical Switchgear
Explosion protection of electrical switchgear
Example of designation / Type of protection [Extract from DIN EN 50014 ... 50020]
Example of designation Ex EEx
Symbol for equipment certified
by an EC testing authority
Symbol for equipment made
according to European Standards
II B d
Intrinsic
safety
T 3
Type of protection
Explosion group
Temperature class
Types of protection
Type of
protection
Symbol Scheme Application
Flameproof
enclosure
d
Gap-s
Heavy-current engineering
(commutator) motors,
transformers, switchgear,
lighting fittings, and other
spark generating parts
Pressurized
enclosure
p Especially for large apparata,
switchgears, motors, genera-
tors
Oil-immersion
enclosure
o Switchgears, transformers
q
Potentially explosive atmosphere
Low-voltage engineering:
measuring and control
devices (electrical
equipment and circuits)
Squirrel-cage motors,
terminal and junction boxes,
lighting fittings, current
transformers, measuring and
control devices
Capacitors
Increased
safety
i
e
Sand-filled
enclosure
80
Explosion Protection of Electrical Switchgear
Explosion protection of electrical switchgear
Designation of electrical equipment / Classification of areas acc. to gases and vapours
[Extract from DIN EN 50014 ... 50020]
Zone 2
Areas where potentially ex-
plosive atmospheres are ex-
pected to occur only rarely
and then only for short pe-
riods.

Designation of electrical equipment
Designation acc. to VDE 0170/0171/2.61 EN 50014 ... 50020
Firedamp protection Sch EEx..I
Explosion protection Ex EEx..II
Classification according to
gases and vapours
Explosion class Explosion group
For flame
proof
enclosures:
maximum
width of gap
For intrinsically
safe circuits: mi-
nimum ignition
current ratio re-
ferred to me-
thane
1)
> 0.9 mm
0.5 - 0.9mm
< 0.5 mm
> 0.8 mm
0.45 - 0.8mm
< 0.45 mm
1
2
3a ... 3n
A
B
C
Ignition temperature of gases
and vapours in C
1) For definition, see
EN 50014, Annex A
Ignition group
Ignition
temperature
Permissible
limiting tem-
perature
C
G1> 450
G2> 300...450
G3> 200...300
G4> 135...200
G5 from 100...135
C
360
240
160
110
80
Temperature class
Ignition
temperature
C
T1 > 450
T2 > 300
T3 > 200
T4 > 135
T5 > 100
T6 > 85
C
450
300
200
135
100
85
Zone 0
Areas with permanent or
long-term potentially explo-
sive atmospheres.
Classification of areas according to gases and vapours
Zone 1
Areas where potentially ex-
plosive atmospheres are ex-
pected to occur occasio-
nally.
(n) additionally
ZONE Safe area
Potentially
explosive
atmosphere
Existing explos.
atmosphere
permanent or
long-term
probably during
normal operation
(occasionally)
rarely and at
short terms
practically
never
Ignition sources
Maximum
surface
temperature
81
Materials Page
Conversion of Fatigue Strength Values of Miscellaneous Materials 82
Mechanical Properties of Quenched and Tempered Steels 83
Fatigue Strength Diagrams of Quenched and Tempered Steels 84
General-Purpose Structural Steels 85
Fatigue Strength Diagrams of General-Purpose Structural Steels 86
Case Hardening Steels 87
Fatigue Strength Diagrams of Case Hardening Steels 88
Cold Rolled Steel Strips for Springs 89
Cast Steels for General Engineering Purposes 89
Round Steel Wire for Springs 90
Lamellar Graphite Cast Iron 91
Nodular Graphite Cast Iron 91
Copper-Tin- and Copper-Zinc-Tin Casting Alloys 92
Copper-Aluminium Casting Alloys 92
Aluminium Casting Alloys 93
Lead and Tin Casting Alloys for Babbit Sleeve Bearings 94
Comparison of Tensile Strength and Miscellaneous Hardness Values 95
Values of Solids and Liquids 96
Coefficient of Linear Expansion 97
Iron-Carbon Diagram 97
Fatigue Strength Values for Gear Materials 97
Heat Treatment During Case Hardening of Case Hardening Steels 98
82
Materials
Conversion of Fatigue Strength Values
of Miscellaneous Materials
Conversion of fatigue strength values of miscellaneous materials
Material
Tension
3)
Bending
1)
Torsion
1)
Material
Sch
bW
bSch
bF
tW
tSch
F
Structural
steel
0.45 R
m
1.3
W
0.49 R
m
1.5
bW
1.5 R
e
0.35 R
m
1.1
tW
0.7 R
e
Quenched
and temper-
ed steel
0.41 R
m
1.7
W
0.44 R
m
1.7
bW
1.4 R
e
0.30 R
m
1.6
tW
0.7 R
e
Case harden-
ing steel
2)
0.40 R
m
1.6
W
0.41 R
m
1.7
bW
1.4 R
e
0.30 R
m
1.4
tW
0.7 R
e
Grey cast iron 0.25 R
m
1.6 W 0.37 R
m
1.8
bW
0.36 R
m
1.6
tW
Light metal 0.30 R

m
0.40 R
m
0.25 R
m

1) For polished round section test piece of about 10 mm diameter.
2) Case-hardened; determined on round section test piece of about 30 mm diameter. R
m
and R
e
of
core material.
3) For compression,
Sch
is larger, e.g. for spring steel
dSch
1.3
Sch
For grey cast iron
dSch
3
.

Sch
Ultimate stress values Type of load
R
m
Tensile strength Tension
R
e
Yield point Tension
W
Tension
Sch
Tension
bW
Bending
bSch
Bending
bF
Yield point Bending
tW
Torsion
tSch
Torsion
tF
Yield point Torsion
83
Materials
Mechanical Properties of
Quenched and Tempered Steels
Quenched and tempered steels [Extract from DIN 17200 (3.87)]
Mechanical properties of steels in quenched and tempered condition (Code letter V)
Diameter
Steel grade
up to 16 mm
above 16
up to 40 mm
above 40
up to 100 mm
above 100
up to 160 mm
above 160
up to 250 mm
Symbol
Mate-
rial
no.
Yield
point
(0.2
Gr)
N/mm
2
min.
Re,
Rp 0.2
Tensile
strength
N/mm
2
Rm
Yield
point
(0.2
Gr)
N/mm
2
min.
Re,
Rp 0.2
Tensile
strength
N/mm
2
Rm
Yield
point
(0.2
Gr)
N/mm
2
min.
Re,
Rp 0.2
Tensile
strength
N/mm
2
Rm
Yield
point
(0.2
Gr)
N/mm
2
min.
Re,
Rp 0.2
Tensile
strength
N/mm
2
Rm
Yield
point
(0.2
Gr)
N/mm
2
min.
Re,
Rp 0.2
Tensile
strength
N/mm
2
Rm
C 22
C 35
C 45
C 55
C 60
1.0402
1.0501
1.0503
1.0535
1.0601
350
430
500
550
580
550 700
630 780
700 850
800 950
8501000
300
370
430
500
520
500 650
600 750
650 800
750 900
800 950
320
370
430
450
550 700
630 780
700 850
750 900
Ck 22
Ck 35
Cm 35
Ck 45
Cm 45
Ck 55
Cm 55
Ck 60
Cm 60
1.1151
1.1181
1.1180
1.1191
1.1201
1.1203
1.1209
1.1221
1.1223
350
430
430
500
500
550
550
580
580
550 700
630 780
630 780
700 850
700 850
800 950
800 950
8501000
8501000
300
370
370
430
430
500
500
520
520
500 650
600 750
600 750
650 800
650 800
750 900
750 900
800 950
800 950
320
320
370
370
430
430
450
450
550 700
550 700
630 780
630 780
700 850
700 850
750 900
750 900
28 Mn 6 1.1170 590 780 930 490 690 840 440 640 790
38 Cr 2
46 Cr 2
34 Cr 4
34 Cr S4
37 Cr 4
37 Cr S4
41 Cr 4
41 Cr S4
1.7003
1.7006
1.7033
1.7037
1.7034
1.7038
1.7035
1.7039
550
650
700
700
750
750
800
800
800 950
9001100
9001100
9001100
9501150
9501150
10001200
10001200
450
550
590
590
630
630
660
660
700 850
800 950
800 950
800 950
8501000
8501000
9001100
9001100
350
400
460
460
510
510
560
560
600 750
650 800
700 850
700 850
750 900
750 900
800 950
800 950
25 CrMo 4
34 CrMo 4
34 CrMo S4
42 CrMo 4
42 CrMo S4
50 CrMo 4
1.7218
1.7220
1.7226
1.7225
1.7227
1.7228
700
800
800
900
900
900
9001100
10001200
10001200
11001300
11001300
11001300
600
650
650
750
750
780
800 950
9001100
9001100
10001200
10001200
10001200
450
550
550
650
650
700
700 850
800 950
800 950
9001100
9001100
9001100
400
500
500
550
550
650
650 800
750 900
750 900
800 950
800 950
8501000
450
450
500
500
550
700 850
700 850
750 900
750 900
800 950
36 CrNiMo 4
34 CrNiMo 6
30 CrNiMo 6
1.6511
1.6582
1.6580
900
1000
1050
11001300
12001400
12501450
800
900
1050
10001200
11001300
12501450
700
800
900
9001100
10001200
11001300
600
700
800
800 950
9001100
10001200
550
600
700
750 900
800 950
9001100
50 CrV 4
30 CrMoV9
1.8159
1.7707
900
1050
11001300
12501450
800
1020
10001200
12001450
700
900
9001100
11001300
650
800
8501000
10001200
600
700
800 950
9001100
84
Materials
Fatigue Strength Diagrams of
Quenched and Tempered Steels
Fatigue strength diagrams of quenched and tempered steels, DIN 17200
(in quenched and tempered condition, test piece diameter d = 10 mm)
Quenched and tempered steels not
illustrated may be used as follows:
34 CrNiMo 6 like 30 CrNiMo 8
30 CrMoV 4 like 30 CrNiMo 8
42 CrMo 4 like 50 CrMo 4
36 CrNiMo 4 like 50 CrMo 4
50 CrV 4 like 50 CrMo 4
34 CrMo 4 like 41 Cr 4
28 Cr 4 like 46 Cr 2
C 45 like Ck 45
C 22 like Ck 22
C 60 and C 50 lie approximately
between Ck 45 and 46 Cr 2.
C 40, 32 Cr 2, C 35 , C 30 and
C 25 lie approximately between
Ck 22 and Ck 45.
a) Tension/compression fatigue strength
b) Bending fatigue strength
c) Torsional fatigue strength
Loading type I: static
Loading type II: dynamic
Loading type III: alternating
T
o

b
e

a
g
r
e
e
d

u
p
o
n
T
o

b
e

a
g
r
e
e
d

u
p
o
n
85
Materials
General-Purpose Structural Steels
General-purpose structural steels [Extract from DIN 17100 (1.80)]
Steel grade
Treat-
ment
condi
Similar steel
grades
Tensile strength R
m
in N/mm
2
for product
Upper yield point R
eH
in N/mm
2
(minimum) for product thickness in
Mate
condi-
tion
grades
EURON. 25
in N/mm for roduct
thickness in mm
(minimum) for roduct thickness in
mm
Symbol
Mate-
rial no. 1)
<3
3
100
>100 16
>16
40
>40
63
>63
80
>80
100
>100
St 33 1.0035 U, N Fe 310-0
310...
540
290 185
175
2)

St 37-2
U St 37-2
1.0037
1.0036
U, N
U, N
Fe 360-BFU
360 340
235 225 215 205 195
R St 37-2
St 37-3
1.0038
1.0116
U, N,
U
N
Fe 360-BFN
Fe 360-C
Fe 360-D
360...
510
340...
470
235 225 215 215 215
St 44-2
St 44-3
St 44-3
1.0044
1.0144
U, N
U
N
Fe 430-B
Fe 430-C
Fe 430-D
430...
580
410...
540
275 265 255 245 235
St 52-3 1.0570
U
N
Fe 510-C
Fe 510-D
510...
680
490...
630
355 345 335 325 315
St 50-2 1.0050 U, N Fe 490-2
490...
660
470...
610
295 285 275 265 255
St 60-2 1.0060 U, N Fe 590-2
590...
770
570...
710
335 325 315 305 295
St 70-2 1.0070 U, N Fe 690-2
690...
900
670...
830
365 355 345 335 325
1) N normalized; U hot-rolled, untreated
2) This value applies to thicknesses up to 25 mm only
86
Materials
General-Purpose Structural Steels
Fatigue strength diagrams of general-purpose structural steels, DIN 17100
(test piece diameter d = 10 mm)
F
o
r

d
e
t
a
i
l
s
,

s
e
e

D
I
N

1
7
2
1
0
T
r
e
a
t
m
e
n
t
c
o
n
d
i
t
i
o
n

1
)
87
Materials
Case Hardening Steels
Case hardening steels; Quality specifications to DIN 17210 (12.69)
from SI tables (2.1974) of VDEh
Steel grade For dia. 11 For dia. 30 For dia. 63
Symbol
Material
no.
Yield
point
R
e
N/mm
2
min.
Tensile
strength
R
m
N/mm
2
Yield
point
R
e
N/mm
2
min.
Tensile
strength
R
m
N/mm
2
Yield
point
R
e
N/mm
2
min.
Tensile
strength
R
m
N/mm
2
C 10
Ck 10
1.0301
1.1121
390
390
640 790
640 790
295
295
490 640
490 640
C 15
Ck 15
Cm 15
1.0401
1.1141
1.1140
440
440
440
740 890
740 890
740 890
355
355
355
590 790
590 790
590 790
15 Cr 13 1.7015 510 7801030 440 690 890

16 MnCr 5
16 MnCrS 5
20 MnCr 5
20 MnCrS5
1.7131
1.7139
1.7147
1.7149
635
635
735
735
8801180
8801180
10801380
10801380
590
590
685
685
7801080
7801080
9801280
9801280
440
440
540
540
640 940
640 940
7801080
7801080
20 MoCr 4
20 MoCrS 4
25 MoCrS4
25 MoCrS 4
1.7321
1.7323
1.7325
1.7326
635
635
735
735
8801180
8801180
10801380
10801380
590
590
685
685
7801080
7801080
9801280
9801280
15 CrNi 6
18 CrNi 8
1.5919
1.5920
685
835
9601280
12301480
635
785
8801180
11801430
540
685
7801080
10801330
17 CrNiMo 6 1.6587 835 11801430 785 10801330 685 9801280
1) Dependent on treatment, the Brinell hardness is different.
Treatment condition Meaning
C treated for shearing load
G soft annealed
BF treated for strength
BG treated for ferrite/pearlite structure
88
Materials
Case Hardening Steels
Fatigue strength diagrams of case hardening steels, DIN 17210
(Core strength after case hardening, test piece diameter d = 10 mm)
Case hardening steels not illustrated
may be used as follows:
25 MoCr 4 like 20 MnCr 5
17 CrNiMo 6 like 18 CrNi 8
89
Materials
Cold Rolled Steel Strips for Springs
Cast Steels for General Engineering Purposes
Cold rolled steel strips for springs [Extract from DIN 17222 (8.79)]
Steel grade
Comparable grade
Degree of
Tensile strength R
m
Symbol
Material
no.
Com arable grade
acc. to
EURONORM 132
Degree of
conformity
1)
Tensile strength R
m
2)
N/mm
2
maximum
C 55
Ck 55
1.0535
1.1203
1 CS 55
2 CS 55
F
F
610
C 60
Ck 60
1.0601
1.1221
1 CS 60
2 CS 60
F
F
620
C 67
Ck 67
1.0603
1.1231
1 CS 67
2 CS 67
F
F
640
C 75
CK75
1.0605
1.1248
1 CS 75
2 CS 75
F
F
640
Ck 85
CK 101
1.1269
1.1274
2 CS 85
CS 100
F
F
670
690
55 Si 7 1.0904 740
71 Si 7 1.5029 800
67 SiCr 5 1.7103 67 SiCr 5 f 800
50 CrV 4 1.8159 50 CrV 4 F 740
1) F = minor deviations
f = substantial deviations
2) R
m
for cold rolled and soft-annealed condition; for strip thicknesses up to 3 mm
Cast steels for general engineering purposes [Extract from DIN 1681 (6.85)]
Cast steel grade Yield point
R
e
R
p 0 2
Tensile strength
R
m
Notched bar impact work
(ISO-V-notch specimens)
A
v
R
e,
R
p

0.2
R
m
30 mm > 30 mm
Symbol
Material
no.
N/mm
2
min.
N/mm
2
min.
Mean value
1)
J
min.
GS-38 1.0420 200 380 35 35
GS-45 1.0446 230 450 27 27
GS-52 1.0552 260 520 27 22
GS-60 1.0558 300 600 27 20
The mechanical properties apply to specimens which are taken from test pieces with thicknesses up
to 100 mm. Furthermore, the yield point values also apply to the casting itself, in so far as the wall
thickness is 100 mm.
1) Determined from three individual values each.
90
Materials
Round Steel Wire for Springs
Round steel wire for springs [Extract from DIN 17223, Part 1 (12.84)]
Grade of wire A B C D
Diameter of wire
mm
Tensile strength R
m
in N/mm
2
0.07 28003100
0.3 23702650 26602940
1 17201970 19802220 22302470
2 15201750 17601970 19802200 19802200
3 14101620 16301830 18402040 18402040
4 13201520 15301730 17401930 17401930
5 12601450 14601650 16601840 16601840
6 12101390 14001580 15901770 15901770
7 11601340 13501530 15401710 15401710
8 11201300 13101480 14901660 14901660
9 10901260 12701440 14501610 14501610
10 10601230 12401400 14101570 14101570
11 12101370 13801530 13801530
12 11801340 13501500 13501500
13 11601310 13201470 13201470
14 11301280 12901440 12901440
15 11101260 12701410 12701410
16 10901230 12401390 12401390
17 10701210 12201360 12201360
18 10501190 12001340 12001340
19 10301170 11801320 11801320
20 10201150 11601300 11601300
91
Materials
Lamellar Graphite Cast Iron
Nodular Graphite Cast Iron
Lamellar graphite cast iron [Extract from DIN 1691 (5.85)]
Grade
Material
Wall thicknesses
in mm
Tensile
strength
1)
R
m
Brinell
hardness
1)
Compres-
sive
strength
2)
dB
Symbol Number above up to N/mm
2
HB 30 N/mm
2
GG-10 0.6010 5 40 min. 100
2)

