T121 8 - Design & Calculation High Speed Gears
T121 8 - Design & Calculation High Speed Gears
by
Dr. Manfred Hirt
Director of Engineering
Renk Gear Company
ABSTRACT (1)
High-speed gears of very high powers and/or very high The admissible Hertzian pressure ratio is about 2. 0; e.g., to
speeds must be exactly analyzed and optimized in gearing, DIN/ISO for 60 HRC case-carburized material, as c ompared
bearing and housing in order to achieve low noise, low vibra with through-hardened teeth of 300 HB [1]. For the centre
tion running with maximum safety in operation. The gearing distance, the following is applicable:
must be checked by detailed calculations in load capacity,
including an exact analysis of the scoring safety. Special design a = 0.62a' (2)
means must be applied in order to cover thermal problems at
the gearing. where
Besides this, the calculation and design of the plain bear
a = centre distance for case-carburized teeth
ings are of main interest. They also must be analyzed in detail,
not only in general hydrodynamic load capacity, but also in a' = centre distance for through-hardened teeth
their real temperature and pressure conditions in the oil film. Since the weight of the gear set, W, is
The design of the plain bearing then has to be adapted to its
vibration behaviour. w�a2 (3)
Using modern CAE methods, the design process can be
made faster and safer. Practical examples of some of the the weight of the case-carburized gear set will be reduced:
highest-powered high-speed gears of the world prove the
methods used in design, calculations and manufacturii).g. W = 0.4W'. (4)
INTRODUCTION where
Gear units for high-speed plants are used for a wide range W = weight of the gear set for case-carburized teeth
of applications, such as generators, compressors, pumps, gas W' = weight of the gear set for through-hardened teeth
turbines, steam turbines and motors. These drive systems On the other hand, as has already been said, the casing
must provide maximum reliability and smooth operation. Such and the bearings must be designed to accommodate the high
gears are designed with single-helical or double-helical teeth. load capacity of the case-carburized teeth. This results in a
In most cases, they are running in high-precision plain bear comparative weight of the case-carburized gear approximately
ings. High-speed gears in use today transmit as much as 70,000 half that of the through-hardened gear. Such a comparison is
kW, with circumferential speeds in the teeth of over 200 shown in Figure 1.
meters per second (m/s). To ensure optimum running be The centre distance, a, and the gear weight, W, for case
haviour with maximum reliability, it is imperative to analyze carburized teeth are shown as a function of the transmitted
both the load capacity and the design of gearing, bearings, and power, P. One can recognize the interrelations illustrated: the
casings. In the following, a number of items will be presented reduced centre distance, a, and the considerably decreased
that must be considered in a modern analysis. Only a detailed weight, W, of the case-carburized teeth, as compared with the
examination, accompanied by high-precision manufacture and values a' and W' of the through-hardened teeth. In addition, it
careful monitoring of the operation, will ensure the optimum is evident that increased power can be transmitted by the case
running behaviour which has become a standard requirement carburized gears for a determined circumferential speed of the
for such plants today. Installations in the petrochemical indus- teeth. For instance, a limit circumferential speed of 125 m/s
1
2 PROCEEDINGS OF THE TWELFTH TURBOMACHINERY SYMPOSIUM
I
same safety factors for bending strength and pitting durability,
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Pitting Durability " 10
The pitting durability is calculated from the Hcrtzian �
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pressure, oH, on the tooth flank and an admissible Hertzian
pressure, OHP· The latter results from a strength value, oHlim·
and a safety factor, Su. For this calculation, the influences of
external loads, KA, the internal dynamic forces, Kv, and the
load distribution, KHB· over the width are considered. Addi
tional influential factors are the oil film between the tooth
flanks (Zv X Z X ZR), and the material combination, Zw. 500 1000
CR SH
·
There is only one limit value of the critical temperature
depending on oil viscosity; therefore, it is not possible to duly
consider products such as EP oils. The new AGMA standard
Figure 2. Load Capacity Calculation Formulas. 42l.X.X [4] mentions a criterion derived from the temperature
DESIGN AND CALCULATION METHODS FOR HIGH-SPEED GEARS OF ADVANCED TECHNOLOGY 3
where
Scoring criterion number=
(6) Ti = a result of the blank temperature before the gear
mesh and a mean flash temperature.
where In Figure 4, this safety value, Ssr. is also represented as a
Wt = tangential load, lbs. function of the power.