GG-15 0.6015
10
20
40
80
20
40
80
150
130
110
95
80
225
205
600
GG-20 0.6020
10
20
40
80
20
40
80
150
180
155
130
115
250
235
720
GG-25 0.6025
10
20
40
80
20
40
80
150
225
195
170
155
265
250
840
GG-30 0.6030
10
20
40
80
20
40
80
150
270
240
210
195
285
265
960
GG-35 0.6035
10
20
40
80
20
40
80
150
315
280
250
225
285
275
1080
The values apply to castings which are made in sand moulds or moulds with comparable heat
diffusibility.
1) These values are reference values.
2) Values in the separately cast test piece with 30 mm diameter of the unfinished casting.
Nodular graphite cast iron [Extract from DIN 1693, Part 2 (10.77)]
Properties in cast-on test pieces
Grade
Material
Wall thickness
of casting
Thickness
of cast-on
test piece
Tensile
strength
R
m
0.2%
proof stress
Rp
0.2
Symbol Number mm mm mm N/mm
2
N/mm
2
GGG-40.3 0.7043
from 30
above 60
up to 60
up to 200
40
70
390
370
250
240
GGG-40 0.7040
from 30
above 60
up to 60
up to 200
40
70
390
370
250
240
GGG-50 0.7050
from 30
above 60
up to 60
up to 200
40
70
450
420
300
290
GGG-60 0.7060
from 30
above 60
up to 60
up to 200
40
70
600
550
360
340
GGG-70 0.7070
from 30
above 60
up to 60
up to 200
40
70
700
650
400
380
92
Materials
Copper-Tin- and Copper-Zinc-Tin Casting Alloys
Copper-Aluminium Casting Alloys
Copper-tin- and copper-zinc-tin casting alloys [Extract from DIN 1705 (11.81)]
Material Condition on delivery
0.2%
proof stress 1)
R
p0.2
Tensile strength
1)
R
m
Symbol Number min. in N/mm
2
min. in N/mm
2
G-CuSn 12
GZ-CuSn 12
GC-CuSn12
2.1052.01
2.1052.03
2.1052.04
Sand-mould cast iron
Centrifugally cast iron
Continuously cast iron
140
150
140
260
280
280
G-CuSn 12 Ni
GZ-CuSn 12 Ni
GC-CuSn 12 Ni
2.1060.01
2.1060.03
2.1060.04
160
180
170
280
300
300
G-CuSn 12 Pb
GZ-CuSn 12 Pb
GC-CuSn 12 Pb
2.1061.01
2.1061.03
2.1061.04
140
150
140
260
280
280
G-CuSn 10 2.1050.01 Sand-mould cast iron 130 270
G-CuSn 10 Zn 2,1086.01 Sand-mould cast iron 130 260
G-CuSn 7 ZnPb
GZ-CuSn 7 ZnPb
GC-CuSn 7 ZnPb
2.1090.01
2.1090.03
2.1090.04
120
130
120
240
270
270
G-CuSn 6 ZnNi 2.1093.01 Sand-mould cast iron 140 270
G-CuSn 5 ZnPb 2.1096.01 Sand-mould cast iron 90 220
G-CuSn 2 ZnPb 2.1098.01 Sand-mould cast iron 90 210
1) Material properties in the test bar
Copper-aluminium casting alloys [Extract from DIN 1714 (11.81)]
Material
Condition on delivery
0.2%
proof stress 1)
R
p0.2
Tensile strength
1)
R
m
Symbol Number min. in N/mm
2
min. in N/mm
2
G-CuAl 10 Fe
GK-CuAl 10 Fe
GZ-CuAl 10 Fe
2.0940.01
2.0940.02
2.0940.03
Chilled casting
180
200
200
500
550
550
G-CuAl 9 Ni
GK-CuAl 9 Ni
GZ-CuAl 9 Ni
2.0970.01
2.0970.02
2.0970.03
Chilled casting
200
230
250
500
530
600
G-CuAl 10 Ni
GK-CuAl 10 Ni
GZ-CuAl 10 Ni
GC-CuAl 10 Ni
2.0975.01
2.0975.02
2.0975.03
2.0975.04
Chilled casting
270
300
300
300
600
600
700
700
G-CuAl 11 Ni
GK-CuAl 11 Ni
GZ-CuAl 11 Ni
2.0980.01
2.0980.02
2.0980.03
Chilled casting
320
400
400
680
680
750
G-CuAl 8 Mn
GK-CuAl 8 Mn
2.0962.01
2.0962.02
Chilled casting
180
200
440
450
93
Materials
Aluminium Casting Alloys
Aluminium casting alloys [Extract from DIN 1725 (2.86)]
Material Casting method and
condition on delivery
0.2 proof stress
R
p0.2
Tensile strength
R
m
Symbol Number in N/mm
2
in N/mm
2
G-AlSi 12 3.2581.01
as cast
70 up to 100 150 up to 200
G-AlSi 12 g 3.2581.44
annealed and quenched
70 up to 100 150 up to 200
GK-AlSi 12 3.2581.02
Chilled casting
as cast
80 up to 110 170 up to 230
GK-AlSi 12 g 3.2581.45
Chilled casting
annealed and quenched
80 up to 110 170 up to 230
G-AlSi 10 Mg 3.2381.01
as cast
80 up to 110 160 up to 210
G-AlSi 10 Mg wa 3.2381.61
temper-hardened
180 up to 260 220 up to 320
GK-AlSi 10 Mg 3.2381.02
Chilled casting
as cast
90 up to 120 180 up to 240
GK-AlSi 10 Mg
wa
3.2381.62
Chilled casting
temper-hardened
210 up to 280 240 up to 320
G-AlSi 11 3.2211.01
as cast
70 up to 100 150 up to 200
G-AlSi 11 g 3.2211.81 annealed 70 up to 100 150 up to 200
GK-AlSi 11 3.2211.02
Chilled casting
as cast
80 up to 110 170 up to 230
GK-AlSi 11g 3.2211.82 annealed 80 up to 110 170 up to 230
G-AlSi 7 Mg wa 3.2371.61
temper-hardened
190 up to 240 230 up to 310
GK-AlSi 7 Mg wa 3.2371.62
Chilled casting
temper-hardened
200 up to 280 250 up to 340
GF-AlSi 7 Mg wa 3.2371.63
High-quality casting
temper-hardened
200 up to 260 260 up to 320
G-AlMg 3 Si 3.3241.01
as cast
80 up to 100 140 up to 190
G-AlMg 3 Si wa 3.3241.61
temper-hardened
120 up to 160 200 up to 280
GK-AlMg 3 Si 3.3241.02
Chilled casting
as cast
80 up to 100 150 up to 200
GK-AlMg 3 Si wa 3.3241.62
Chilled casting
temper-hardened
120 up to 180 220 up to 300
GF-AlMg 3 Si wa 3.3241.63
Chilled casting
temper-hardened
120 up to 160 200 up to 280
94
Materials
Lead and Tin Casting Alloys for Babbit Sleeve Bearings
Lead and tin casting alloys for babbit sleeve bearings [Extract from DIN ISO 4381 (10.82)]
Grade
Material
Brinell hardness
1)
HB 10/250/180
0.2% proof stress
1)
R
p

0.2
in N/mm
2
Symbol Number 20 C 50 C 120 C 20 C 50 C 100 C
PbSb 15 SnAs 2.3390 18 15 14 39 37 25
PbSb 15 Sn 10 2.3391 21 16 14 43 32 30
PbSb 14 Sn 9 CuAs 2.3392 22 22 16 46 39 27
PbSb 10 Sn 6 2.3393 16 16 14 39 32 27
SnSb 12 Cu 6 Pb 2.3790 25 20 12 61 60 36
SnSb 8 Cu 4 2.3791 22 17 11 47 44 27
SnSb 8 Cu 4 Cd 2.3792 28 25 19 62 44 30
95
Materials
Comparison of Tensile Strength and
Miscellaneous Hardness Values
Tensile
strength
Vickers
hard-
ness
Brinell
hardness 2)
Rockwell
hardness
Tensile
strength
Vickers
hard-
ness
Brinell
hardness 2)
Rockwell
hardness
N/mm
2
(F>98N)
0.102 +
F
D
2
)30
N
mm
2
HRB HRC HRA
HRD
1)
N/mm
2
(F>98N)
0.102 +
F
D
2
)30
N
mm
2
HRC HRA
HRD
1)
255
270
285
305
320
80
85
90
95
100
76.0
80.7
85.5
90.2
95.0
41.0
48.0
52.0
56.2
1155
1190
1220
1255
1290
360
370
380
390
400
342
352
361
371
380
36.6
37.7
38.8
39.8
40.8
68.7
69.2
69.8
70.3
70.8
52.8
53.6
54.4
55.3
56.0
335
350
370
385
400
105
110
115
120
125
99.8
105
109
114
119
62.3
66.7
1320
1350
1385
1420
1455
410
420
430
440
450
390
399
409
418
428
41.8
42.7
43.6
44.5
45.3
71.4
71.8
72.3
72.8
73.3
56.8
57.5
58.2
58.8
59.4
415
430
450
465
480
130
135
140
145
150
124
128
133
138
143
71.2
75.0
78.7
1485
1520
1555
1595
1630
460
470
480
490
500
437
447
(456)
(466)
(475)
46.1
46.9
47.7
48.4
49.1
73.6
74.1
74.5
74.9
75.3
60.1
60.7
61.3
61.6
62.2
495
510
530
545
560
155
160
165
170
175
147
152
156
162
166
81.7
85.0
1665
1700
1740
1775
1810
510
520
530
540
550
(485)
(494)
(504)
(513)
(523)
49.8
50.5
51.1
51.7
52.3
75.7
76.1
76.4
76.7
77.0
62.9
63.5
63.9
64.5
64.8
575
595
610
625
640
180
185
190
195
200
171
176
181
185
190
87.1
89.5
91.5
1845
1880
1920
1955
1995
560
570
580
590
600
(532)
(542)
(551)
(561)
(570)
53.0
53.6
54.1
54.7
55.2
77.4
77.8
78.0
78.4
78.6
65.4
65.8
66.2
66.7
67.0
660
675
690
705
720
205
210
215
220
225
195
199
204
209
214
92.5
93.5
94.0
95.0
96.0
2030
2070
2105
2145
2180
610
620
630
640
650
(580)
(589)
(599)
(608)
(618)
55.7
56.3
56.8
57.3
57.8
78.9
79.2
79.5
79.8
80.0
67.5
67.9
68.3
68.7
69.0
740
755
770
785
800
230
235
240
245
250
219
223
228
233
238
96.7
98.1
99.5
20.3
21.3
22.2
60.7
61.2
61.6
40.3
41.1
41.7
660
670
680
690
700
58.3
58.8
59.2
59.7
60.1
80.3
80.6
80.8
81.1
81.3
69.4
69.8
70.1
70.5
70.8
820
835
850
865
880
255
260
265
270
275
242
247
252
257
261
(101)
(102)
23.1
24.0
24.8
25.6
26.4
62.0
62.4
62.7
63.1
63.5
42.2
43.1
43.7
44.3
44.9
720
740
760
780
800
61.0
61.8
62.5
63.3
64.0
81.8
82.2
82.6
83.0
83.4
71.5
72.1
72.6
73.3
73.8
900
915
930
950
965
280
285
290
295
300
266
271
276
280
285
(104)
(105)
27.1
27.8
28.5
29.2
29.8
63.8
64.2
64.5
64.8
65.2
45.3
46.0
46.5
47.1
47.5
820
840
860
880
900
64.7
65.3
65.9
66.4
67.0
83.8
84.1
84.4
84.7
85.0
74.3
74.8
75.3
75.7
76.1
995
1030
1060
1095
1125
310
320
330
340
350
295
304
314
323
333
31.0
32.3
33.3
34.4
35.5
65.8
66.4
67.0
67.6
68.1
48.4
49.4
50.2
51.1
51.9
920
940
67.5
68.0
85.3
85.6
76.5
76.9
The figures in brackets are hardness values outside the domain of definition of standard hardness test
methods which, however, in practice are frequently used as approximate values. Furthermore, the Brinell
hardness values in brackets apply only if the test was carried out with a carbide ball.
1) Internationally usual, e.g. ASTM E 18-74 (American Society for Testing and Materials)
2) Calculated from HB = 0.95 HV (Vickers hardness)
Determination of Rockwell hardness HRA, HRB, HRC, and HRD acc. to DIN 50103 Part 1 and 2
Determination of Vickers hardness acc. to DIN 50133 Part 1
Determination of Brinell hardness acc. to DIN 50351
Determination of tensile strength acc. to DIN 50145
96
Materials
Values of Solids and Liquids
Values of solids and liquids Mean density of the earth = 5.517 g/cm
3
Substance (solid)
Sym-
bol
Density
p
Melting
point
Thermal
conductivity
at 20 C
Substance (solid)
Sym-
bol
Density
p
Melting
point
Thermal
conducti-
vity
at 20 C bol
g/cm
3
t in C W/(mK)
bol
g/cm
3
t in C W/(mK)
Agate 2.5...2.8 1600 11.20 Porcelain 2.2...2.5 1650 1
Aluminium Al 2.7 658 204 Pyranite 3.3 1800 8.14
Aluminium bronze 7.7 1040 128 Quartz-flint 2.5...2.8 1480 9.89
Antimony Sb 6.67 630 22.5 Radium Ra 5 700
Arsenic As 5.72 Rhenium Re 21 3175 71
Asbestos 2.5 1300 Rhodium Rh 12.3 1960 88
Asphaltum 1.1...1.5 80...100 0.698 Gunmetal (CuSn5ZnPb) 8.8 950 38
Barium Ba 3.59 704 Rubidium Rb 1.52 39 58
Barium chloride 3.1 960 Ruthenium Ru 12.2 2300 106
Basalt, natural 2.7...3.2 1.67 Sand, dry 1.4...1.6 1480 0.58
Beryllium Be 1.85 1280 1.65 Sandstone 2.1...2.5 1500 2.3
Concrete 2 1 Brick, fire 1.8...2.3 2000 1.2
Lead Pb 11.3 327.4 34.7 Slate 2.6...2.7 2000 0.5
Boron (amorph.) B 1.73 2300 Emery 4 2200 11.6
Borax 1.72 740 Sulphur, rhombic S 2.07 112.8 0.27
Limonite 3.4...3.9 1565 Sulphur, monoclinic S 1.96 119 0.13
Bronze (CuSn6) 8.83 910 64 Barytes 4.5 1580
Chlorine calcium 2.2 774 Selenium, red Se 4.4 220 0.2
Chromium Cr 7.1 1800 69 Silver Ag 10.5 960 407
Chromium nickel (NiCr 8020) 7.4 1430 52.335 Silicon Si 2.33 1420 83
Delta metal 8.6 950 104.7 Silicon carbide 3.12 15.2
Diamond C 3.5 Sillimanite 2.4 1816 1.69
Iron, pure Fe 7.86 1530 81 Soapstone (talcous) 2.7 3.26
Grease 0.92...0.94 30...175 0.209 Steel, plain + low-alloy 7.9 1460 47...58
Gallium Ga 5.9 29.75 stainless 18Cr8Ni 7.9 1450 14
Germanium Ge 5.32 936 58.615 non-magnetic 15Ni7Mn 8 1450 16.28
Gypsum 2.3 1200 0.45 Tungsten steel 18W 8.7 1450 26
Glass, window 2.5 700 0.81 Steanit 2.6...2.7 1520 1.63
Mica 2.8 1300 0.35 Hard coal 1.35 0.24
Gold Au 19.29 1063 310 Strontium Sr 2.54 797 0.23
Granite 2.6...2.8 3.5 Tantalum Ta 16.6 2990 54
Graphite C 2.24 3800 168 Tellurium Te 6.25 455 4.9
Grey cast iron 7.25 1200 58 Thorium Th 11.7 1800 38
Laminated fabric 1.3...1.42 0.34...0.35 Titanium Ti 4.5 1670 15.5
Hard rubber 1.4 0.17 Tombac 8.65 1000 159
Hard metal K20 14.8 2000 81 Uranium 99.99% 1.8...2.6 1500..1700 0.93...1.28
Woods 0.45...0.85 0.12...0.17 Uranium 99.99% U 18.7 1133 28
Indium In 7.31 156 24 Vanadium V 6.1 1890 31.4
Iridium Ir 22.5 2450 59.3 Soft rubber 1...1.8 0.14...0.23
Cadmium Cd 8.64 321 92.1 White metal 7.5...10.1 300...400 34.9...69.8
Potassium K 0.86 63.6 110 Bismuth Bi 9.8 271 8.1
Limestone 2.6 2.2 Wolfram W 19.2 3410 130
Calcium Ca 1.55 850 Cesium Cs 1.87 29
Calcium oxide (lime) 3.4 2572 Cement, hard 2...2.2 0.9...1.2
Caoutchouc, crude 0.95 125 0.2 Cerium Ce 6.79 630
Cobalt Co 8.8 1490 69.4 Zinc Zn 6.86 419 110
Salt, common 2.15 802 Tin Sn 7.2 232 65
Coke 1.6...1.9 0.184 Zirconium Zr 6.5 1850 22
Constantan 8.89 1600 23.3
Corundum (AL2O3) 3.9...4 2050 12...23
Chalk 1.8...2.6 0.92
Boiling Thermal
Copper Cu 8.9 1083 384 Density
Boiling
point
Thermal
conducti-
Leather, dry 0.9....1 0.15
Substance (liquid) Sym-
Density
p
oint
at
MP
conducti-
vity
C Lithium Li 0.53 179 71
Substance (liquid) Sym-
bol
p at
1.013MPa
vity
at 20 C
Magnesium Mg 1.74 657 157
bol
g/cm
3 at
C
C W/(mK)
Magnesium, alloyed 1.8...1.83 650 69.8..145.4 Ether 0.72 20 35 0.14
Manganese Mn 7.43 1250 30 Benzine 0.73 15 25...210 0.13
Marble 2.6...2.8 1290 2.8 Benzole, pure 0.83 15 80 0.14
Red lead oxide 8.6...9.1 0.7 Diesel oil 0.83 15 210...380 0.15
Brass (63Cu37Zn) 8.5 900 116 Glycerine 1.26 20 290 0.29
Molybdenum Mo 10.2 2600 145 Resin oil 0.96 20 150...300 0.15
Monel metal 8.8 1300 19.7 Fuel oil EL 0.83 20 > 175 0.14
Sodium Na 0.98 97.5 126 Linseed oil 0.93 20 316 0.17
Nickel silver 8.7 1020 48 Machinery oil 0.91 15 380...400 0.125
Nickel Ni 8.9 1452 59 Methanol 0.8 15 65 0.21
Niobium Nb 8.6 2415 54.43 Methyl chloride 0.95 15 24 0.16
Osmium Os 22.5 2500 Mineral oil 0.91 20 > 360 0.13
Palladium Pd 12 1552 70.9 Petroleum ether 0.66 20 > 40 0.14
Paraffin 0.9 52 0.26 Petroleum 0.81 20 > 150 0.13
Pitch 1.25 0.13 Mercury Hg 13.55 20 357 10
Phosphorus (white) P 1.83 44 Hydrochloric acid 10% 1.05 15 102 0.5
Platinum Pt 21.5 1770 70 Sulphuric acid, strong 1.84 15 338 0.47
Polyamide A, B 1.13 250 0.34 Silicon fluid 0.94 20 0.22
97
Materials
Coefficient of Linear Expansion; Iron-Carbon Diagram;
Fatigue Strength Values for Gear Materials
Cementite content in weight percentage
Coefficient of linear expansion
The coefficient of linear expansion gives
the fractional expansion of the unit of length
of a substance per 1 degree K rise in tempe-
rature. For the linear expansion of a body
applies:
l )lo +m + T
where
l: change of length
l
: original length
: coefficient of linear expansion
T: rise of temperature
Coefficients of linear expansion
of some substances at 0 ... 100 C
Substance [10
6
/K]
Aluminium alloys 21 ... 24
Grey cast iron
(e.g. GG-20, GG-25) 10.5
Steel, plain and
low-alloy 11.5
Steel, stainless
(18Cr 8Ni) 16
Steel, rapid machining steel 11.5
Copper 17
Brass CuZn37 18.5
Bronze CuSn8 17.5
Iron-carbon diagram
(cubic face centered)
(cubic body centered)
Mixed crystals
T
e
m
p
e
r
a
t
u
r
e

i
n

C
(Ferrite)
Melting + -mixed crystals
Melting
Melting +
-mixed crystals
Melting +
primary cementite
-mixed crystals
(austenite)
-mixed crystals
+ sec. cementite
+ ledeburite
Primary cementite
+ ledeburite
-m.c. +
sec.cem.
Pearlite
Sec.cem.
+ pearlite
Sec.cem. + pear-
lite + ledeburite
L
e
d
e
b
u
r
it
e
Primary cementite
+ ledeburite
Carbon content in weight percentage
Mixed crystals
Mixed crystals
Mixed crystals
(Cementite)
P
e
a
r
lit
e
Pitting and tooth root fatigue strength of case hardening steels, DIN 17210
Symbol
Hardness on finished gear
Hlim
Flim
Symbol
HV1 N/mm
2
N/mm
2
16 MnCr 5
15 CrNi 6
17 CrNiMo 6
720
730
740
1470
1490
1510
430
460
500
98
Materials
Heat Treatment During Case Hardening
of Case Hardening Steels
Heat treatment during case hardening of case hardening steels acc. to DIN 17210
Usual heat treatment during case hardening
A. Direct hardening or double
hardening
B. Single hardening C. Hardening after isothermal
transformation
Direct hardening from carburizing
temperature
Single hardening from core or case
hardening temperature
Hardening after isothermal transfor-
mation in the pearlite stage (e)
Direct hardening after lowering to
hardening temperature
Single hardening after intermediate
annealing (soft annealing) (d)
Hardening after isothermal transfor-
mation in the pearlite stage (e) and
cooling-down to room temperature
a carburizing temperature
b hardening temperature
c tempering temperature
d intermediate annealing (soft annealing) temperature
Double hardening
d intermediate annealing (soft annealing) tem erature
e transformation temperature in the pearlite stage
Usual case hardening temperatures
Grade of steel a b c
Symbol
Material
number
Carburizing
temperature
1)
Core hardening
temperature
2)
Case
hardening
temperature
2)
Quenchant Tempering
C C C C
C 10
Ck 10
Ck 15
Cm 15
1.0301
1.1121
1.0401
1.1141
1.1140
880
up to
920
With regard to the
17 Cr 3
20 Cr 4
20 CrS 4
16 MnCr 5
16 MnCrS5
20 MnCr 5
20 MnCrS 5
20 MoCr 4
20 MoCrS 4
22 CrMoS 3 5
21 NiCrMo 2
21 NiCrMoS 2
1.7016
1.7027
1.7028
1.7131
1.7139
1.7147
1.7149
1.7321
1.7323
1.7333
1.6523
1.6526
880
up to
980
860
up to
900
780
up to
820
With regard to the
properties of the
component, the selec-
tion of the quenchant
depends on the
hardenability or case-
hardenability of the
steel, the shape and
cross section of the
work piece to be
hardened, as well as
on the effect of the
quenchant.
150
up to
200
15 CrNi 6
17 CrNiMo 6
1.5919
1.6587
830
up to
870
1) Decisive criteria for the determination of the carburizing temperature are mainly the required time of carburizing, the
chosen carburizing agent, and the plant available, the provided course of process, as well as the required structural
constitution. For direct hardening, carburizing usually is carried out at temperatures below 950 C. In special cases,
carburizing temperatures up to above 1000 C are applied.
2) In case of direct hardening, quenching is carried out either from the carburizing temperature or any lower temperature. In
particular if there is a risk of warping, lower hardening temperatures are preferred.
99
Lubricating Oils Page
Viscosity-Temperature-Diagram for Mineral Oils 100
Viscosity-Temperature-Diagram for Synthetic Oils of Polyglycole Base 101
Viscosity-Temperature-Diagram for Synthetic Oils of Poly--Olefine Base 102
-
Kinematic Viscosity and Dynamic Viscosity 103
Viscosity Table for Mineral Oils 104
100
Lubricating Oils
Viscosity-Temperature-Diagram for Mineral Oils
Viscosity-temperature-diagram for mineral oils
Temperature (C)
K
i
n
e
m
a
t
i
c

v
i
s
c
o
s
i
t
y

(
m
m
2
/
s
)
101
Lubricating Oils
Viscosity-Temperature-Diagram for Synthetic Oils of Poly--Olefine Base
Viscosity-temperature-diagram for synthetic oils of poly--olefine base
Temperature (C)
K
i
n
e
m
a
t
i
c

v
i
s
c
o
s
i
t
y

(
m
m
2
/
s
)
102
Lubricating Oils
Viscosity-Temperature-Diagram for Synthetic Oils of Polyglycole Base
Viscosity-temperature-diagram for synthetic oils of polyglycole base
Temperature (C)
K
i
n
e
m
a
t
i
c

v
i
s
c
o
s
i
t
y

(
m
m
2
/
s
)
103
Lubricating Oils
Kinematic Viscosity and Dynamic Viscosity
for Mineral Oils at any Temperature
Kinematic viscosity
Quantities for the determination of the kinematic viscosity
VG grade W
40
[] m []
32
46
68
0.18066
0.22278
0.26424
3.7664
3.7231
3.6214
100
150
220
0.30178
0.33813
0.36990
3.5562
3.4610
3.4020
320
460
680
0.39900
0.42540
0.45225
3.3201
3.3151
3.2958
1000
1500
0.47717
0.50192
3.2143
3.1775
W = m (2.49575 lgT) + W
40
(1)
(2)
m +10
10
W
)0.8
m [-]: slope
T [K]: thermodynamic temperature
1)
W
40
[-]: auxiliary quantity at 40 C
W [-]: auxiliary quantity
[cSt]: kinematic viscosity
1) T = t + 273.15 [K]
Dynamic viscosity
=
.

.
0.001 (3)
=
15
(t 15)
.
0.0007 (4)
t [C]: temperature
15
[kg/dm
3
]: density at 15 C
[kg/dm
3
]: density
[cSt]: kinematic viscosity
[Ns/m
2
]: dynamic viscosity
Density
15
in kg/dm
3
of lubricating oils for gear units ) (Example)
2)
VG grade 68 100 150 220 320 460 680
ARAL
Degol BG
0.890 0.890 0.895 0.895 0.900 0.900 0.905
ESSO
Spartan EP
0.880 0.885 0.890 0.895 0.900 0.905 0.920
MOBIL OIL
Mobilgear 626 ... 636
0.882 0.885 0.889 0.876 0.900 0.905 0.910
OPTIMOL
Optigear BM
0.890 0.901 0.904 0.910 0.917 0.920 0.930
TRIBOL
Tribol 1100
0.890 0.895 0.901 0.907 0.912 0.920 0.934
2) Mineral base gear oils in accordance with designation CLP as per DIN 51502. These oils comply
with the minimum requirements as specified in DIN 51517 Part 3. They are suitable for operating
temperatures from -10 C up to +90 C (briefly +100 C).
104
Lubricating Oils
Viscosity Table for Mineral Oils
ISO-VG
Approx.
Mean viscosity (40 C) and approx.
viscosities in mm
2
/s (cSt) at
Saybolt
universal
seconds
AGMA
lubricant
Approx.
assignment
to
ISO-VG
DIN
51519
A rox.
assignment
to previous
DIN 51502
20 C 40 C 50 C 100 C
seconds
(SSU) at
40 C
(mean
value)
lubricant
N at
40 C
1)
motor
oils
motor-
car
gear
oils
cSt cSt cSt Engler cSt
)
1)
1)
SAE SAE
5 2
8
4 6 4 1 3 1 5 5 2
(1.7 E)
4.6 4 1.3 1.5
7 4
12
6 8 5 1 4 2 0 7 4
(2 E)
6.8 5 1.4 2.0
10 9
21
10 8 1 7 2 5 10 9
(3 E)
10 8 1.7 2.5
15 34 15 11 1 9 3 5 5W 15 34 15 11 1.9 3.5 5W
22 55 22 15 2 3 4 5 22
16
55 22 15 2.3 4.5
10 W 70 W
32 88 32 21 3 5 5
10 W 70 W
75 W
32
25
88 32 21 3 5.5
75 W
46
25
137 46 30 4 6 5 214 1 EP 46
36
137 46 30 4 6.5 214 1 EP
15 W
20 W
68
36
219 68 43 6 8 5 316 2 2 EP
20 W
20
80 W 68
49
219 68 43 6 8.5 316 2.2 EP
20
80 W
49
100
68
345 100 61 8 11 464 3.3 EP 30
85 W
150 92 550 150 90 12 15 696 4 4 EP 40
85 W
150 92 550 150 90 12 15 696 4.4 EP 40
220
114
865 220 125 16 19 1020 5 5 EP 50
90
220
144
865 220 125 16 19 1020 5.5 EP 50
90
320 169 1340 320 180 24 24 1484 6 6 EP 320 169 1340 320 180 24 24 1484 6.6 EP
460 225 2060 460 250 33 30 2132 7 EP 460 225 2060 460 250 33 30 2132 7 EP
140
680 324 3270 680 360 47 40 3152 8 EP 680 324 3270 680 360 47 40 3152 8 EP
1000 5170 1000 510 67 50 1000 5170 1000 510 67 50
250
1500 8400 1500 740 98 65
250
1500 8400 1500 740 98 65
1) Approximate comparative value to ISO VG grades
105
Cylindrical Gear Units Page
Symbols and Units 106/107
General Introduction 108
Geometry of Involute Gears
Concepts and Parameters Associated With Involute Teeth 108
Reference Profile 108
Module 109
Tool Profile 109
Generating Tooth Flanks 110
Concepts and Parameters Associated With Cylindrical Gears 111
Geometric Definitions 111
Pitch 111
Addendum Modification 112
Concepts and Parameters Associated With a Cylindrical Gear Pair 113
Definitions 113
Mating Quantities 113
Contact Ratios 114
Summary of the Most Important Formulae 115-117
Gear Teeth Modifications 118/119
Load Carrying Capacity of Involute Gears
Scope of Application and Purpose 119/120
Basic Details 120/121
General Factors 122
Application Factor 122
Dynamic Factor 122
Face Load Factor 122
Transverse Load Factor 122
Tooth Flank Load Carrying Capacity 123
Effective Hertzian Pressure 123
Permissible Hertzian Pressure 123/124
Tooth Root Load Carrying Capacity 124
Effective Tooth Root Stress 124/125
Permissible Tooth Root Stress 126
Safety Factors 126
Calculation Example 126/127
Gear Unit Types
Standard Designs 127
Load Sharing Gear Units 127
Comparisons 127/128
Load Value 128
Referred Torques 129
Efficiencies 130
Example 130
Noise Emitted by Gear Units
Definitions 131
Measurements 132
Determination via Sound Pressure 132
Determination via Sound Intensity 132/133
Prediction 133
Possibilities of Influencing 134
106
Symbols and units for cylindrical gear units
a mm Centre distance
a
d
mm Reference centre distance
b mm Facewidth
c
p
mm
Bottom clearance between
standard basic rack tooth
profile and counter profile
d mm Reference diameter
d
a
mm Tip diameter
d
b
mm Base diameter
d
f
mm Root diameter
d
w
mm Pitch diameter
e mm
Spacewidth on the reference
cylinder
e
p
mm
Spacewidth on the standard
basic rack tooth profile
f Hz Frequency
g
mm Length of path of contact

h mm Tooth depth
h
a
mm Addendum
h
aP
mm
Addendum of the standard
h
aPO
mm
Addendum of the tools stand-
ard basic rack tooth profile
h
f
mm Dedendum
h
fP
mm
Dedendum of the standard
h
fPO
mm
Dedendum of the tools stand-
h
p
mm
Tooth depth of the standard
h
PO
mm
Tooth depth of the tools stand-
h
prPO
mm
Protuberance height of the
tools standard basic rack
tooth profile
h
wP
mm
Working depth of the standard
basic rack tooth profile and the
counter profile
k
Tip diameter modification
coefficient
m mm Module
m
n
mm Normal module
m
t
mm Transverse module
n 1/min Speed
p N/mm
2
Sound pressure
p mm Pitch on the reference circle
p
bt
mm Pitch on the base circle
p
e
mm Normal base pitch
p
en
mm Normal base pitch at a point
p
et
mm Normal transverse pitch
p
ex
mm Axial pitch
p
t
mm
Transverse base pitch, refer-
ence circle pitch
p
rPO
mm
Protuberance value on the
tooth profile
q mm
Machining allowance on the
cylindrical gear tooth flanks
r mm
Reference circle radius, ra-
dius
r
a
mm Tip radius
r
b
mm Base radius
r
w
mm
Radius of the working pitch
circle
s mm
Tooth thickness on the refer-
ence circle
s
an
mm
Tooth thickness on the tip
circle
s
p
mm
Tooth thickness of the stand-
s
PO
mm
Tooth thickness of the tools
standard basic rack tooth
profile
u Gear ratio
v m/s
Circumferential speed on the
reference circle
w N/mm Line load
x
Addendum modification coef-
ficient
x
E
Generating addendum modifi-

cation coefficient
z Number of teeth
A m
2
Gear teeth surface
A
s
mm Tooth thickness deviation
B
L
N/mm
2
Load value
107
Symbols and units for cylindrical gear units
D mm Construction dimension
F
n
N Load
F
t
N
Nominal peripheral force at
the reference circle
G kg Gear unit weight
HV1
Vickers hardness at
F = 9.81 N
K
A
Application factor
K
F
Transverse load factor (for

tooth root stress)
K
F
Face load factor (for tooth root

stress)
K
H
Transverse load factor (for

contact stress)
K
H
Face load factor (for contact

stress)
K
v
Dynamic factor
L
pA
dB Sound pressure level A
L
WA
dB Sound power level A
P kW
Nominal power rating of driven
machine
R
Z
m
Mean peak-to-valley rough-
ness
S
F
Factor of safety from tooth

breakage
S
H
Factor of safety from pitting
S m
2
Enveloping surface
T Nm Torque
V
40
mm
2
/s
Lubricating oil viscosity
at 40 C
Y
Helix angle factor

Y Contact ratio factor
Y
FS
Tip factor
Y
R
Roughness factor
Y
X
Size factor
Z
Helix angle factor

Z
Contact ratio factor

Z
H
Zone factor
Z
L
Lubricant factor
Z
V
Speed factor
Z
X
Size factor
Degree
Transverse pressure angle at
a point; Pressure angle
^ rad
Angle in the circular
measure
^
) m +180
at
Degree
the tip circle
n
Degree Normal pressure angle
P
Degree
Pressure angle at a point of
the standard basic rack tooth
profile
PO
Degree
Pressure angle at a point of
the tools standard basic rack
tooth profile
prPO
Degree
Protuberance pressure angle
at a point
t
Degree
the reference circle
wt
Degree
Working transverse pressure
angle at the pitch circle
Degree
Helix angle at the reference
circle
b
Degree Base helix angle
Transverse contact ratio
Overlap ratio
Total contact ratio

Efficiency
Degree Working angle of the involute
p mm Radius of curvature
p
aPO
mm
Tip radius of curvature of the
tooth profile
p
fPO
mm
Root radius of curvature of the
tooth profile
H
N/mm
2
Effective Hertzian pressure
Hlim
N/mm
2
Allowable stress number for
contact stress
HP
N/mm
2
Allowable Hertzian pressure
F
N/mm
2
Effective tooth root stress
Flim
N/mm
2
Bending stress number
FB
N/mm
2
Allowable tooth root stress
Note: The unit rad may be replaced by 1.
108
General Introduction
1. Cylindrical gear units
1.1 Introduction
In the industry, mainly gear units with case har-
dened and fine-machined gears are used for
torque and speed adaptation of prime movers
and driven machines. After carburising and har-
dening, the tooth flanks are fine-machined by
hobbing or profile grinding or removing material
(by means of shaping or generating tools coated
with mechanically resistant material). In compar-
ison with other gear units, which, for example,
have quenched and tempered or nitrided gears,
gear units with case hardened gears have higher
power capacities, i.e. they require less space for
the same speeds and torques. Further, gear
units have the best efficiencies. Motion is trans-
mitted without slip at constant speed. As a rule,
an infinitely variable change-speed gear unit with
primary or secondary gear stages presents the
most economical solution even in case of vari-
able speed control.
In industrial gear units mainly involute gears are
used. Compared with other tooth profiles, the
technical and economical advantages are
basically:
H Simple manufacture with straight-sided
flanked tools;
H The same tool for all numbers of teeth;
H Generating different tooth profiles and centre
distances with the same number of teeth
by means of the same tool by addendum
modification;
H Uniform transmission of motion even in case
of centre distance errors from the nominal
value;
H The direction of the normal force of teeth
remains constant during meshing;
H Advanced stage of development;
H Good availability on the market.
When load sharing gear units are used, output
torques can be doubled or tripled in comparison
with gear units without load sharing. Load shar-
ing gear units mostly have one input and one out-
put shaft. Inside the gear unit the load is distri-
buted and then brought together again on the
output shaft gear. The uniform sharing of the load
between the individual branches is achieved by
special design measures.
1.2 Geometry of involute gears
The most important concepts and parameters
associated with cylindrical gears and cylindrical
gear pairs with involute teeth in accordance with
DIN 3960 are represented in sections 1.2.1 to
1.2.4. /1/
1.2.1 Concepts and parameters associated
with involute teeth
1.2.1.1 Standard basic rack tooth profile
The standard basic rack tooth profile is the
normal section through the teeth of the basic rack
which is produced from an external gear tooth
system with an infinitely large diameter and an
infinitely large number of teeth. From figure 1
follows:
The flanks of the standard basic rack tooth
profile are straight lines and are located
symmetrically below the pressure angle at a
point
P
to the tooth centre line;
Between module m and pitch p the relation is
p = m;
The nominal dimensions of tooth thickness
and spacewidth on the datum line are equal,
i.e. s
P
= e
P
= p/2;
The bottom clearance c
P
between basic rack
tooth profile and counter profile is 0.1 m up to
0.4 m;
The addendum is fixed by h
aP
= m, the deden-
dum by h
fP
= m + c
P
and thus, the tooth depth
by h
P
= 2 m + c
P
;
The working depth of basic rack tooth profile
and counter profile is h
wP
= 2 m.
Tip line Counter profile
Datum line
Standard basic rack tooth profile
Root line
Fillet
Tooth root surface
Tooth centre line
Figure 1 Basic rack tooth profiles for involute teeth of cylindrical gears (acc. to DIN 867)
109
1.2.1.2 Module
The module m of the standard basic rack tooth
profile is the module in the normal section m
n
of
the gear teeth. For a helical gear with helix angle
on the reference circle, the transverse module
in a transverse section is m
t
= m
n
/cos. For a
spur gear = 0 and the module is m = m
n
= m
t
.
In order to limit the number of the required gear
cutting tools, module m has been standardized in
preferred series 1 and 2, see table 1.
Table 1 Selection of some modules m in mm (acc. to DIN 780)
Series 1 1 1.25 1.5 2 2.5 3 4 5 6 8 10 12 16 20 25 32
Series 2 1.75 3.5 4.5 7 9 14 18 22 28
1.2.1.3 Tool reference profile
The tool reference profile according to figure 2a
is the counter profile of the standard basic rack
tooth profile according to figure 1. For industrial
gear units, the pressure angle at a point of the
tool reference profile
PO
=
P
is 20, as a rule.
The tooth thickness s
PO
of the tool on the tool
datum line depends on the stage of machining.
The pre-machining tool leaves on both flanks of
the teeth a machining allowance q for finish-
machining. Therefore, the tooth thickness for
pre-machining tools is s
PO
< p/2, and for finish-
machining tools s
PO
= p/2.
The pre-machining tool generates the root dia-
meter and the fillet on a cylindrical gear. The
finish-machining tool removes the machining
allowance on the flanks, however, normally it
does not touch the root circle - like on the tooth
profile in figure 3a.
Between pre- and finish- machining, cylindrical
gears are subjected to a heat treatment which, as
a rule, leads to warping of the teeth and growing
of the root and tip circles.
Especially for cylindrical gears with a relatively
large number of teeth or a small module there is a
risk of generating a notch in the root on finish
machining. To avoid this, pre-machining tools are
provided with protuberance flanks as shown in
figure 2b. They generate a root undercut on the
gear, see figure 3b. On the tool, protuberance
value pr
PO
, protuberance pressure angle at a
point
prPO
, as well as the tip radius of curvature
m
a
PO
must be so dimensioned that the active
tooth profile on the gear will not be reduced and
the tooth root will not be weakened too much.
On cylindrical gears with small modules one of-
ten accepts on purpose a notch in the root if its
distance to the root circle is large enough and
thus the tooth root load carrying capacity is not
impaired by a notch effect, figure 3c. In order to
prevent the tip circle of the mating gear from
touching the fillet it is necessary that a check for
meshing interferences is carried out on the gear
pair. /1/
b) Protuberance flank a) Tool datum line
Figure 2 Reference profiles of gear cutting tools for involute teeth of cylindrical gears
a) For pre-machining and finish-machining
b) For pre-machining with root undercut (protuberance)
110
Figure 3 Tooth profiles of cylindrical gears during pre- and finish-machining
Root undercut
Finish-machining
Machining
allowance q
Pre-machining
Notch
a) Pre- and finish-machining down to the root circle
b) Pre-machining with root undercut (protuberance)
c) Finish-machining with notch
c) a) b)
1.2.1.4 Generating tooth flanks
With the development of the envelope, an enve-
lope line of the base cylinder with the base dia-
meter d
b
generates the involute surface of a spur
gear.
A straight line inclined by a base helix angle
b
to
the envelope line in the developed envelope is
the generator of an involute surface (involute
helicoid) of a helical gear, figure 4.
The involute which is always lying in a transverse
section, figure 5, is described by the transverse
pressure angle at a point and radius r in the
equations
inv = tan
^
(1)
r = r
b
/ cos (2)
r
b
= d
b
/2 is the base radius. The angle inv is
termed involute function, and the angle
=
^
+ inv = tan is termed working angle.
Figure 5 Involute in a transverse section
Developed base cylinder envelope
Figure 4 Base cylinder with involute
helicoid and generator
Base cylinder envelope line
Involute of base cylinder
Involute helicoid
Developed
involute
line
Generator
Involute of base
cylinder
Base cylinder
Involute
111
with cylindrical gears
1.2.2.1 Geometric definitions
In figure 6 the most important geometric quanti-
ties of a cylindrical gear are shown.
The reference circle is the intersection of the re-
ference cylinder with a plane of transverse sec-
tion. When generating tooth flanks, the straight
pitch line of the tool rolls off at the reference
circle. Therefore, the reference circle periphery
corresponds to the product of pitch p and number
of teeth z, i.e. d = p z. Since m
t
= p/, the equa-
tion for the reference diameter thus is d = m
t
z.
Many geometric quantities of the cylindrical gear
are referred to the reference circle.
For a helical gear, at the point of intersection of
the involute with the reference circle, the trans-
verse pressure angle at a point in the trans-
verse section is termed transverse pressure
angle
t
, see figures 5 and 7. If a tangent line is
put against the involute surface in the normal
section at the point of intersection with the
reference circle, the corresponding angle is
termed normal pressure angle
n
; this is equal to
the pressure angle
PO
of the tool. The interrela-
tionship with the helix angle at the reference
circle is tan
n
= cos tan
t
. On a spur gear
n
=
t
.
Between the base helix angle
b
and the helix
angle on the reference circle the relationship is
sin
b
= cos
n
sin. The base diameter d
b
is given
by the reference diameter d, by d
b
= d cos
t
.
In the case of internal gears, the number of teeth
z and thus also the diameters d, d
b
, d
a
, d
f
are
negative values.
Left flank
Right flank
Tooth trace
Reference cylinder
Reference circle
d Reference diameter
d
a
Tip diameter
d
f
Root diameter
b Facewidth
h Tooth depth
h
a
Addendum
h
f
Dedendum
s Tooth thickness on the reference circle
e Spacewidth on the reference circle
p Pitch on the reference circle
Figure 6 Definitions on the cylindrical gear
1.2.2.2 Pitches
The pitch p
t
of a helical gear (p in the case of a
spur gear) lying in a transverse section is the
length of the reference circle arc between two
successive right or left flanks, see figures 6 and
7. With the number of teeth z results p
t
= d/z =
m
t
.
The normal transverse pitch p
et
of a helical gear
is equal to the pitch on the basic circle p
bt
, thus
p
et
= p
bt
= d
b
/z. Hence, in the normal section the
normal base pitch at a point p
en
= p
et
cos
b
is re-
sulting from it, and in the axial section the axial
pitch p
ex
= p
et
/tan
b
, see figure 13.
Figure 7 Pitches in the transverse
section of a helical gear
112
1.2.2.3 Addendum modification
When generating tooth flanks on a cylindrical
gear by means of a tooth-rack-like tool (e.g. a
hob), a straight pitch line parallel to the datum line
of tool rolls off on the reference circle. The dis-
tance (x m
n
) between the straight pitch line and
the datum line of tool is the addendum modifica-
tion, and x is the addendum modification coeffi-
cient, see figure 8.
An addendum modification is positive, if the
datum line of tool is displaced from the reference
circle towards the tip, and it is negative if the
datum line is displaced towards the root of the
gear. This is true for both external and internal
gears. In the case of internal gears the tip points
to the inside. An addendum modification for
external gears should be carried through approx-
imately within the limits as shown in figure 9.
The addendum modification limits x
min
and x
max
are represented dependent on the virtual
number of teeth z
n
= z/(cos cos
2
b
). The upper
limit x
max
takes into account the intersection
circle of the teeth and applies to a normal crest
width in the normal section of s
an
= 0.25 m
n
.
When falling below the lower limit x
min
this results
in an undercut which shortens the usable invo-
lute and weakens the tooth root.
A positive addendum modification results in a
greater tooth root width and thus in an increase in
the tooth root carrying capacity. In the case of
small numbers of teeth this has a considerably
stronger effect than in the case of larger ones.
One mostly strives for a greater addendum modi-
fication on pinions than on gears in order to
achieve equal tooth root carrying capacities for
both gears, see figure 19.
Further criteria for the determination of adden-
dum modification are contained in /2/, /3/, and /4/.
The addendum modification coefficient x refers
to gear teeth free of backlash and deviations. In
order to take into account tooth thickness devia-
tion A
s
(for backlash and manufacturing toler-
ances) and machining allowances q (for pre-
machining), one has to give the following
generating addendum modification coefficient
for the manufacture of a cylindrical gear:
X
E
= x +
A
s
2m
n
tan
n
+
q
m
n
sin
n
(3)
Figure 8 Different positions of the datum line
of tool in relation to the straight pitch line
through pitch point C.
a) Zero addendum modification; x = 0
b) Negative addendum modification; x < 0
c) Positive addendum modification; x > 0
a)
Datum line of tool = straight pitch line
b)
c)
Datum line of tool
Straight pitch line
Straight pitch line
Figure 9 Addendum modification limit x
max
(intersection circle) and x
min
(undercut limit)
for external gears dependent on the virtual
number of teeth zn (for internal gears, see /1/
and /3/).
113
with a cylindrical gear pair
1.2.3.1 Terms
The mating of two external cylindrical gears (ex-
ternal gears) gives an external gear pair. In the
case of a helical external gear pair one gear has
left-handed and the other one right-handed flank
direction.
The mating of an external cylindrical gear with an
internal cylindrical gear (internal gear) gives an
internal gear pair. In the case of a helical internal
gear pair, both gears have the same flank direc-
tion, that is either right-handed or left-handed.
The subscript 1 is used for the size of the smaller
gear (pinion), and the subscript 2 for the larger
gear (wheel or internal gear).
In the case of a zero gear pair both gears have as
addendum modification coefficient x
1
= x
2
= 0
(zero gears).
In the case of a V-zero gear pair, both gears have
addendum modifications (V-gears), that is with
x
1
+ x
2
= 0, i.e. x
1
= -x
2
.
For a V-gear pair, the sum is not equal to zero, i.e.
x
1
+ x
2
0. One of the cylindrical gears in this
case may, however, have an addendum modifi-
cation x = 0.
1.2.3.2 Mating quantities
The gear ratio of a gear pair is the ratio of the
number of teeth of the gear z
2
to the number of
teeth of the pinion z
1
, thus u = z
2
/z
1
. Working
pitch circles with diameter d
w
= 2r
w
are those
transverse intersection circles of a cylindrical
gear pair, which have the same circumferential
speed at their mutual contact point (pitch point
C), figure 10. The working pitch circles divide the
centre distance a = r
w1
+ r
w2
in the ratio of the
tooth numbers, thus d
w1
= 2 a/(u + 1) and d
w2
=
2 a u/(u +1).
In the case of both a zero gear pair and a V-zero
gear pair, the centre distance is equal to the zero
centre distance a
d
= (d
1
+ d
2
)/2, and the pitch
circles are simultaneously the reference circles,
i.e. d
w
= d. However, in the case of a V-gear pair
the centre distance is not equal to the zero centre
distance, and the pitch circles are not simulta-
neously the reference circles.
If in the case of V-gear pairs the bottom
clearance c
p
corresponding to the standard
basic rack tooth profile is to be retained (which is
not absolutely necessary), then an addendum
modification is to be carried out. The addendum
modification factor is k = (a - a
d
)/m
n
- (x
1
+ x
2
). For
zero gear pairs and V-zero gear pairs k = 0. In the
case of external gear pairs k < 0, i.e. the tip
diameters of both gears become smaller. In the
case of internal gear pairs k > 0, i.e. the tip
diameters of both gears become larger (on an
internal gear with negative tip diameter the
Figure 10 Transverse section of an external
gear pair with contacting left-handed flanks
absolute value becomes smaller).
In a cylindrical gear pair either the left or the right
flanks of the teeth contact each other on the line
of action. Changing the flanks results in a line of
action each lying symmetrical in relation to the
centre line through O
1
O
2
. The line of action with
contacting left flanks in figure 10 is the tangent to
the two base circles at points T
1
and T
2
. With the
common tangent on the pitch circles it includes
the working pressure angle
wt
.
The working pressure angle
wt
is the transverse
pressure angle at a point belonging to the
working pitch circle. According to figure 10 it is
determined by cos
wt
= d
b1
/d
w1
= d
b2
/d
w2
. In the
case of zero gear pairs and V-zero gear pairs, the
working pressure angle is equal to the transverse
pressure angle on the reference circle, i.e.
wt
=
t
.
The length of path of contact g
is that part of the