Fe = face width, in. It is evident that this safety value varies only within a
relatively restricted area between 2.0 and about 1.3. It can also
np = pinion speed
be seen, however, that the safety factors have a tendency to be
Pd = diametral pitch = 25.4/m lowered as the transmittable power increases. The reason is
that for large output values, there is an ever-increasing tenden
In Figure 4, this scoring index, SI, is represented as a cy towards reduced centre distance and, consequently, re
function of the transmittable load. It can be seen that this duced circumferential speeds. As a result, a relatively large
scoring index has no fixed value for gear units in actual use, but module must be chosen, and the risk of scoring rises. So, it is
that it increases considerably with the transmittable power. all the more important to correctly determine all influential
The admissible constant number of AGMA 42l.XX is definitely factors: surface finish, tooth correction, material, friction coeffi
below the values obtained from actual use. In the latest cient, driving pinion or gear, additives to the oils, etc.
calculation methods according to Winter and Michaelis [5], the Figure 5 shows limit powers as a function of the centre
scoring capacity is based on a weighted mean integral tempera distance for both bending strength, S F, and scoring resistance,
ture. For this calculation, a mean surface temperature is used Ss1, for case-carburized teeth. It can be seen that, for centre
that is calculated from the mean values of the friction coeffi distances of about 400 mm and higher, the scoring load limit
cients and the mean dynamic loads. The decisive mean flank restricts the transmittable power. In the case of large gears,
temperature, the so-called integral temperature, is represent therefore, it may be necessary to take special measures, such as
ed from the blank temperature and a weighted integrated flash surface treatment of the tooth flanks.
temperature.
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Transmittable Power
Centre distance
This procedure now is being adopted also by DIN/ISO.
The limit values of the integral temperature are ascertained Figure 5. Power Limits in Bending Strength and Scoring
with the same procedure as the known scoring tests carried out Resistance.
on gear wheels. The safety, Ss, then, is the ratio of the
admissible integral temperature and the actually occurring Figure 6 shows a high-speed gear for 70,000 kW. In order
integral temperature. to increase the tooth root load capacity and improve the
running-in effect, the flanks of the wheel are copper-plated. To
Ssr = improve the scoring capacity by means of copper-plating,
(7) DIN/ISO provide certain reference values. In addition to this
special treatment by copper-plating, tooth corrections were
with carried out with special care in this gear unit. The tooth
corrections included relieving those areas of the tooth that are
g subject to scoring, and influencing the temperature variation
Ti = TM + B f TsLd x/g = TM + BTslm (8) on the tooth flank.
4 PROCEEDINGS OF THE 1WELFTH TURBOMACHINERY SYMPOSIUM
Bearing Design
Design of the high-speed plain bearings is an essential
factor in gear unit optimization. Bearings must be designed for
maximum load capacity and for optimum vibration.
The high-speed pinion shaft must be investigated to as
sure the elimination of unbalance-excited vibrations and self
excited oil-whip vibrations. The damping effect of the plain
bearings determines the vibration behaviour with respect to
the self-excited "oil-whip" vibrations. This damping behaviour
depends on the type of bearing; i. e. , the bearing bore design.