line of action which is limited by the two tip circles
of the cylindrical gears, figure 11.
The starting point A of the length of path of
contact is the point at which the line of action
intersects the tip circle of the driven gear, and the
finishing point E is the point at which the line of
action intersects the tip circle of the driving gear.
114
Figure 11 Length of path of contact AE in the
transverse section of an external gear pair
A Starting point of engagement
E Finishing point of engagement
C Pitch point
Driving
Line of action
Driven
1.2.3.3 Contact ratios
The transverse contact ratio
in the transverse
section is the ratio of the length of path of
contact g
to the normal transverse pitch p

et
, i.e.
= g
/p
et
, see figure 12.
In the case of spur gear pairs, the transverse
contact ratio gives the average number of pairs
of teeth meshing during the time of contact of a
tooth pair. According to figure 12, the left-hand
tooth pair is in the individual point of contact D
while the right-hand tooth pair gets into mesh at
the starting point of engagement A. The right-
hand tooth pair is in the individual point of
contact B when the left-hand tooth pair leaves
the mesh at the finishing point of engagement
E. Along the individual length of path of contact
BD one tooth pair is in mesh, and along the
double lengths of paths of contact AB and DE
two pairs of teeth are simultaneously in mesh.
In the case of helical gear pairs it is possible to
achieve that always two or more pairs of teeth
are in mesh simultaneously. The overlap ratio
gives the contact ratio, owing to the helix of the

teeth, as the ratio of the facewidth b to the axial
pitch p
ex
, i.e.
= b/p
ex
, see figure 13.
The total contact ratio
is the sum of
transverse contact ratio and overlap ratio, i.e.
.
With an increasing total contact ratio, the load
carrying capacity increases, as a rule, while the
generation of noise is reduced.
Figure 12 Single and double contact region
in the transverse section of an external gear
pair
B, D Individual points of contact
A, E Starting and finishing point of
engagement, respectively
C Pitch point
Driving
Line of action
Driven
Figure 13 Pitches in the plane of action
A Starting point of engagement
E Finishing point of engagement
Length of path of contact
115
1.2.4 Summary of the most important
formulae
Tables 2 and 3 contain the most important formu-
lae for the determination of sizes of a cylindrical
gear and a cylindrical gear pair, and this for both
external and internal gear pairs.
The following rules for signs are to be observed:
In the case of internal gear pairs the number of
teeth z
2
of the internal gear is a negative quantity.
Thus, also the centre distance a or a
d
and the
gear ratio u as well as the diameters d
2
, d
a2
, d
b2
,
d
f2
, d
w2
and the virtual number of teeth z
n2
are
negative.
When designing a cylindrical gear pair for a gear
stage, from the output quantities of tables 2 and 3
only the normal pressure angle
n
and the gear
ratio u are given, as a rule. The number of teeth of
the pinion is determined with regard to silent
running and a balanced foot and flank load
carrying capacity, at approx. z
1
= 18 ... 23. If a
high foot load carrying capacity is required, the
number may be reduced to z
1
= 10. For the helix
angle, = 10 up to 15 degree is given, in excep-
tional cases also up to 30 degree. The addendum
modification limits as shown in figure 9 are to
be observed. On the pinion, the addendum modi-
fication coefficient should be within the range of
x
1
= 0.2 to 0.6 and from IuI > 2 the width within
the range b
1
= (0.35 to 0.45) a. Centre distance a
is determined either by the required power to be
transmitted or by the constructional conditions.
m
t
=
m
n
cos
tan
t
=
tan
n
cos
sin
b
= sin cos
n
d = m
t
z
d
f
= d 2 (h
aPO
m
n
x
E
)
d
b
= d cos
t
p
t
=
z
d
= m
t
p
et
= p
bt
=
z
d
b
= p
t
cos
t
cos
at
=
d
b
d
a
s
t
= m
t
(
2
+ 2 x tan
n
)
s
n
= s
t
cos
s
at
= d
a
(
d
+ inv
t
inv
at
)
s
t
z
n
=
cos cos
2
b
z
**)
d
a
= d + 2 m
n
(1 + x + k)
116
Table 2 Parameters for a cylindrical gear *)
Output quantities:
m
n
mm normal module
n
degree normal pressure angle
degree reference helix angle
z number of teeth *)
x addendum modification coefficient
x
E
generating addendum modification coefficient, see equation (3)
h
aPO
mm addendum of the tool
Item Formula
Transverse module
Transverse pressure angle
Base helix angle
Reference diameter
Tip diameter (k see table 3)
Root diameter
Base diameter
Transverse pitch
Transverse pitch on path of contact;
Transverse base pitch
Transverse pressure angle at tip circle
Transverse tooth thickness on the pitch
circle
Normal tooth thickness on the pitch circle
Transverse tooth thickness on the
addendum circle
Virtual number of teeth
*) For an internal gear, z is to be used as a negative quantity. **) For inv, see equation (1).
u =
z
2
a =
d
w1
=
g
=
cos
wt
=
m
t
2a
z
1
x
1
+ x
2
=
z
1
+ z
2
2 tan
n
(inv
wt
inv
t
)
inv
wt
= 2
x
1
+ x
2
tan
n
+ inv
t
z
1
+ z
2
m
t
2
(z
1
+ z
2
)
cos
t
cos
wt
a
d
=
m
t
2
(z
1
+ z
2
)
k =
a a
d
m
n
(x
1
+ x
2
)
2a
u + 1
= d
1
cos
t
cos
wt
d
w2
=
2au
u + 1
= d
2
cos
t
cos
wt
1
2
( d
a1
2
d
b1
2
+
u
IuI
d
a2
2
d
b2
2
) asin
wt
g
p
et
=
b tan
b
p
et
b = min (b
1
, b
2
)
(z
1
+ z
2
) cos
t
117
Table 3 Parameters for a cylindrical gear pair *)
Output quantities:
The parameters for pinion and wheel according to table 2 must be given, further the facewidths b
1

and b
2
, as well as either the centre distance a or the sum of the addendum modification coefficients
x
1
+ x
2.
Item Formula
Gear ratio
Working transverse pressure angle
(a given)
Sum of the addendum modification
coefficients (a given)
Working transverse pressure angle
(x
1
+ x
2
given)
Centre distance (x
1
+ x
2
given)
Reference centre distance
Addendum modification factor **)
Working pitch circle diameter of the pinion
Working pitch circle diameter of the gear
Length of path of contact
Overlap ratio
Total contact ratio
*) For internal gear pairs, z
2
and a are to be used as negative quantities.
**) See subsection 1.2.3.2.
118
1.2.5 Tooth corrections
The parameters given in the above subsections
1.2.1 to 1.2.4 refer to non-deviating cylindrical
gears. Because of the high-tensile gear materi-
als, however, a high load utilization of the gear
units is possible. Noticeable deformations of the
elastic gear unit components result from it.
The deflection at the tooth tips is, as a rule, a mul-
tiple of the manufacturing form errors. This leads
to meshing interferences at the entering and
leaving sides, see figure 14. There is a negative
effect on the load carrying capacity and
generation of noise.
Figure 14 Cylindrical gear pair under load
1 Driving gear
2 Driven gear
a, b Tooth pair being in engagement
c, d Tooth pair getting into engagement
Line of
action
Further, the load causes bending and twisting of
pinion and wheel shaft, pinion and wheel body,
as well as settling of bearings, and housing de-
formations. This results in skewing of the tooth
flanks which often amounts considerably higher
than the tooth trace deviations caused by manu-
facture, see figure 15. Non-uniform load carrying
occurs along the face width which also has a ne-
gative effect on the load carrying capacity and
generation of noise.
The running-in wear of case hardened gears
amounts to a few micrometers only and cannot
compensate the mentioned deviations. In order
to restore the high load carrying capacity of case
hardened gears and reduce the generation of
noise, intentional deviations from the involute
(profile correction) and from the theoretical tooth
trace (longitudinal correction) are produced in or-
der to attain nearly ideal geometries with uniform
load distribution under load again.
The load-related form corrections are calculated
and made for one load only - as a rule for 70 ...
100% of the permanently acting nominal load -
/5, 6, 7/. At low partial load, contact patterns
which do not cover the entire tooth depth and
facewidth are achieved. This has to be taken into
consideration especially in the case of checks of
contact patterns carried out under low loads. Un-
der partial load, however, the local maximum
load rise is always lower than the theoretical uni-
form load distribution under full load. In the case
of modified gear teeth, the contact ratio is re-
duced under partial load because of incomplete
carrying portions, making the noise generating
levels increase in the lower part load range. With
increasing load, the carrying portions and thus
the contact ratio increase so that the generating
levels drop. Gear pairs which are only slightly
loaded do not require any modification.
Load distribution
across the face-
width w
Figure 15 Deformations and manufacturing
deviations on a gear unit shaft
Pinion
Wheel
Bending
Torsion
Manufac-
turing
deviation
Bearing
deformation
Housing
deformation
Running-in wear
Effective tooth
trace deviation
F
= f-y
In figure 16, usual profile and longitudinal correc-

tions are illustrated. In the case of profile correc-
tion, the flanks on pinion and wheel are relieved
at the tips by an amount equal to the length they
are protruding at the entering and leaving sides
due to the bending deflection of the teeth. Root
relief may be applied instead of tip relief which,
however, is much more expensive. Thus, a gra-
dual load increase is achieved on the tooth get-
119
ting into engagement, and a load reduction on
the tooth leaving the engagement. In the case of
longitudinal correction, the tooth trace relief often
is superposed by a symmetric longitudinal
crowning. With it, uniform load carrying along the
face width and a reduction in load concentration
at the tooth ends during axial displacements is
attained.
Profile correction
Figure 16
Tooth corrections designed for removing local load increases due to deformations
under nominal load
Longitudinal correction
1.3 Load carrying capacity of involute gears
1.3.1 Scope of application and purpose
The calculation of the load carrying capacity of
cylindrical gears is generally carried out in
accordance with the calculation method accord-
ing to DIN 3990 /8/ (identical with ISO 6336)
which takes into account pitting, tooth root
bending stress and scoring as load carrying
limits. Because of the relatively large scope of
standards, the calculation in accordance with
this method may be carried out only by using
EDP programs. As a rule, gear unit manufactur-
ers have such a tool at hand. The standard work
is the FVA-Stirnradprogramm /9/ which includes
further calculation methods, for instance,
according to Niemann, AGMA, British Standard,
and other.
In DIN 3990, different methods A, B, C ... are
suggested for the determination of individual
factors, where method A is more exact but also
more time-consuming than method B, etc. The
application standard /10/ according to DIN 3990
is based on simplified methods.
Because of its - even though limited - universal
validity it still is relatively time-consuming.
The following calculation method for pitting re-
sistance and tooth strength of case-hardened
cylindrical gears is a further simplification if
compared with the application standard, ho-
wever, without losing some of its meaning.
Certain conditions must be adhered to in order to
attain high load carrying capacities which also
results in preventing scuffing. Therefore, a
calculation of load carrying capacity for scuffing
will not be considered in the following.
It has to be expressly emphasized that for the
load carrying capacity of gear units the exact
calculation method - compared with the
simplified one - is always more meaningful and
therefore is exclusively decisive in borderline
cases.
Design, selection of material, manufacture, heat
treatment and operation of industrial gear units
are subject to certain rules which lead to a long
service life of the cylindrical gears. Those rules
are:
Gear teeth geometry acc. to DIN 3960;
Cylindrical gears out of case-hardened steel;
Tooth flanks in DIN quality 6 or better, fine
machined;
Quality of material and heat treatment proved
by quality inspections acc. to DIN 3990 /11/;
Effective case depth after carburizing accord-
ing to instructions /12/ with surface hardnes-
ses of 58 ... 62 HRC;
Gears with required tooth corrections and
without harmful notches in the tooth root;
Gear unit designed for fatigue strength, i.e.
life factors Z
NT
= Y
NT
= 1.0;
Flank fatigue strength
Hlim
y 1,200 N/mm
2
;
Subcritical operating range, i.e. pitch circle
velocity lower than approx. 35 m/s;
Sufficient supply of lubricating oil;
Use of prescribed gear oils with sufficient
scuffing load capacity (criteria stage 12) and
grey staining load capacity (criteria stage
10);
Maximum operating temperature 95 C.
120
If these requirements are met, a number of fac-
tors can be definitely given for the calculation of
the load carrying capacity according to DIN
3990, so that the calculation procedure is partly
considerably simplified. Non-observance of the
above requirements, however, does not neces-
sarily mean that the load carrying capacity is re-
duced. In case of doubt one should, however,
carry out the calculation in accordance with the
more exact method.
1.3.2 Basic details
The calculation of the load carrying capacity is
based on the nominal torque of the driven ma-
chine. Alternatively, one can also start from the
nominal torque of the prime mover if this corre-
sponds with the torque requirement of the driven
machine.
In order to be able to carry out the calculation for
a cylindrical gear stage, the details listed in table
4 must be given in the units mentioned in the
table. The geometric quantities are calculated
according to tables 2 and 3. Usually, they are
contained in the workshop drawings for cylindri-
cal gears.
Table 4 Basic details
Abbreviation Meaning Unit
P Power rating kW
n
1
Pinion speed 1/min
a Centre distance mm
m
n
Normal module mm
d
a1
Tip diameter of the pinion mm
d
a2
Tip diameter of the wheel mm
b
1
Facewidth of the pinion mm
b
2
Facewidth of the wheel mm
z
1
Number of teeth of the pinion
z
2
Number of teeth of the wheel
x
1
Addendum modification coefficient of the pinion
x
2
Addendum modification coefficient of the wheel
n
Normal pressure angle Degree
Reference helix angle Degree
V
40
Kinematic viscosity of lubricating oil at 40 C cSt
R
z1
Peak-to-valley height on pinion flank m
R
z2
Peak-to-valley height on wheel flank m
g
=
1
2
( d
a1
2
d
b1
2
+
u
IuI
d
a2
2
d
b2
2
) asin
wt
121
In the further course of the calculation, the quantities listed in table 5 are required. They are derived
from the basic details according to table 4.
Table 5 Derived quantities
Designation Relation Unit
Gear ratio u = z
2
/z
1
Reference diameter
of the pinion
d
1
= z
1
m
n
/cos mm
Transverse tangential force
at pinion reference circle
F
t
= 19.1 S 10
6
P/(d
1
n
1
) N
Circumferential speed
at reference circle
v = d
1
n
1
/60 000 m/s
Base helix angle
b
= arc sin(cos
n
sin) Degree
of the pinion
z
n1
= z
1
/ (cos cos
2
b
)
of the wheel
z
n2
= z
2
/ (cos cos
2
b
)
Transverse module m
t
= m
n
/ cos mm
Transverse pressure angle
t
= arc tan (tan
n
/ cos) Degree
Working transverse
pressure angle
wt
= arc cos [(z
1
+ z
2
) m
t
cos
t
/ (2a)] Degree
Transverse pitch p
et
= m
t
cos
t
mm
Base diameter of the pinion d
b1
= z
1
m
t
cos
t
mm
Base diameter of the wheel d
b2
= z
2
m
t
cos
t
mm
Length of path of contact mm
= g
/ p
et
Overlap ratio
= b tan
b
/ p
et
b = min (b
1
, b
2
)
122
1.3.3 General factors
1.3.3.1 Application factor
With the application factor K
A
, all additional for-
ces acting on the gears from external sources
are taken into consideration. It is dependent on
the characteristics of the driving and driven ma-
chines, as well as the couplings, the masses and
stiffness of the system, and the operating condi-
tions.
The application factor is determined by the
service classification of the individual gear. If
possible, the factor K
A
should be determined by
means of a careful measurement or a compre-
hensive analysis of the system. Since very often
it is not possible to carry out the one or other
method without great expenditure, reference
values are given in table 6 which equally apply to
all gears in a gear unit.
Table 6 Application factor K
A
Working mode
Working mode of the driven machine
Working mode
of prime mover
Uniform
Moderate
shock loads
Average
shock loads
Heavy
shock loads
Uniform 1.00 1.25 1.50 1.75
Moderate shock loads 1.10 1.35 1.60 1.85
Average shock loads 1.25 1.50 1.75 2.00 or higher
Heavy shock loads 1.50 1.75 2.00 2.25 or higher
1.3.3.2 Dynamic factor
With the dynamic factor K
V
, additional dynamic
forces caused in the meshing itself are taken into
consideration. Taking z
1
, v and u from tables 4
and 5, it is calculated from
K
v
= 1 + 0.0003 z
1
v
1 + u
2
u
2
(4)
1.3.3.3 Face load factor
The face load factor K
H
takes into account the
increase in the load on the tooth flanks caused by
non-uniform load distribution over the facewidth.
According to /8/, it can be determined by means
of different methods. Exact methods based on
comprehensive measurements or calculations
or on a combination of both are very expensive.
Simple methods, however, are not exact, as a
consequence of which estimations made to be
on the safe side mostly result in higher factors.
For normal cylindrical gear teeth without longitu-
dinal correction, the face load factor can be cal-
culated according to method D in accordance
with /8/ dependent on facewidth b and reference
diameter d
1
of the pinion, as follows:
K
H
= 1.15 + 0.18 (b/d
1
)
2
+ 0.0003 b (5)
with b = min (b
1
, b
2
). As a rule, the gear unit
manufacturer carries out an analysis of the load
distribution over the facewidth in accordance
with an exact calculation method /13/. If required,
he makes longitudinal corrections in order to
attain uniform load carrying over the facewidth,
see subsection 1.2.5. Under such conditions, the
face load factor lies within the range of K
H
= 1.1
... 1.25. As a rough rule applies: A sensibly
selected crowning symmetrical in length reduces
the amount of K
H
lying above 1.0 by approx. 40
to 50%, and a directly made longitudinal correc-
tion by approx. 60 to 70%.
In the case of slim shafts with gears arranged on
one side, or in the case of lateral forces or mo-
ments acting on the shafts from external
sources, for the face load factors for gears
without longitudinal correction the values may lie
between 1.5 and 2.0 and in extreme cases even
at 2.5.
Face load factor K
F
for the determination of in-
creased tooth root stress can approximately be
deduced from face load factor K
H
according to
the relation
K
F
= (K
H
)
0.9
(6)
1.3.3.4 Transverse load factors
The transverse load factors K
H
and K
F
take
into account the effect of the non-uniform distri-
bution of load between several pairs of simulta-
neously contacting gear teeth. Under the condi-
tions as laid down in subsection 1.3.1, the result
for surface stress and for tooth root stress
according to method B in accordance with /8/ is
K
H
= K
F
= 1.0 (7)
N/mm
2
123
1.3.4 Tooth flank load carrying capacity
The calculation of surface durability against pit-
ting is based on the Hertzian pressure at the pitch
circle. For pinion and wheel the same effective
Hertzian pressure
H
is assumed. It must not ex-
ceed the permissible Hertzian pressure
Hp
, i.e.
H
)
Hp
.
1.3.4.1 Effective Hertzian pressure
The effective Hertzian pressure is dependent on
the load, and for pinion and wheel is equally de-
rived from the equation
H
= Z
E
Z
H
Z
(8)
u
u + 1 F
t
d
1
b
K
A
K
v
K
H
K
H

H
Effective Hertzian pressure in N/mm
2
Further:
b is the smallest facewidth b
1
or b
2
of pinion
or wheel acc. to table 4
F
t
, u, d
1
acc. to table 5
K
A
Application factor acc. to table 6
K
V
Dynamic factor acc. to equation (4)
K
H
Face load factor acc. to equ. (5)
K
H
Transverse load factor acc. to equ. (7)
Z
E
Elasticity factor; Z
E
= 190
for gears out of steel
Z
H
Zone factor acc. to figure 17
Z
Helix angle factor acc. to equ. (9)

Z
Contact ratio factor acc. to equ. (10)

or (11)
With according to table 4 applies:
cos Z
= (9)
With
and
according to table 5 applies:

(10)
3
4
(1
) +
for
< 1 Z
=
Z
= (11)
1
for
+ 1
Figure 17
Zone factor Z
H
depending on helix angle as
well as on the numbers of teeth z
1
, z
2
, and
addendum modification coefficients x
1
, x
2
;
see table 4.
1.3.4.2 Permissible Hertzian pressure
The permissible Hertzian pressure is determined
by
HP
= Z
L
Z
v
Z
X
Z
R
Z
W
Hlim
S
H
(12)
HP
permissible Hertzian pressure in N/mm
2
. It is
of different size for pinion and wheel if the
strengths of materials
Hlim
are different. Factors
Z
L
, Z
v
, Z
R
, Z
W
and Z
X
are the same for pinion and
wheel and are determined in the following.
The lubricant factor is computed from the
lubricating oil viscosity V
40
according to table 4
using the following formula:
0.25
1 +
Z
L
= 0.91 +
112
V
40
2
) (
(13)
124
For the speed factor, the following applies using
the circumferential speed v according to table 5:
Z
v
= 0.93 +
0.157
1 +
40
v
(14)
The roughness factor can be determined as a
function of the mean peak-to-valley height R
Z
=
(R
Z1
+ R
Z2
)/2 of the gear pair as well as the gear
ratio u and the reference diameter d
1
of the
pinion, see tables 4 and 5, from
Z
R
=
0.513
R
z
(15)
3
(1 + IuI) d
1 [ ]
0.08
For a gear pair with the same tooth flank hard-
ness on pinion and wheel, the work hardening
factor is
Z
W
= 1.0 (16)
The size factor is computed from module m
n
according to table 4 using the following formula:
Z
X
= 1.05 0.005 m
n
(17)
with the restriction 0.9 x Z
X
x 1.
Hlim
Endurance strength of the gear material.
For gears made out of case hardening
steel, case hardened, figure 18 shows a
range from 1300 ... 1650 N/mm
2
depend-
ing on the surface hardness of the tooth
flanks and the quality of the material. Under
the conditions as described in subsection
1.3.1, material quality MQ may be selected
for pinion and wheel, see table on page 97.
S
H
required safety factor against pitting, see
subsection 1.3.6.
1.3.5 Tooth strength
The maximum load in the root fillet at the 30-de-
gree tangent is the basis for rating the tooth
strength. For pinion and wheel it shall be shown
separately that the effective tooth root stress
F
does not exceed the permissible tooth root stress
FP
, i.e.
F
<
FP
.
Figure 18
Allowable stress number for contact stress
Hlim
of alloyed case hardening steels, case
hardened, depending on the surface hard-
ness HV1 of the tooth flanks and the material
quality.
ML modest demands on the material quality
MQ normal demands on the material quality
ME high demands on the material quality,
see /11/
Flank hardness HV1
1.3.5.1 Effective tooth root stress
As a rule, the load-dependent tooth root stresses
for pinion and wheel are different. They are cal-
culated from the following equation:
s
F
= Y
Y
FS
K
A
K
v
K
F
K
F
(18)
b m
n
F
t
F
Effective tooth root stress in N/mm
2
The following factors are of equal size for pinion
and wheel:
m
n
, F
t
acc. to tables 4 and 5
K
A
Application factor acc. to table 6
K
V
Dynamic factor acc. to equation (4)
K
F
Face load factor acc. to equation (6)
K
F
Transverse load factor acc. to equ. (7)
Y
Contact ratio factor acc. to equ. (19)

Y
Helix angle factor acc. to equ. (20)

The following factors are of different size for
pinion and wheel:
b
1,
b
2
Facewidths of pinion and wheel acc. to
table 4. If the facewidths of pinion and
wheel are different, it may be assumed
that the load bearing width of the wider
facewidth is equal to the smaller face-
width plus such extension of the wider that
does not exceed one times the module at
each end of the teeth.
125
Figure 19
Tip factor Y
FS
for external gears with standard basic rack tooth profile acc. to DIN 867
depending on the number of teeth z (or z
n
in case of helical gears) and addendum modification
coefficient x, see tables 4 and 5. The following only approximately applies to internal gears:
Y
FS
= Y
FS
( value for x = 1.0 and z = 300).
degree
degree
degree
126
Y
FS1,
Y
FS2
Tip factors acc. to figure 19. They
account for the complex stress condi-
tion inclusive of the notch effect in the
root fillet.
With the helix angle acc. to table 4 and the
overlap ratio
acc. to table 5 follows:

0.75
(19) Y = 0.25 + cos

2
with the restriction 0.625 ) Y
) 1

(20) Y
= 1
120
with the restriction
Y
+ max [(1 - 0.25
); (1 /120)].
1.3.5.2 Permissible tooth root stress
The permissible tooth root stress for pinion and
wheel is determined by
(S
F
)
FP
= Y
ST
Y
relT
Y
RrelT
Y
X
Flim (21)
FP
permissible tooth root stress in N/mm
2
.
It is not equal for pinion and wheel if the material
strengths
Flim
are not equal. Factors Y
ST
, Y
relT
,
Y
RrelT
and Y
X
may be approximately equal for
pinion and wheel.
Y
ST
is the stress correction factor of the refer-
ence test gears for the determination of
the bending stress number
Flim
. For
standard reference test gears, Y
ST
= 2.0
has been fixed in the standard.
Y
relT
is the notch relative sensitivity factor
(notch sensitivity of the material) refer-
ring to the standard reference test gear.
By approximation Y
relT
= 1.0.
For the relative surface factor (surface rough-
ness factor of the tooth root fillet) referring to the
standard reference test gear the following
applies by approximation, depending on module
m
n
:
Y
RrelT
= 1.00 for m
n
) 8 mm
= 0.98 for 8 mm < m
n
) 16 mm (22)
= 0.96 for m
n
> 16 mm
and for the size factor
Y
X
= 1.05 0.01 m
n
(23)
with the restriction 0.8 ) Y
X
) 1.
Flim
Bending stress number of the gear mate-
rial. For gears out of case hardening steel,
case hardened, a range from 310 ... 520
N/mm
2
is shown in figure 20 depending
on the surface hardness of the tooth
flanks and the material quality. Under the
conditions according to subsection 1.3.1,
a strength pertaining to quality MQ may
be used as a basis for pinion and wheel
see table on page 97.
S
F
Safety factor required against tooth
breakage, see subsection 1.3.6.
Figure 20
Bending stress number
Flim
of alloyed case
hardening steel, case hardened, depending
on the surface hardness HV1 of the tooth
flanks and the material quality.
ML modest demands on the material quality
MQ normal demands on the material quality
ME high demands on the material quality,
see /11/
Flank hardness HV1
1.3.6 Safety factors
The minimum required safety factors according
to DIN are:
against pitting S
H
= 1.0
against tooth breakage S
F
= 1.3.
In practice, higher safety factors are usual. For
multistage gear units, the safety factors are de-
termined about 10 to 20% higher for the expen-
sive final stages, and in most cases even higher
for the cheaper preliminary stages.
Also for risky applications a higher safety factor is
given.
1.3.7 Calculation example
An electric motor drives a coal mill via a multi-
stage cylindrical gear unit. The low speed gear
stage is to be calculated.
Given: Nominal power rating P = 3300 kW;
pinion speed n
1
= 141 1/min.; centre distance a =
815 mm; normal module m
n
= 22 mm; tip diame-
ter d
a1
= 615.5 mm and d
a2
= 1100 mm; pinion
and wheel widths b
1
= 360 mm and b
2
= 350 mm;
numbers of teeth z
1
= 25 and z
2
= 47; addendum
modification coefficients x
1
= 0.310 and x
2
=
0.203; normal pressure angle
n
= 20 degree;
127
Gear Unit Types
helix angle = 10 degree; kinematic viscosity of
the lubricating oil V
40
= 320 cSt; mean peak-to-
valley roughness R
z1
= R
z2
= 4.8 m.
The cylindrical gears are made out of the mate-
rial 17 CrNiMo 6. They are case hardened and
ground with profile corrections and width-sym-
metrical crowning.
Calculation (values partly rounded):
Gear ratio u = 1.88; reference diameter of the pin-
ion d
1
= 558.485 mm; nominal circumferential
force on the reference circle F
t
= 800,425 N; cir-
cumferential speed on the reference circle v =
4.123 m/s; base helix angle
b
= 9.391 degree;
virtual numbers of teeth z
n1
= 26.08 and z
n2
=
49.03; transverse module m
t
= 22.339 mm;
transverse pressure angle
t
= 20.284 degree;
working transverse pressure angle
wt
= 22.244
degree; normal transverse pitch p
et
= 65.829;
base diameters d
b1
= 523.852 mm and d
b2
=
984.842 mm; length of path of contact g
=
98.041 mm; transverse contact ratio
= 1.489;
overlap ratio
= 0.879.
Application factor K
A
= 1.50 (electric motor with
uniform mode of operation, coal mill with medium
shock load); dynamic factor K
V
= 1.027; face load
factor K
H
= 1.20 [acc. to equation (5) follows K
H
= 1.326, however, because of symmetrical
crowning the calculation may be made with a
smaller value]; K
F
= 1.178; K
H
= K
F
= 1.0.
Load carrying capacity of the tooth flanks:
Elasticity factor Z
E
= 190 N mm
2
; zone factor
Z
H
= 2.342; helix angle factor Z
= 0.992; contact
ratio factor Z
= 0.832. According to equation (8),

the Hertzian pressure for pinion and wheel is
H
= 1251 N/mm
2
.
Lubricant factor Z
L
= 1.047; speed factor Z
V
=
0.978; roughness factor Z
R
= 1.018; work
hardening factor Z
W
= 1.0; size factor Z
X
= 0.94.
With the allowable stress number for contact
stress (pitting)
Hlim
= 1500 N/mm
2
, first the
permissible Hertzian pressure
HP
= 1470
N/mm
2
is determined from equation (12) without
taking into account the safety factor.
The safety factor against pitting is found by S
H
=
HP
/
H
= 1470/1251 = 1.18. The safety factor re-
ferring to the torque is S
H
2
= 1.38.
Load carrying capacity of the tooth root:
Contact ratio factor Y
= 0.738; helix angle factor