The types of bearings used are cylindrical, two-lobe, four-lobe,
and tilting pad. Extensive computing programs are available
for the calculation of the damping behaviour, which allows
calculation of the so-called stability border speed. Self-excited
oil whip vibrations may occur above this border speed. For a
specific bearing type, this stability border speed depends on
the relative load, SoK, and the relative shaft stiffness, fl.·
Figure 8 illustrates this stability border speed, with regard
to the lateral natural frequency (with rigidly supported shaft),
Figure 6. High-Speed Gear for 70,000 kW at Assembling for as a function of the load for a fl.-value of 0.1, which, roughly,
Use at a Gas Turbine Power Station. will occur in practice. One can see that the cylindrical bearing
Figure 7 illustrates the calculated temperature variation shows the most reduced stability border speed over the entire
over the entire zone of contact, with and without tooth correc load range. The values given by the two-lobe and four-lobe
tions. A reduction of the peak temperatures is clearly visible bearings are already considerably improved, while the tilting
for properly performed tooth corrections. pad bearing has extremely stable border speeds.
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Apart from the check of the stability border speed for oil
whip vibrations, running behaviour must be investigated for
unbalance-excited vibrations; i. e. , the lateral natural frequen
cies of the various lateral vibration modes are to be ascer
tained. In this regard, the stiffness of the bearing, including
the oil film effect, is of decisive importance. For this problem,
too, there are extensive computing programs available. The
lateral natural frequency with rigidly supported shafts is re
duced by the resilience of the bearings. It is imperative that
B
there be sufficient distance between the operational speed and
this reduced lateral natural frequency. Limit values are given
for the admissible vibration amplitude under operational con
ditions; e. g. , according to API 613. This problem will be
further dealt with below.
E When analyzing the load capacity of the bearings, the
Figure 7. Calculated Distribution of Flash Temperature With hydrodynamic quantities must be precisely determined. These
out and With (Lower Part) Tooth Correction for the 70,000 kW are the oil film thickness, and the film's temperatures and
Gear. pressures. When considering the relative oil film thickness (oil
DESIGN AND CALCULATION METHODS FOR HIGH-SPEED GEARS OF ADVANCED TECHNOLOGY 5
film thickness compared with half of the bearing clearance) as a TWO LOBE BEARING
function of the referred load (Figure 9), one recognizes that the
conditions here are roughly contrary to those for the damping Measured values
behaviour. In other words, bearings with high damping values spud: n=10055 r.p.m
have relatively reduced oil film thicknesses. For example, it Calculated temperature
may appear desirable to use a four-lobe bearing because of its
high stability limit. However, the reduced oil film thickness
might lead to an overload of the bearing. A favourable com
promise must be reached, perhaps by use of a two-lobe bearing
by a modification to the shaft.
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Figure 11. Hydrodynamic Pressure Distribution over Circumference and Width of the Bearing.
Vibration Behaviour
As stated under Bearing Design, the bearings are rated to
achieve low lateral vibration values. High damping effects
must be achieved. Also, the complete system-shaft, casing,
and bearings-must be designed so that small residual unba
lance does not produce important transverse vibration am
plitudes. According to API, the admissible shaft vibration
Figure 12. Finite Element Structure of Gear Housing for amplitude is
Stiffness Calculations.
25.4 (f¥2000 .
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95.8
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For a balancing quality, Q, to equal 1, this means that a specific
55
magnifying factor, f, can be accepted:
0.145Vll
suitability of the measures taken. Its noise level of dBA
sound pressure level at MW is at the lower level of noise
f = (11)
values that have yet been achieved for such power output
.25.
values.
Figure 13 illustrates the admissible magnifying factors for
balancing qualities of Q = 1 and Q = The balancing quali
OPERATIONAL BEHAVIOUR ty, Q, is defined as speed of the centre of gravity, v, of the
In this section, experience in practical service with gear theoretical eccentricity of the centre of gravity, e:
units will be discussed, especially with regard to the operation
al reliability and the noise and vibration behaviour. Q = v5 = e w, in mm/s (12)
DESIGN AND CALCULATION METHODS FOR HIGH-SPEED GEARS OF ADVANCED TECHNOLOGY 7
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