Y
= 0.927; tip factors Y

FS1
= 4.28 and Y
FS2
=
4.18 (for h
a0
= 1.4 m
n
;
a0
= 0.3 m
n
;
pro
= 10 de-
gree; p
rO
= 0.0205 m
n
). The effective tooth root
stresses
F1
= 537 N/mm
2
for the pinion and
F2
= 540 N/mm
2
for the wheel can be obtained from
equation (18).
Stress correction factor Y
ST
= 2.0; relative sensi-
tivity factor Y
relT
= 1.0; relative surface factor
Y
RelT
= 0.96; size factor Y
X
= 0.83. Without taking
into consideration the safety factor, the permis-
sible tooth root stresses for pinion and wheel
FP1
=
FP2
= 797 N/mm
2
can be obtained from
equation (21) with the bending stress number
Flim
= 500 N/mm
2.
The safety factors against tooth breakage refer-
ring to the torque are S
F
=
FP
/
F
: for the pinion
S
F1
= 797/537 = 1.48 and for the wheel S
F2
=
797/540 = 1.48.
1.4 Gear unit types
1.4.1 Standard designs
In the industrial practice, different types of gear
units are used. Preferably, standard helical and
bevel-helical gear units with fixed transmission
ratio and size gradation are applied. These sin-
gle-stage to four-stage gear units according to
the modular construction system cover a wide
range of speeds and torques required by the
driven machines. Combined with a standard
electric motor such gear units are, as a rule, the
most economical drive solution.
But there are also cases where no standard
drives are used. Among others, this is true for
high torques above the range of standard gear
units. In such cases, special design gear units
are used, load sharing gear units playing an im-
portant role there.
1.4.2 Load sharing gear units
In principle, the highest output torques of gear
units are limited by the manufacturing facilities,
since gear cutting machines can make gears up
to a maximum diameter only. Then, the output
torque can be increased further only by means of
load sharing in the gear unit. Load sharing gear
units are, however, also widely used for lower
torques as they provide certain advantages in
spite of the larger number of internal
components, among others they are also used in
standard design. Some typical features of the
one or other type are described in the following.
1.4.3 Comparisons
In the following, single-stage and two-stage gear
units up to a ratio of i = 16 are examined. For
common gear units the last or the last and the last
but one gear stage usually come to approx. 70 to
80% of the total weight and also of the manufac-
turing expenditure. Adding further gear stages in
order to achieve higher transmission ratios thus
does not change anything about the following
fundamental description.
In figure 21, gear units without and with load
sharing are shown, shaft 1 each being the HSS
and shaft 2 being the LSS. With speeds n
1
and
n
2
, the transmission ratio can be obtained from
the formula
i = n
1
/ n
2
(24)
128
Gear Unit Types
The diameter ratios of the gears shown in figure
21 correspond to the transmission ratio i = 7. The
gear units have the same output torques, so that
in figure 21 a size comparison to scale is illustrat-
ed. Gear units A, B, and C are with offset shaft ar-
rangement, and gear units D, E, F, and G with
coaxial shaft arrangement.
Figure 21
Diagrammatic view of cylindrical gear unit
types without and with load sharing. Trans-
mission ratio i = 7. Size comparison to scale of
gear units with the same output torque.
Gear unit A has one stage, gear unit B has two
stages. Both gear units are without load sharing.
Gear units C, D, E, F, and G have two stages and
are load sharing. The idler gears in gear units C
and D have different diameters. In gear units E, F,
and G the idler gears of one shaft have been
joined to one gear so that they are also con-
sidered to be single-stage gear units.
Gear unit C has double load sharing. Uniform
load distribution is achieved in the high-speed
gear stage by double helical teeth and the axial
movability of shaft 1.
In gear unit D the load of the high-speed gear
stage is equally shared between three interme-
diate gears which is achieved by the radial mova-
bility of the sun gear on shaft 1. In the low-speed
gear stage the load is shared six times altogether
by means of the double helical teeth and the axial
movability of the intermediate shaft.
In order to achieve equal load distribution be-
tween the three intermediate gears of gear units
E, F, and G the sun gear on shaft 1 mostly is ra-
dially movable. The large internal gear is an an-
nulus gear which in the case of gear unit E is con-
nected with shaft 2, and in the case of gear units
F and G with the housing. In gear units F and G,
web and shaft 2 form an integrated whole. The id-
ler gears rotate as planets around the central
axle. In gear unit G, double helical teeth and axial
movability of the idler gears guarantee equal
load distribution between six branches.
1.4.3.1 Load value
By means of load value B
L
, it is possible to com-
pare cylindrical gear units with different ultimate
stress values of the gear materials with each
other in the following examinations.
According to /14/, the load value is the tooth peri-
pheral force F
u
referred to the pinion pitch diame-
ter d
w
and the carrying facewidth b, i.e.
B
L
=
(25)
F
u
b d
w
The permissible load values of the meshings of
the cylindrical gear units can be computed from
the pitting resistance by approximation, as
shown in /15/ (see section 1.3.4), using the
following formula:
B
L
7
.
10
-6
(26)
u
u + 1
2
Hlim
K
A
S
H
2
with B
L
in N/mm
2
and allowable stress number
for contact stress (pitting)
Hlim
in N/mm
2
as well
as gear ratio u, application factor K
A
and factor of
safety from pitting S
H
. The value of the gear ratio
u is always greater than 1, and is negative for in-
ternal gear pairs (see table 3).
Load value B
L
is a specific quantity and
independent of the size of the cylindrical gear
unit. The following applies for practically execut-
ed gear units: cylindrical gears out of case
hardening steel B
L
= 4...6 N/mm
2
; cylindrical
gears out of quenched and tempered steel B
L
=
1...1.5 N/mm
2
; planetary gear stages with
annulus gears out of quenched and tempered
steel, planet gears and sun gears out of case
hardening steel B
L
= 2.0...3.5 N/mm
2
.
=
m T
2
D
3
B
L
=
T
2
G B
L
=
T
2
A
3/2
B
L
mm
m mm
2
kg
mm
2
m
2
T
2
in mm
B
L
in N/mm
2
D in mm
G in kg
A in m
2
129
Gear Unit Types
1.4.3.2 Referred torques
In figure 22, referred torques for the gear units
shown in figure 21 are represented, dependent
on the transmission ratio i. Further explanations
are given in table 7. The torque T
2
is referred to
the construction dimension D when comparing
the sizes, to the weight of the gear unit G when
comparing the weights, and to the generated
surface A of the pitch circle cylinders when
comparing the gear teeth surfaces. Gear unit
weight G and gear teeth surface A (= generated
surface) are one measure for the manufacturing
cost. The higher a curve, in figure 22, the better
the respective gear unit in comparison with the
others.
Table 7 Referred Torques
Comparison criteria Definition Dimension
Units of the
basic details
Size
Weight
Gear teeth surface
d) Full-load efficiency c) Torque referred to gear teeth surface
Figure 22
Comparisons of cylindrical gear unit types in figure 21 dependent on the transmission ratio i.
Explanations are given in table 7 as well as in the text.
b) Torque referred to gear unit weight a) Torque referred to size
Ratio i Ratio i
Ratio i Ratio i
130
Gear Unit Types
For all gear units explained in figures 21 and 22,
the same prerequisites are valid. For all gear
units, the construction dimension D is larger than
the sum of the pitch diameters by the factor 1.15.
Similar definitions are valid for gear unit height
and width. Also the wall thickness of the housing
is in a fixed relation to the construction dimension
D /15/.
With a given torque T
2
and with a load value B
L
computed according to equation (26), the
construction dimension D, the gear unit weight
G, and the gear teeth surface A can be deter-
mined by approximation by figure 22 for a given
transmission ratio i. However, the weights of
modular-type gear units are usually higher, since
the housing dimensions are determined
according to different points of view.
Referred to size and weight, planetary gear units
F and G have the highest torques at small ratios i.
For ratios i < 4, the planetary gear becomes the
pinion instead of the sun gear. Space require-
ment and load carrying capacity of the planetary
gear bearings decrease considerably. Usually,
the planetary gear bearings are arranged in the
planet carrier for ratio i < 4.5.
Gear units C and D, which have only external
gears, have the highest torque referred to size
and weight for ratios above i 7. For planetary
gear units, the torque referred to the gear teeth
surface is more favourable only in case of small
ratios, if compared with other gear units. It is to be
taken into consideration, however, that internal
gears require higher manufacturing expenditure
than external gears for the same quality of manu-
facture.
The comparisons show that there is no optimal
gear unit available which combines all advan-
tages over the entire transmission ratio range.
Thus, the output torque referred to size and
weight is the most favourable for the planetary
gear unit, and this all the more, the smaller the
transmission ratio in the planetary gear stage.
With increasing ratio, however, the referred
torque decreases considerably. For ratios above
i = 8, load sharing gear units having external
gears only are more favourable because with
increasing ratio the referred torque decreases
only slightly.
With regard to the gear teeth surface, planetary
gear units do not have such big advantages if
compared to load sharing gear units having
external gears only.
1.4.3.3 Efficiencies
When comparing the efficiency, figure 22d, only
the power losses in the meshings are taken into
consideration. Under full load, they come to
approx. 85% of the total power loss for common
cylindrical gear units with rolling bearings. The
efficiency as a quantity of energy losses results
from the following relation with the input power at
shaft 1 and the torques T
1
and T
2
(27) h )
+
1
i
T
2
T
1
+
All gear units shown in figure 21 are based on
the same coefficient of friction of tooth profile
z = 0.06. Furthermore, gears without adden-
dum modification and numbers of teeth of the
pinion z = 17 are uniformly assumed for all gear
units /15/, so that a comparison is possible.
The single stage gear unit A has the best
efficiency. The efficiencies of the two stage gear
units B, C, D, E, F, and G are lower because the
power flow passes two meshings. The internal
gear pairs in gear units E, F, and G show better
efficiencies owing to lower sliding velocities in the
meshings compared to gear units B, C, and D
which only have external gear pairs.
The lossfree coupling performance of planetary
gear units F and G results in a further improve-
ment of the efficiency. It is therefore higher than
that of other comparable load sharing gear units.
For higher transmission ratios, however, more
planetary gear stages are to be arranged in
series so that the advantage of a better efficiency
compared to gear units B, C, and D is lost.
1.4.3.4 Example
Given: Two planetary gear stages of type F
arranged in series, total transmission ratio
i = 20, output torque T
2
= 3
.
10
6
Nm, load value
B
L
= 2.3 N/mm
2
. A minimum of weight is approxi-
mately achieved by a transmission ratio division
of i = 5
.
4 of the HS and LS stage. At
1
= 30 m
mm
2
/kg and
2
= 45 m mm
2
/kg according to
figure 22b, the weight for the HS stage is approxi-
mately 10.9 t and for the LS stage approxi-
mately 30 t, which is a total 40.9 t. The total
efficiency according to figure 22d is =
0.986
.
0.985 = 0.971.
In comparison to a gear unit of type D with the
same transmission ratio i = 20 and the same
output torque T
2
= 3
.
10
6
Nm, however, with a
better load value B
L
= 4 N/mm
2
this gear unit has
a weight of 68.2 t according to figure 22 with
= 11 m mm
2
/kg and is thus heavier by 67%. The
advantage is a better efficiency of = 0.98. The
two planetary gear stages of type F together
have a power loss which is by 45% higher than
that of the gear unit of type D. In addition, there is
not enough space for the rolling bearings of the
planet gears in the stage with i = 4.
131
Figure 23
Correction curve according to DIN 45635 /16/ for the A-weighted sound power level or sound
pressure level
L
e
v
e
l

c
o
r
r
e
c
t
i
o
n

(
d
B
)
Correction curve A
Frequency (Hz)
1.5 Noise emitted by gear units
1.5.1 Definitions
Noise emitted by a gear unit - like all other noises
- is composed of tones having different frequen-
cies f.
Measure of intensity is the sound pressure p
which is the difference between the highest (or
lowest) and the mean pressure in a sound wave
detected by the human ear.
The sound pressure can be determined for a sin-
gle frequency or - as a combination - for a fre-
quency range (single-number rating). It is
dependent on the distance to the source of
sound.
In general, no absolute values are used but
amplification or level quantities in bel (B) or
decibel (dB). Reference value is, for instance,
the sound pressure at a threshold of audibility
p
o
= 2
.
10
-5
N/m
2
.
In order to take into consideration the different
sensitivities of the human ear at different
frequencies, the physical sound pressure value
at the different frequencies is corrected
according to rating curve A, see figure 23.
Apart from sound pressures at certain places,
sound powers and sound intensities of a whole
system can be determined.
From the gear unit power a very small part is
turned into sound power. This mainly occurs in
the meshings, but also on bearings, fan blades,
or by oil movements. The sound power is
transmitted from the sources to the outside gear
unit surfaces mainly by structure-borne noise
(material vibrations). From the outside surfaces,
air borne noise is emitted.
The sound power L
WA
is the A-weighted sound
power emitted from the source of sound and thus
a quantity independent of the distance. The
sound power can be converted to an average
sound pressure for a certain place. The sound
pressure decreases with increasing distance
from the source of sound.
The sound intensity is the flux of sound power
through a unit area normal to the direction of
propagation. For a point source of sound it
results from the sound power L
W
divided by the
spherical enveloping surface 4 r
2
, concentri-
cally enveloping the source of sound. Like the
sound pressure, the sound intensity is depend-
ent on the distance to the source of sound,
however, unlike the sound pressure it is a
directional quantity.
The recording instrument stores the sound pres-
sure or sound intensity over a certain period of
time and writes the dB values in frequency
ranges (bands) into the spectrum (system of
coordinates).
Very small frequency ranges, e.g. 10 Hz or 1/12
octaves are termed narrow bands, see figure 24.
132
Figure 24
Narrow band frequency spectrum for L
pA
(A-weighted sound pressure level) at a di-
stance of 1 m from a gear unit.
(Frequency)
Histograms occur in the one-third octave spectrum
and in the octave spectrum, see figures 25 and 26.
In the one-third octave spectrum (spectrum with 1/3
octaves), the bandwidth results from
f
o
/ f
u
= 2, i.e. f
o
/ f
u
= 1.26,
3
f
o
= f
m

.
1.12 and f
u
= f
m
/ 1.12;
f
m
= mean band frequency, f
o
= upper band fre-
quency, f
u
= lower band frequency. In case of oc-
taves, the upper frequency is as twice as big as the
lower one, or f
o
= f
m

.
1.41 and f
u
= f
m
/ 1.41.
Bandwidth
S
o
u
n
d

i
n
t
e
n
s
i
t
y
l
e
v
e
l

d
B
(
A
)
Frequency (HZ)
Figure 25
One-third octave spectrum of a gear unit
(sound intensity level, A-weighted)
S
o
u
n
d

i
n
t
e
n
s
i
t
y
l
e
v
e
l

d
B
(
A
)
Frequency (HZ)
Bandwidth
Figure 26
Octave spectrum of a gear unit (sound inten-
sity level, A-weighted)
The total level (resulting from logarithmic addi-
tion of individual levels of the recorded frequency
range) is a single-number rating. The total level is
the common logical value for gear unit noises.
The pressure level is valid for a certain distance,
in general 1 m from the housing surface as an
ideal parallelepiped.
1.5.2 Measurements
The main noise emission parameter is the sound
power level.
1.5.2.1 Determination via sound pressure
DIN 45635 Part 1 and Part 23 describe how to de-
termine the sound power levels of a given gear
unit /16/. For this purpose, sound pressure levels
L
pA
are measured at fixed points surrounding the
gear unit and converted to sound power levels
L
WA
. The measurement surface ratio L
S
is an
auxiliary quantity which is dependent on the sum
of the measurement surfaces. When the gear
unit is placed on a reverberant base, the bottom
is not taken into consideration, see example in
figure 27.
Measure-
ment
surface
Figure 27
Example of arrangement of measuring
points according to DIN 45 635 /16/
Machine enclosing reference box
In order to really detect the noise radiated by the
gear unit alone, corrections for background noise
and environmental influences are to be made. It
is not easy to find the correct correction values,
because in general, other noise radiating ma-
chines are in operation in the vicinity.
1.5.2.2 Determination via sound intensity
The gear unit surface is scanned manually all
around at a distance of, for instance, 10 cm, by
means of a special measuring device containing
two opposing microphones. The mean of the lev-
els is taken via the specified time, e.g. two min-
utes. An analyzer computes the intensity or
power levels in one-third octave or octave bands.
The results can be seen on a display screen. In
most cases, they can also be recorded or printed,
see figures 25 and 26.
133
The results correspond to the sound power lev-
els as determined in accordance with DIN 45635.
This procedure requires a larger number of de-
vices to be used, however, it is a very quick one.
Above all, foreign influences are eliminated in the
simplest way.
1.5.3 Prediction
It is not possible to exactly calculate in advance
the sound power level of a gear unit to be made.
However, one can base the calculations on expe-
rience. In the VDI guidelines 2159 /17/, for exam-
ple, reference values are given. Gear unit manu-
facturers, too, mostly have own records.
The VDI guidelines are based on measurements
carried out on a large number of industrial gear
units. Main influence parameters for gear unit
noises are gear unit type, transmitted power,
manufacturing quality and speed. In VDI 2159, a
distinction is made between cylindrical gear units
with rolling bearings, see figure 28, cylindrical
gear units with sliding bearings (high-speed gear
units), bevel gear and bevel-helical gear units,
planetary gear units and worm gear units.
Furthermore, information on speed variators can
be found in the guidelines.
Figure 28 exemplary illustrates a characteristic
diagram of emissions for cylindrical gear units.
Similar characteristic diagrams are also avail-
able for the other gear unit types mentioned.
Within the characteristic diagrams, 50%- and
80%-lines are drawn. The 80%-line means, for
example, that 80% of the recorded industrial
gear units radiate lower noises.
The lines are determined by mathematical equa-
tions. For the 80%-lines, the equations according
to VDI 2159 are:
Gear units Total sound power level L
WA
Cylindrical gear units (rolling bearings) 77.1 + 12.3
.
log P / kW (dB)
Cylindrical gear units (sliding bearings) 85.6 + 6.4
.
log P / kW (dB)
Bevel gear and bevel-helical gear units 71.7 + 15.9
.
log P / kW (dB)
Planetary gear units 87.7 + 4.4
.
log P / kW (dB)
Worm gear units 65.0 + 15.9
.
log P / kW (dB)
For restrictions, see VDI 2159.
Type: Cylindrical gear units with external teeth mainly (> 80%) having the following characteristic
features:
Housing:
Cast iron housing
Bearing arrangement:
Rolling bearings
Lubrication:
Dip lubrication
Installation:
Rigid on steel or concrete
Power rating: 0.7 up to 2400 kW
Input speed (= max. speed):
1000 up to 5000 min
-1
(mostly 1500 min
-1
)
Max. circumferential speed:
1 up to 20 ms
-1
Output torque:
100 up to 200000 Nm
No. of gear stages: 1 to 3
Information on gear teeth:
HS gear stage with helical teeth
(b = 10 up to 30), hardened,
fine-machined, DIN quality 5 to 8
Figure 28
Characteristic diagram of emissions for cylindrical gear units
(industrial gear units) acc. to VDI 2159 /17/
Logarithmic regression
LWA = 77.1 + 12.3 x log P/kW dB
(80%-line)
Certainty rate r
2
= 0.83
Probability 90%
S
o
u
n
d

p
o
w
e
r

l
e
v
e
l

L
W
A
Mechanical power rating P
134
The measurement surface sound pressure level
L
pA
at a distance of 1 m is calculated from the to-
tal sound power level
L
pA
= L
WA
L
s
(dB) (28)
L
s
= 10
.
log S (dB) (29)
S = Sum of the hypothetical surfaces (m
2
)
enveloping the gear unit at a distance of 1 m
(ideal parallelepiped)
Example of information for P = 100 kW in a
2-stage cylindrical gear unit of size 200 (centre
distance in the 2nd gear stage in mm), with rolling
bearings, of standard quality:
The sound power level, determined in accord-
ance with DIN 45635 (sound pressure measure-
ment) or according to the sound intensity meas-
urement method, is 102 + 2 dB (A). Room and
connection influences have not been taken into
consideration. If it is agreed that measurements
are to be made they will be carried out on the ma-
nufacturers test stand.
Note:
For this example, a measurement surface sound
pressure level of 102 - 13.2 89 db (A), tolerance
+ 2 dB, is calculated at a distance of 1 m with a
measurement surface S = 21 m
2
and a measure-
ment surface ratio L
S
= 13.2 dB.
Individual levels in a frequency spectrum cannot
safely be predicted for gear units because of the
multitude of influence parameters.
1.5.4 Possibilities of influencing
With the selection of other than standard geome-
tries and with special tooth modifications (see
section 1.2.5), gear unit noises can be positively
influenced. In some cases, such a procedure re-
sults in a reduction in the performance (e.g. mo-
dule reduction) for the same size, in any case,
however, in special design and manufacturing
expenditure. Housing design, distribution of
masses, type of rolling bearing, lubrication and
cooling are also important.
Sometimes, the only way is to enclose the gear
units which makes possible that the total level is
reduced by 10 to 25 dB, dependent on the condi-
tions.
Attention has to be paid to it, that no structure-
borne noise is radiated via coupled elements
(couplings, connections) to other places from
where then airborne noise will be emitted.
A sound screen does not only hinder the propa-
gation of airborne noise but also the heat dissipa-
tion of a gear unit, and it requires more space.
135
Shaft Couplings Page
General Fundamental Principles 136
Rigid Couplings 136
Torsionally Flexible Couplings 136-138
Torsionally Rigid Couplings 138
Positive Clutches 138
Friction Clutches 138
Synoptical Table of Torsionally Flexible and Torsionally Rigid Couplings 139
Positive Clutches and Friction Clutches 140
136
Shaft Couplings
General Fundamental Principles
Rigid and Torsionally Flexible Couplings
2. Shaft couplings
2.1 General fundamental principles
In mechanical equipment, drives are consisting
of components like prime mover, gear unit, shafts
and driven machine. Such components are con-
nected by couplings which have the following
tasks:
- Transmitting an as slip-free as possible motion
of rotation, and torques;
- Compensating shaft misalignments (radial,
axial, angular);
- Reducing the torsional vibration load, influenc-
ing and displacing the resonant ranges;
- Damping torque and speed impulses;
- Interrupting the motion of rotation (clutches);
- Limiting the torque;
- Sound isolation;
- Electrical insulation.
The diversity of possible coupling variants is
shown in the overview in figure 29. A distinction is
made between the two main groups couplings
and clutches, and the subgroups rigid/flexible
couplings and positive/friction clutches.
Shaft couplings
Couplings
Flexible Positive Rigid
Torsionally
flexible
Rigid,
universal joint
Clutches
Friction
Friction Hydrodyn. Electrodyn.
Clamp,
Flange,
Radial tooth
Pin and bush,
Claw,
Tyre,
Flange,
Coil spring,
Leaf spring,
Air bag
spring,
Cardan
Gear,
Steel plate,
Membrane,
Universal joint,
Rolling contact
joint,
Oldham coupling
Claw,
Pin and
bush,
Gear
(*)
Cone,
Plate,
Multiple disk,
Centrifugal
force,
Overrunning,
Automatic
disengaging,
Friction
Foettinger Eddy current
(*) In case of additional gearing, all clutches are disengageable when stationary.
Figure 29
Overview of possible shaft coupling designs
2.2 Rigid couplings
Rigid couplings connect two shaft ends and do
practically not allow any shaft misalignment.
They are designed as clamp, flange and radial
tooth couplings and allow the transmission of
high torques requiring only small space. The
coupling halves are connected by means of bolts
(close fitting bolts). In case of clamp and flange
couplings (with split spacer ring), radial disas-
sembly is possible. Radial tooth couplings are
self-centering and transmit both high and alter-
nating torques.
2.3 Torsionally flexible couplings
Torsionally flexible couplings are offered in many
designs. Main functions are the reduction of
torque impulses by elastic reaction, damping of
torsional vibrations by internal damping in case
of couplings with flexible rubber elements, and
frictional damping in case of couplings with
flexible metal elements, transfer of resonance
frequencies by variation of the torsional stiffness,
and compensation of shaft misalignments with
low restoring forces.
137
Shaft Couplings
Torsionally Flexible Couplings
The flexible properties of the couplings are gen-
erated by means of metal springs (coil springs,
leaf springs) or by means of elastomers (rubber,
plastics). For couplings incorporating flexible
metal elements, the torsional flexibility is be-
tween 2 and 25 degree, depending on the type.
The stiffness characteristics, as a rule, show a
linear behaviour, unless a progressive character-
istic has intentionally been aimed for by design
measures. Damping is achieved by means of
friction and viscous damping means.
In case of couplings incorporating elastomer ele-
ments, a distinction is made between couplings
of average flexibility with torsion angles of 2 up to
5 degree and couplings of high flexibility with tor-
sion angles of 5 up to 30 degree. Depending on
the type, the flexible elements of the coupling are
subjected to compression (tension), bending and
shearing, or to a combined form of stressing. In
some couplings (e.g. tyre couplings), the flexible
elements are reinforced by fabric or thread in-
serts. Such inserts absorb the coupling forces
and prevent the elastic-viscous flow of the ela-
stomer.
Couplings with elastomer elements primarily
subjected to compression and bending have
non-linear progressive stiffness characteristics,
while flexible elements (without fabric insert)
merely subjected to shearing generate linear
stiffness characteristics. The quasi-statical
torsional stiffness of an elastomer coupling
increases at dynamic load (up to approximately
30 Hz, test frequency 10 Hz) by approximately 30
to 50%. The dynamic stiffness of a coupling is
influenced [(+) increased; () reduced] by the
average load (+), the oscillation amplitude (),
temperature (), oscillation frequency (+), and
period of use ().
For rubber-flexible couplings, the achievable
damping values are around = 0.8 up to 2
(damping coefficient ; DIN 740 /18/). Damping
leads to heating of the coupling, and the heat loss
has to be dissipated via the surface. The
dynamic loading capacity of a coupling is
determined by the damping power and the
restricted operating temperature of elastomers
of 80C up to max. 100C.
When designing drives with torsionally flexible
couplings according to DIN 740 /18/, torsional
vibrations are taken into account by reducing the
drive to a two-mass vibration generating system,
or by using torsional vibration simulation pro-
grams which can compute detailed vibration sys-
tems for both steady and unsteady conditions.
Examples of couplings incorporating elastomer
elements of average flexibility are claw-, pin-,
and pin and bush couplings.
The N-EUPEX coupling is a wear-resistant pin
coupling for universal use (figure 30) absorbing
large misalignments. The coupling is available
as fail-safe coupling and as coupling without fail-
safe device. In its three-part design it is suitable
for simple assembly and simple replacement of
flexible elements. The coupling is made in differ-
ent types and sizes for torques up to 62,000 Nm.
The BIPEX coupling is a flexible fail-safe claw
coupling in compact design for high power
capacity and is offered in different sizes for
maximum torques up to 3,700 Nm. The coupling
is especially suitable for plug-in assembly and
fitting into bell housings.
The RUPEX coupling is a flexible fail-safe pin
and bush coupling which as a universal coupling
is made in different sizes for low up to very high
torques (10
6
Nm) (figure 31). The coupling is
suitable for plug-in assembly and capable of
absorbing large misalignments. The optimized
shape of the barrelled buffers and the conical
seat of the buffer bolts facilitate assembly and
guarantee maintenance-free operation.
Because of their capability to transmit high
torques, large RUPEX couplings are often used
on the output side between gear unit and driven
machine. Since the coupling hubs are not only
offered in grey cast iron but also in steel, the
couplings are also suitable for high speeds.
Examples of highly flexible couplings incorporat-
ing elastomer elements are tyre couplings,
flange couplings, ring couplings, and large-vol-
ume claw couplings with cellular elastic materi-
als. Examples of flexible couplings incorporating
metal elements are coil spring and leaf spring
couplings.
The ELPEX coupling (figure 32) is a highly flex-
ible ring coupling without torsional backlash
which is suitable for high dynamic loads and has
good damping properties. Rings of different elas-
ticity are suitable for optimum dynamic tuning of
drives. Torque transmitting thread inserts have
been vulcanized into the rings out of high-quality
natural rubber. Due to the symmetrical design
the coupling is free from axial and radial forces
and allows large shaft misalignments even under
torque loads. Typical applications for ELPEX
couplings which are available for torques up to
90,000 Nm are drives with periodically exciting
aggregates (internal combustion engines,
reciprocating engines) or extremely shock-
loaded drives with large shaft misalignments.
Another highly flexible tyre coupling with a simple
closed tyre as flexible element mounted between
two flanges is the ELPEX-B coupling. It is avai-
lable in different sizes for torques up to 20,000
Nm.
138
Shaft Couplings
Torsionally Flexible Couplings
Torsionally Rigid Couplings
Positive and Friction Clutches
This coupling features high flexibility without
torsional backlash, absorbs large shaft
misalignments, and permits easy assembly and
disassembly (radial).
The ELPEX-S coupling (figure 33) is a highly
flexible, fail-safe claw coupling absorbing large
shaft misalignments. The large-volume cellular
flexible elements show very good damping
properties with low heating and thus allow high
dynamic loads. The couplings have linear
stiffness characteristics, and with the use of
different flexible elements they are suitable for
optimum dynamic tuning of drives. The couplings
are of compact design and are suitable for
torques up to 80,000 Nm. Plug-in assembly is
possible. This universal coupling can be used in
drives with high dynamic loads which require low
frequency with good damping.
2.4 Torsionally rigid couplings
Torsionally rigid couplings are used where the
torsional vibration behaviour should not be
changed and exact angular rotation is required,
but shaft misalignment has to be absorbed at the
same time. With the use of long floating shafts
large radial misalignments can be allowed.
Torsionally rigid couplings are very compact,
however, they have to be greased with oil or
grease (exception: steel plate and membrane
couplings). Typical torsionally rigid couplings are
universal joint, gear, membrane and steel plate
couplings, which always have to be designed as
double-jointed couplings with floating shafts
(spacers) of different lengths.
Universal joints allow large angular
misalignments (up to 40 degree), the dynamic
load increasing with the diffraction angle. In order
to avoid pulsating angular rotation (2 times the
torsional frequency), universal joints must
always be arranged in pairs (same diffraction
angle, forks on the intermediate shaft in one
plane, input and output shaft in one plane).
Constant velocity joints, however, always
transmit uniformly and are very short.
Gear couplings of the ZAPEX type (figure 34)
are double-jointed steel couplings with crowned
gears which are capable of absorbing shaft
misalignments (axial, radial and angular up to 1
degree) without generating large restoring
forces. The ZAPEX coupling is of compact
design, suitable for high speeds, and transmits
very high torques (depending on the size up to >
10
6
Nm), and in addition offers large safety
reserves for the absorption of shock loads. It is
lubricated with oil or grease. Fields of application
are, among others, rolling mills, cement mills,
conveyor drives, turbines.
The ARPEX coupling (figure 35) is a double-
jointed, torsionally rigid plate coupling for the
absorption of shaft misalignments (angular up to
1 degree). The coupling is maintenance-free (no
lubrication) and wear-resistant and owing to its
closed plate packs allows easy assembly. A wide
range of ARPEX couplings is available - from the
miniature coupling up to large-size couplings for
torques up to > 10
6
Nm. The coupling transmits
torques very uniformly, and owing to its all-steel
design is suitable for high ambient temperatures
(up to 280C) and high speeds. Fields of
application are, among others, paper machines,
ventilators, pumps, drives for materials-handling
equipment as well as for control systems.
2.5 Positive clutches
This type includes all clutches which can be
actuated when stationary or during synchronous
operation in order to engage or disengage a
machine to or from a drive. Many claw, pin and
bush, or gear couplings can be used as clutches
by axially moving the driving member. With the
additional design element of interlocking teeth,
all flexible couplings can be used as clutches.
2.6 Friction clutches
In friction clutches, torques are generated by
friction, hydrodynamic or electrodynamic effect.
The clutch is actuated externally, even with the
shaft rotating (mechanically, hydraulically,
pneumatically, magnetical), speed-dependent
(centrifugal force, hydrodynamic), torque-
dependent (slip clutches, safety clutches), and
dependent on the direction of rotation (overrun-
ning clutches).
Of the different clutch types, friction clutches are
most commonly used which may contain either
dry- or wet- (oil-lubricated) friction elements.
Dependent on the friction element and the
number of friction surface areas, a distinction is
made between cylindrical, cone, flange and disk
clutches. The larger the number of friction
surface areas, the smaller the size of the clutch.
Further criteria are wear, service life, idle torque,
cooling, cycle rate, and uniform friction effect
(non-chattering).
The PLANOX clutch is a dry-friction multiple
disk clutch with one up to three disks, which has
been designed with overload protection for appli-
cation in general mechanical engineering. It is
actuated externally by mechanical, electrical,
pneumatic or hydraulic force. Uniform transmis-
sion of torque is guaranteed by spring pressure
even after high cylce rates. The clutch is made in
different types and sizes for torques up to 3 S 10
5
Nm.
139
Shaft Couplings
Synoptical Table of Torsionally Flexible and
Torsionally Rigid Couplings
Figure 30
Flexible pin coupling,
N-EUPEX, in three parts
Figure 31
Flexible pin and bush coupling, RUPEX
Figure 32
Highly flexible ring coupling, ELPEX
Figure 33
Highly flexible claw coupling with
cellular flexible elements, ELPEX-S
Figure 34
Gear coupling, ZAPEX
Figure 35
All-steel coupling, with plate packs, ARPEX
140
Shaft Couplings
Friction Clutches
Fluid Couplings
The AUTOGARD torque limiter is an automati-
cally actuating safety clutch which disconnects
driving and driven side by means of a high-accu-
racy ball-operated mechanism and interrupts the
transmission of torque as soon as the set disen-
gagement torque is exceeded. The torque limiter
is ready for operation again when the mechan-
ism has been re-engaged during standstill. The
clutch is made in different sizes for disengage-
ment torques up to 56,500 Nm.
Speed-controlled clutches allow soft starting of
heavy-duty driven machines, the motor accel-
erating itself at first and then driving the machine.
This permits the use of smaller dimensioned mo-
tors for high mass moments of inertia and a high
number of starts. Speed-controlled clutches are
designed as centrifugal clutches with segments,
e.g. retaining springs which transmit torques only
from a specified operating speed on, or with pel-
lets (powder, balls, rollers). The torque which is
generated by friction on the lateral area of the
output part increases as the square of the input
speed. After running up, the clutch operates
without slip.
The FLUDEX coupling (figure 36) is a hydrody-
namic fluid coupling operating according to the
Fttinger principle without mechanical friction.
The coupling parts on the input (pump) and out-
put (turbine) side are not mechanically connect-
ed and thus wear-resistant.
Torque is transmitted by the rotating oil fluid in the
coupling accelerated by the radial blades (pulse
exchange). Fluid couplings have the same char-
acteristics as turbines; torque increases with the
second power, and power capacity is proportion-
al to the third power of the input speed. During
steady torque transmission little operating slip
occurs which heats up the coupling. As safety
elements for limiting the temperature, fusible
safety plugs and electronically or mechanically
controlled temperature monitors are used.
Fluid couplings are mainly used for starting great
masses, for separating torsional vibrations, and
for limiting overloads during starting and in case
of blockages.
1 Blade wheel housing
(outer wheel)
2 Cover
3 Fusible safety plug
4 Filler plug
5 Impeller (inner wheel)
6 Hollow shaft
Figure 36
Basic design of a fluid coupling with and without delay chamber, FLUDEX type
Outer wheel drive
7 Delay chamber
8 Working chamber
9 Flexible coupling
(N-EUPEX D)
10 Damming chamber
141
Vibrations Page
Symbols and Units 142
General Fundamental Principles 143-145
Solution Proposal for Simple Torsional Vibrators 145/146
Solution of the Differential Equation of Motion 146/147
Formulae for the Calculation of Vibrations 147
Mass 147
Mass Moment of Inertia 147
Symbols and Units of Translational and Torsional Vibrations 148
Determination of Stiffness 149
Overlaying of Different Stiffnesses 150
Conversions 150
Natural Frequencies 150/151
Evaluation of Vibrations 151/152
x
^
^
.
..
h
^
p
^
stat
p
o
142
Vibrations
Symbols and Units
a m Length of overhanging end
A m
2
Cross-sectional area
A m, rad Amplitude of oscillation
A
D
;
A
e
Damping energy; elastic energy
c
Nm/
rad
Torsional stiffness
c N/m
Translational stiffness;
bending stiffnes
d m Diameter
d
i
m Inside diameter
d
a
m Outside diameter
D Attenuation ratio (Lehrs damping)
D
m
m Mean coil diameter (coil spring)
e = 2.718 Natural number
E N/m
2
Modulus of elasticity
f, f
e
Hz Frequency; natural frequency
f m Deformation
F N Force
F (t) N Time-variable force
G N/m
2
Shear modulus
i Transmission ratio
i
F
Number of windings (coil spring)
l
a
m
4
Axial moment of area
l
p
m
4
Polar moment of area
J, J
i
kgm
2
Mass moment of inertia
J* kgm
2
Reduced mass moment of inertia
of a two-mass vibration generating
system
k
Nms/
rad
Viscous damping in case of
torsional vibrations
k Ns/m
Viscous damping in case of trans-
lational and bending vibrations
l m
Length;
distance between bearings
m, m
i
kg Mass
M (t) Nm Time-variable excitation moment
M
o
Nm Amplitude of moment
M
o
* Nm
Reduced amplitude of moment of
a two-mass vibration generating
system
n
e
1/min
Natural frequency (vibrations per
minute)
n
1
; n
2
1/min Input speed; output speed
q
Influence factor for taking into
account the mass of the shaft
when calculating the natural
bending frequency
t s Time
T s Period of a vibration
T Nm Torque
V m
3
Volume
V
Magnification factor; Dynamic/
static load ratio
x m
Displacement co-ordinate
(translational, bending)
m Displacement amplitude
rad Phase angle
rad Phase angle with free vibration
1/s Damping constant
rad
Phase displacement angle with
forced vibration

Excitation frequency/natural
frequency ratio
Inherent value factor for i-th

natural frequency
Logarithmic decrement
= 3.142 Peripheral/diameter ratio
r kg/m
3
Specific density
,
i
rad Angle of rotation
rad Angular amplitude of a vibration
rad/s
Angular velocity (first time deri-
vation of )
rad/s
2
Angular acceleration (second
time derivation of )
rad
Vibratory angle of the free vibra-
tion (homogeneous solution)
rad
Vibratory angle of the forced
vibration (particular solution)
rad
Angular amplitude of the forced
vibration
rad
Angular amplitude of the forced
vibration under load ( = 0)

Damping coefficient acc. to DIN
740 /18/
rad/s
Angular velocity, natural radian
frequency of the damped
vibration
rad/s
Natural radian frequency of the
undamped vibration
rad/s
Radian frequency of the excitat-
ing vibration
Note: The unit rad may be replaced by 1.
143
Vibrations
3. Vibrations
3.1 General fundamental principles
Vibrations are more or less regularly occurring
temporary variations of state variables. The state
of a vibrating system can be described by
suitable variables, such as displacement, angle,
velocity, pressure, temperature, electric voltage/
current, and the like.
The simplest form of a mechanical vibrating
system consists of a mass and a spring with fixed
ends, the mass acting as kinetic energy store
and the spring as potential energy store, see
figure 37. During vibration, a periodic conversion
of potential energy to kinetic energy takes place,
and vice versa, i.e. the kinetic energy of the mass
and the energy stored in the spring are converted
at certain intervals of time. Dependent on the
mode of motion of the mass, a distinction is made
between translational (bending) and torsional
vibrating systems as well as coupled vibrating
systems in which translational and torsional
vibrations occur at the same time, influencing
each other.
Translational vibration
generatig system
Bending vibration
generating system
Figure 37
Different vibrating systems with one degree of freedom
Torsional vibration
generating system
Further, a distinction is made between free
vibrations and externally forced vibrations, and
whether the vibration takes place without energy
losses (undamped) or with energy losses
(damped).
A vibration is free and undamped if energy is
neither supplied nor removed by internal friction
so that the existing energy content of the vibra-
tion is maintained. In this case the system carries
out steady-state natural vibrations the frequency
of which is determined only by the characteristics
of the spring/mass system (natural frequency),
figure 39a.
The vibration variation with time x can be
described by the constant amplitude of
oscillation A and a harmonic function (sine,
cosine) the arguments of which contain natural
radian frequency = 2
.
f (f = natural frequency
in Hertz) and time, see figure 38.
Amplitude
V
i
b
r
a
t
i
o
n
Period
x = A
.
sin
.
t
A = Amplitude
= Radian frequency
t = Time
x = A
.
sin (
.
t + )
= Phase angle
Figure 38
Mathematical description of an undamped vibration with and without phase angle
Amplitude
144
Vibrations
A damped vibration exists, if during each period
of oscillation a certain amount of vibrational
energy is removed from the vibration generating
system by internal or external friction. If a con-
stant viscous damping (Newtons friction) exists,
the amplitudes of oscillation decrease in accord-
ance with a geometric progression, figure 39b.
All technical vibration generating systems are
subject to more or less strong damping effects.
Displacement x
a)
Undamped
vibration ( = 0)
b)
Damped
vibration ( > 0)
c)
Stimulated
vibration ( < 0)
Time t
Figure 39
Vibration variations with time (A = initial
amplitude at time t = 0; = damping constant)
If the vibrating system is excited by a periodic ex-
ternal force F(t) or moment M(t), this is a forced or
stimulated vibration, figure 39c. With the periodic
external excitation force, energy can be supplied
to or removed from the vibrating system.
After a building-up period, a damped vibrating
system does no longer vibrate with its natural fre-
quency but with the frequency of the external ex-
citation force.
Resonance exists, when the applied frequency is
at the natural frequency of the system. Then, in
undamped systems the amplitudes of oscillation
grow at an unlimited degree. In damped sys-
tems, the amplitude of oscillation grows until the
energy supplied by the excitation force and the
energy converted into heat by the damping
energy are in equilibrium. Resonance points may
lead to high loads in the components and there-
fore are to be avoided or to be quickly traversed.
(Example: natural bending frequency in high-
speed gear units).
The range of the occurring amplitudes of oscilla-
tion is divided by the resonance point (natural
frequency = excitation frequency, critical vibra-
tions) into the subcritical and supercritical oscilla-
tion range. As a rule, for technical vibrating
systems (e.g. drives), a minimum frequency
distance of 15% or larger from a resonance point
is required.
Technical vibrating systems often consist of
several masses which are connected with each
other by spring or damping elements. Such
systems have as many natural frequencies with
the corresponding natural vibration modes as
degrees of freedom of motion. A free, i.e. unfixed
torsional vibration system with n masses, for
instance, has n-1 natural frequencies. All these
natural frequencies can be excited to vibrate by
periodic external or internal forces, where mostly
only the lower natural frequencies and especially
the basic frequency (first harmonic) are of impor-
tance.
In technical drive systems, vibrations are excited
by the following mechanisms:
a) From the input side:
Starting processes of electric motors, system
short circuits, Diesel Otto engines, turbines,
unsteady processes, starting shock im-
pulses, control actions.
b) From transmitting elements:
Meshing, unbalance, universal-joint shaft,
alignment error, influences from bearings.
c) From the output side:
Principle of the driven machine, uniform, non-
uniform, e.g. piston compressor, propeller.
As a rule, periodic excitation functions can be
described by means of sine or cosine functions
and the superpositions thereof. When analysing
vibration processes, a Fourier analysis may
often be helpful where periodic excitation
processes are resolved into fundamental and
harmonic oscillations and thus in comparison
with the natural frequencies of a system show
possible resonance points.
In case of simple vibrating systems with one or
few (maximum 4) masses, analytic solutions for
the natural frequencies and the vibration varia-
tion with time can be given for steady excitation.
For unsteady loaded vibrating systems with one
or more masses, however, solutions can be cal-
culated only with the aid of numerical simulation
programmes. This applies even more to vibrating
systems with non-linear or periodic variable pa-
rameters (non-linear torsional stiffness of cou-
plings; periodic meshing stiffnesses). With EDP
145
Vibrations
Solution Proposal for Simple Torsional Vibrators
programmes, loads with steady as well as
unsteady excitation can be simulated for
complex vibrating systems (linear, non-linear,
parameter-excited) and the results be
represented in the form of frequency analyses,
load as a function of time, and overvoltages
of resonance. Drive systems with torsionally
flexible couplings can be designed dynamically
in accordance with DIN 740 /18/. In this standard,
simplified solution proposals for shock-loaded
and periodically loaded drives are made, the
drive train having been reduced to a two-mass
vibration generating system.
3.2 Solution proposal for simple torsional
vibrators
Analytic solution for a periodically excited one-
(fixed) or two-mass vibration generating system,
figure 40.
Figure 40
Fixed one-mass vibration generating system Free two-mass vibration generating system
J, J
1
, J
2
= mass moment of inertia [kgm
2]
c = torsional stiffness [Nm/rad]
k = viscous damping [Nms/rad]
M (t) = external excitation moment [Nm] , time-variable
= angle of rotation [rad] , ( =
1

2
for 2-mass vibration generating systems as
relative angle)
= angular velocity [rad/s] (first time derivation of )
= angular acceleration [rad/s
2]
(second time derivation of )
..
Torsional vibrators
Differential equation of motion:

One-mass vibration generating system:
..
)
k
J
.
)
c
J
M (t)
J
(30)
((
2
2
o
Two-mass vibration generating system with
relative coordinate:
..
)
k
J *
.
)
c
J *
M(t)
J
1
(31)
((
2
2
o
with
1
+
2
(32)
J *
J
1
J
2
J
1
)J
2
(33)
Natural radian frequency (undamped):
o
c
J
[ rad/s] (34)
o c
J
1
)J
2
J
1
J
2
rad s (35)
Natural frequency:
fe
o
2
[Hz] (36)
ne
o 30
[1/min] (37)
k
J
damping constant [1/s] (38)
o
= natural radian frequency of the undamped
vibration in rad/s
f
e
= natural frequency in Hertz
n
e
= natural frequency in 1/min
Damped natural radian frequency:
2
o
+
2
o 1 +D
2
(39)
146
Vibrations
Solution Proposal for Simple Torsional Vibrators
Solution of the Differential Equation of Motion
Attenuation ratio (Lehrs damping): D
D
o
k o
2 c 4
(40)
= damping coefficient on torsionally flexible
coupling, determined by a damping hystere-
sis of a period of oscillation acc. to DIN 740
/18/ and/or acc. to Flender brochure
damping energy
elastic deformation energy
A
D
Ae
Reference values for some components:
D = 0.001...0.01 shafts (material damping
of steel)
D = 0.04...0.08 gear teeth in gear units
D = 0.04...0.15 (0.2) torsionally flexible cou-
plings
D = 0.01...0.04 gear couplings, all-steel
couplings, universal joint
shafts
Static spring characteristic
for one load cycle
Figure 41
Damping hysteresis of a torsionally
flexible component
3.3 Solution of the differential equation of
motion
Periodic excitation moment
M(t) Mo cos m t (41)
M
o
= amplitude of moment [Nm]
= exciting circuit frequency [rad/s]
Total solution:
h
) p (42)
a) Free vibration (homogeneous solution
h
)
h
A e
{+ t}
cos ( t + ) (43)
Constants A and are determined by the starting
conditions, e.g. by
h
= 0 and
.
h
= 0 (initial-value
problem).
In damped vibrating systems ( > 0) the free com-
ponent of vibration disappears after a transient
period.
b) Forced vibration (particular solution
p
)
p
M
*
o
c
1
(1 +
2
)
2
)4D
2 2
cos(m t + ) (44)
Phase angle: tan
2 D
1 +
2
(45)
Frequency ratio:
m
o
(46)
Mo * Mo (47)
Two-mass vibration generating system:
Mo *
J
2
J
1
)J
2
Mo (48)
c) Magnification factor
p
Mo *
c
V cos (m t + ) (49)
V
1
(1 +
2
)
2
)4D
2 2
^
p
^
stat
M
M
*
o
(50)
^
p
= vibration amplitude of forced vibration
^
stat
= vibration amplitude of forced vibration at
a frequency ratio = 0.
The magnification factor shows the ratio of the
dynamic and static load and is a measure for the
additional load caused by vibrations (figure 42).
147
Vibrations
Solution of the Differential Equation of Motion
Formulae for the Calculation of Vibrations
Figure 42
Magnification factors for forced, damped and undamped
vibrations at periodic moment excitation (power excitation).
Magnification factors V and phase displacement angle .
P
h
a
s
e

d
i
s
p
l
a
c
e
m
e
n
t
a
n
g
l
e

Frequency ratio
m
o
M
a
g
n
i
f
i
c
a
t
i
o
n

f
a
c
t
o
r

V
3.4 Formulae for the calculation of vibra-
tions
For the calculation of natural frequencies and
vibrational loads, a general vibration generating
system has to be converted to a calculable sub-
stitute system with point masses, spring and
damping elements without mass.
3.4.1 Mass
m = r
.
V [kg]
V = volume [m
3
]
r = specific density [kg/m
3
]
3.4.2 Mass moment of inertia
J = r
2
dm: general integral formula
Circular cylinder:
J
1
32
r d
4
l p(kgm
2
r
d = diameter [m]
l = length of cylinder pmr
x
.
.
m x
..
J
..
x
^
n x
^
n)1
o c J
xmax, x
^
, A
^
n
^
n)1
p In (x
^
n x
^
n)1
)
max,
^
, A
2 D
1 +D
2
p In (
^
n
^
n)1
)
o c m
d
2
o
+r
2
148
Vibrations
Terms, Symbols and Units
Table 8 Symbols and units of translational and torsional vibrations
Term Quantity Unit Explanation
Mass,
Mass moment of inertia
m
J
kg
kg
.
m
2
Translatory vibrating mass m; Torsionally
vibrating mass with mass moment of
inertia J
Instantaneous value of
vibration (displacement,
angle)
x
m
rad*)
Instantaneous, time-dependent value of
vibration amplitude
Amplitude
m
rad
Amplitude is the maximum instantaneous
value (peak value) of a vibration.
Oscillating velocity
m/s
rad/s
Oscillating velocity; Velocity is the
instantaneous value of the velocity of
change in the direction of vibration.
Inertia force,
Moment of inertia forces
N
N S m
The dAlemberts inertia force or the
moment of inertia force acts in the oppo-
site direction of the positive acceleration.
Spring rate,
Torsional spring rate
c
c
Nm
N S m/rad
Linear springs
Spring force,
Spring moment
c
.
x
c
.

N
N S m
In case of linear springs, the spring recoil
is proportional to deflection.
Attenuation constant
(Damping coefficient),
Attenuation constant for
rotary motion
k
k
N S s/m
Nms/rad
In case of Newtons friction, the damping
force is proportional to velocity and
attenuation constant (linear damping).
Damping factor
(Decay coefficient)
= k/(2
.
m)
= k/(2
.
J)
1/s
1/s
The damping factor is the damping
coefficient referred to twice the mass.
Attenuation ratio
(Lehrs damping)
D = /
For D < 1, a damped vibration exists; for

D 1, an aperiodic case exists.
Damping ratio
The damping ratio is the relation between

two amplitudes, one cycle apart.
Logarithmic damping
decrement
Time t s Coordinate of running time

Phase angle rad
In case of a positive value, it is a lead
angle.
Phase displacement
angle
=
1

2
rad
Difference between phase angles of two
vibration processes with same radian
frequency.
Period of a vibration T = 2
.
/
s
Time during which a single vibration
occurs.
Frequency of natural
vibration
f = 1/T =
/(2
.
) Hz
Frequency is the reciprocal value to a
period of vibrations; vibrations per sec.
Radian frequency of
natural vibration
= 2
.

.
f rad/s
Radian frequency is the number of
vibrations in 2
.
seconds.
Natural radian frequency
(Natural frequency)
rad/s
rad/s
Vibration frequency of the natural
vibration (undamped) of the system
Natural radian frequency
when damped
For a very small attenuation ratio
D < 1 becomes
d

o
.
Excitation frequency rad/s Radian frequency of excitation
Radian frequency ratio = /
Resonance exists at = 1.
*) The unit rad may be replaced by 1.
Coil spring
Torsion bar
Tension bar
Cantilever beam
Transverse beam (single
load in middle)
Transverse beam
with overhanging
end
c
G d
4
8 D
3
m
i
f
N
m
c
G Ip
I
Nm
rad
Shaft : Ip
d
4
32
Hollow shaft : Ip
32
(d
4
a
+d
4
i
)
c
E A
I
N
m
c
F
f
3 E Ia
l
3
N
m
Shaft : Ia
d
4
64
Hollow shaft : Ia
64
(d
4
a
+d
4
i
)
c
F
f
48 E Ia
l
3
N
m
c
F
f
3 E Ia
a
2
(l )a)
N
m
149
Vibrations
3.4.3 Determination of stiffness
Table 9 Calculation of stiffness (examples)
Example Stiffness Symbol
i
F
= number of windings
G = shear modulus
1)
d = diameter of wire
D
m
= mean coil diameter
I
p
= polar moment of
inertia
l = length
d, d
i
, d
a
= diameters of
shafts
E = modulus of
elasticity
1)
A = cross-sectional area
F = force
f = deformation at centre
of mass under
force F
I
a
= axial moment of area
l = distance between
bearings
a = length of overhang-
ing end
1) For steel: E = 21 S 10
10
N/m
2
; G = 8.1 S 10
10
N/m
2
150
Vibrations
Measuring the stiffness:
In a test, stiffness can be determined by measur-
ing the deformation. This is particularly helpful if
the geometric structure is very complex and very
difficult to acquire.
Translation:
c
F
f
N m (51)
F = applied force [N]
f = measured deformation [m]
Torsion:
c
T
Nm rad (52)
T = applied torsion torque [Nm]
= measured torsion angle [rad]
Measurements of stiffness are furthermore re-
quired if the material properties of the spring ma-
terial are very complex and it is difficult to rate
them exactly. This applies, for instance, to rubber
materials of which the resilient properties are de-
pendent on temperature, load frequency, load,
and mode of stress (tension, compression,
shearing). Examples of application are
torsionally flexible couplings and resilient buffers
for vibration isolation of machines and internal
combustion engines.
These components often have non-linear
progressive stiffness characteristics, dependent
on the direction of load of the rubber material.
For couplings the dynamic stiffness is given, as a
rule, which is measured at a vibrational
frequency of 10 Hz (vibrational amplitude = 25%
of the nominal coupling torque). The dynamic
torsional stiffness is greater than the static
torsional stiffness, see figure 43.
Slope =
static stiffness
Slope =
dynamic stiffness
Figure 43
Static and dynamic torsional stiffness
3.4.4 Overlaying of different stiffnesses
To determine resulting stiffnesses, single stiff-
nesses are to be added where arrangements in
series connection or parallel connection are pos-
sible.
Series connection:
Rule: The individual springs in a series connec-
tion carry the same load, however, they are sub-
jected to different deformations.
1
cges
1
c
1
)
1
c
2
)
1
c
3
) )
1
cn
(53)
Parallel connection:
Rule: The individual springs in a parallel connec-
tion are always subject to the same deformation.
cges c
1
)c
2
)c
3
) ) cn (54)
3.4.5 Conversions
If drives with different speeds or shafts are com-
bined in one vibration generating system, the
stiffnesses and masses are to be converted to a
reference speed (input or output).
Conversion is carried out as a square of the
transmission ratio:
Transmission ratio:
i
n
1
n
2
reference speed
speed
(55)
Conversion of stiffnesses c
n2
and masses J
n2
with speed n
2
to the respective values c
n1
and
J
n1
with reference speed n
1
:
C
n1
c
n2
i
2
(56)
J
n1
J
n2
i
2
(57)
Before combining stiffnesses and masses with
different inherent speeds, conversion to the com-
mon reference speed has to be carried out first.
151
Vibrations
Evaluation of Vibrations
3.4.6 Natural frequencies
a) Formulae for the calculation of the natural
frequencies of a fixed one-mass vibration
generating system and a free two-mass vibra-
tion generating system.
Natural frequency f in Hertz (1/s):
Torsion : fe +
1
2p
c
J
(58)
Two-mass vibration generating system:
fe +
1
2p
c
J
1
)J
2
J
1
J
2
(59)
c = torsional stiffness in [Nm/rad]
J, J
i
= mass moments of inertia in [kgm
2
]
Translation, Bending : fe +
1
2p
c
m
(60) fe +
1
2p
c
m
1
)m
2
m
1
m
2
(61)
c = translational stiffness (bending stiffness) in [N/m]
m, m
i
= masses in [kg]
b) Natural bending frequencies of shafts sup-
ported at both ends with applied masses with
known deformation f due to the dead weight
fe +
q
2p
g
f
[Hz (62)
g = 9.81 m/s
2
gravity
f = deformation due to dead weight [m]
q = factor reflecting the effect of the shaft
masses on the applied mass
q = 1 shaft mass is neglected compared with the
applied mass
q = 1.03 ... 1.09 common values when
considering the shaft masses
q = 1.13 solid shaft without pulley
c) Natural bending frequencies for shafts, taking
into account dead weights (continuum); gene-
ral formula for the natural frequency in the
order f
e
,
i
.
f
e,i
+
1
2p
m
i
l
2
E
r A
Hz (63)
i
= inherent value factor for the i-th natural
frequency
l = length of shaft [m]
E = modulus of elasticity [N/m
2
]
I = moment of area [m
4
]
r = density [kg/m
3
]
A = cross-sectional area [m
2
]
d = diameter of solid shaft [m]
Table 10 -values for the first three natural fre-
quencies, dependent on mode of fixing
Bearing application
1
3
1.875 4.694 7.855
4.730 7.853 10.966
2 3
3.927 7.069 10.210
For the solid shaft with free bearing support on
both sides, equation (63) is simplified to:
f
e,i
+
p d
8
i
l
2
E
r
Hz (64)
i = 1st, 2nd, 3rd ... order of natural bending
frequencies.
3.5 Evaluation of vibrations
The dynamic load of machines can be deter-
mined by means of different measurement
methods. Torsional vibration loads in drives, for
example, can be measured directly on the shafts
by means of wire strain gauges. This requires,
however, much time for fixing the strain gauges,
for calibration, signal transmission and evalua-
tion. Since torques in shafts are generated via
bearing pressure in gear units, belt drives, etc., in
case of dynamic loads, structure-borne noise is
generated which can be acquired by sensing
elements at the bearing points in different
directions (axial, horizontal, vertical).
152
Vibrations
Dependent on the requirements, the amplitudes
of vibration displacement, velocity and accelera-
tion can be recorded and evaluated in a sum
(effective vibration velocity) or frequency-
selective. The structure-borne noise signal
reflects besides the torque load in the shafts also
unbalances, alignment errors, meshing
impulses, bearing noises, and possibly
developing machine damages.
To evaluate the actual state of a machine, VDI
guideline 2056
1)
or DIN ISO 10816-1 /19, 20/ is
consulted for the effective vibration velocity, as a
rule, taking into account structure-borne noise in
the frequency range between 10 and 1,000
Hertz. Dependent on the machine support
structure (resilient or rigid foundation) and power
transmitted, a distinction is made between four
machine groups (table 11). Dependent on the
vibration velocity, the vibrational state of a
machine is judged to be good, acceptable,
still permissible, and non-permissible. If
vibration velocities are in the non-permissible
range, measures to improve the vibrational state
of the machine (balancing, improving the
alignment, replacing defective machine parts,
displacing the resonance) are required, as a rule,
or it has to be verified in detail that the vibrational
state does not impair the service life of the
machine (experience, verification by
calculation). Structure-borne noise is emitted
from the machine surface in the form of airborne
noise and has an impact on the environment by
the generated noises. For the evaluation of
noise, sound pressure level and sound intensity
are measured. Gear unit noises are evaluated
according to VDI guideline 2159 or DIN 45635
/17, 16/, see subsection 1.5.
Table 11 Boundary limits acc. to VDI guideline 2056
1)
for four machine groups
Machine
Including gear units and
machines with input power
Range classification acc. to VDI 2056
(Effective value of the vibration velocity in mm/s)
Machine
groups
machines with input power
ratings of ...
Good Acceptable
Still permis-
sible
Non-per-
missible
K
... up to approx. 15 kW
without special foundation.
up to 0.7 0.7 ... 1.8 1.8 ... 4.5 from 4.5 up
M
... from approx. 15 up to 75
kW without special founda-
tion.
... from approx. 75 up to 300
kW and installation on
highly tuned, rigid or heavy
foundations.
up to 1.1 1.1 ... 2.8 2.8 ... 7.1 from 7.1 up
G
... over 300 kW and installa-
tion on highly tuned, rigid or
heavy foundations.
up to 1.8 1.8 ... 4.5 4.5 ... 11 from 11 up
T
... over 75 kW and installa-
tion on broadly tuned resi-
lient foundations (espe-
cially also steel foundations
designed according to light-
construction guidelines).
up to 2.8 2.8 ... 7 7 ... 18 from 18 up
1) 08/97 withdrawn without replacement; see /20/
153
Page
Bibliography of Sections 10, 11, and 12 154/155
154
Bibliography
/1/ DIN 3960: Definitions, parameters and equations for involute cylindrical gears and gear pairs.
March 1987 edition. Beuth Verlag GmbH, Berlin
/2/ DIN 3992: Addendum modification of external spur and helical gears. March 1964 edition.
Beuth Verlag GmbH, Berlin
/3/ DIN 3993: Geometrical design of cylindrical internal involute gear pairs; Part 3. August 1981
edition. Beuth Verlag GmbH, Berlin
/4/ DIN 3994: Addendum modification of spur gears in the 05-system. August 1963 edition. Beuth
Verlag GmbH, Berlin
/5/ Niemann, G. und Winter, H.: Maschinenelemente, Band II, Getriebe allgemein, Zahnradge-
triebe-Grundlagen, Stirnradgetriebe. 3rd edition. Springer Verlag, Heidelberg, New York,
Tokyo (1985)
/6/ Sigg, H.: Profile and longitudinal corrections on involute gears. Semi-Annual Meeting of the
AGMA 1965, Paper 109.16
/7/ Hsel, Th.: Ermittlung von Tragbild und Flankenrichtungskorrekturen fr Evolventen-Stirn-
rder. Berechnungen mit dem FVA-Programm Ritzelkorrektur. Zeitschrift Antriebstechnik 22
(1983) Nr. 12
/8/ DIN 3990: Calculation of load capacity of cylindrical gears.
Part 1: Introduction and general influence factors
Part 2: Calculation of pitting resistance
Part 3: Calculation of tooth strength
Part 4: Calculation of scuffing load capacity
Beuth Verlag GmbH, Berlin, December 1987
/9/ FVA-Stirnradprogramm: Vergleich und Zusammenfassung von Zahnradberechnungen mit
Hilfe von EDV-Anlagen (jeweils neuester Programmstand). FVA-Forschungsvorhaben Nr. 1.,
Forschungsvereinigung Antriebstechnik, Frankfurt am Main
/10/ DIN 3990: Calculation of load capacity of cylindrical gears. Application standard for industrial
gears.
Part 11: Detailed method; February 1989 edition
Part 12: Simplified method; Draft May 1987
/11/ DIN 3990: Calculation of load capacity of cylindrical gears.
Part 5: Endurance limits and material qualities; December 1987
/12/ FVA-Arbeitsblatt zum Forschungsvorhaben Nr. 8: Grundlagenversuche zur Ermittlung der
richtigen Hrtetiefe bei Wlz- und Biegebeanspruchung. Stand Dezember 1976. Forschungs-
vereinigung Antriebstechnik, Frankfurt am Main
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zum Ausgleich der lastbedingten Zahnverformungen (jeweils neuester Programmstand). FVA-
Forschungsvorhaben Nr. 30.
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/16/ DIN 45635: Measurement of noise emitted by machines.
Part 1: Airborne noise emission; Enveloping surface method; Basic method, divided into 3
grades of accuracy; April 1984 edition
Part 23: Measurement of airborne noise; Enveloping surface method; Gear transmission; July
1978 edition
/17/ VDI-Richtlinien 2159: Emissionskennwerte technischer Schallquellen; Getriebegerusche;
Verein Deutscher Ingenieure, July 1985
/18/ DIN 740: Flexible shaft couplings. Part 2. Parameters and design principles. August 1986
edition; Beuth Verlag GmbH, Berlin
/19/ VDI-Richtlinien 2056: Beurteilungsmasstbe fr mechanische Schwingungen von Maschinen.
VDI-Handbuch Schwingungstechnik; Verein Deutscher Ingenieure; October 1964; (08/97 with-
drawn without replacement)
/20/ DIN ISO 10816-1: Mechanical vibration - Evaluation of machine vibration by measurements on
non-rotating parts. August 1997 edition; Beuth Verlag GmbH, 10772 Berlin

Flender Technical Handbook

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What topics are covered in the document?

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What standards are referenced for gear design?

What standards are referenced for gear design?

18 19

1 short cwt (US)

Number of cycles to failure N

: excess pressure compared to external pressure

Vessel with bottom opening

Light metal 0.30 R

15 Cr 13 1.7015 510 7801030 440 690 890

mm Length of path of contact

Generating addendum modifi-

Transverse load factor (for

Face load factor (for tooth root

Transverse load factor (for

Face load factor (for contact

Factor of safety from tooth

Helix angle factor

Helix angle factor

Contact ratio factor

Transverse contact ratio

Total contact ratio

is that part of the

to the normal transverse pitch p

gives the contact ratio, owing to the helix of the

In figure 16, usual profile and longitudinal correc-

Helix angle factor acc. to equ. (9)

Contact ratio factor acc. to equ. (10)

according to table 5 applies:

Contact ratio factor acc. to equ. (19)

Helix angle factor acc. to equ. (20)

acc. to table 5 follows:

(19) Y = 0.25 + cos

with the restriction 0.625 ) Y

+ max [(1 - 0.25

= 0.832. According to equation (8),

= 0.738; helix angle factor

= 0.927; tip factors Y

Inherent value factor for i-th

Differential equation of motion:

For D < 1, a damped vibration exists; for

The damping ratio is the relation between

Time t s Coordinate of running time

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