19FTM23.

New Standardized Calculation Method of the Tooth Flank Fracture Load Capacity of Bevel and
Hypoid Gears
Author: Josef Pellkofer, Michael Hein, Karsten Stahl, Tobias Reimann, and Ivan Boiadjiev
Bevel and hypoid gears are widespread in automotive, industrial, marine and aeronautical applications for
transmitting power between crossed axles. Future trends show that the demands on bevel and hypoid gears for
higher power transmission and lower weight are continuously increasing. A major aspect in the design process is
therefore the load carrying capacity regarding different failure modes. Beside typical fatigue failures like pitting and
tooth root breakage, which are the results of cracks initiated at or just below the surface, there are also failures
caused by cracks starting in greater material depth in the area of the active flank that can be observed on bevel
and hypoid gears. These cracks typically propagate to the tooth root area of the unloaded flank and to the surface
of the active flank. The failure mode known as tooth flank fracture occurs particularly frequently on large spiral
bevel and hypoid gears because this gear type shows larger equivalent radii of curvature compared to spur and
helical gears. As a result of the larger equivalent radius of curvature the maximum shear stress occurs in a larger
material depth, where the material of a case hardened gear shows a decreased strength. Important parameters
influencing the tooth flank fracture load capacity are geometry, operating conditions, material and heat treatment
of the gear set. Tooth flank fracture usually leads to the total breakdown of the gearbox and generally occurs
suddenly and unexpected since the crack initiation and propagation takes place below the tooth surface and
therefore cannot be identified within visual inspections.
This paper will give an overview of the subsurface failure mode known as tooth flank fracture on bevel and hypoid
gears. Further a newly developed standardized calculation method for determining the tooth flank fracture load
capacity based on the geometry of virtual cylindrical gear according to the standard ISO 10300 (2014) will be
explained in detail.
ISBN: 978-1-64353-062-8

19FTM24. Calculated Scuffing Risk: correlating AGMA 925-A03, AGMA 6011-J14 and Original MAAG Gear
Predictions
Author: John Amendola, Sr., John Amendola III, and Robert Errichello
Predicting scuffing risk is a critical factor when designing high speed gears. In years past, scuffing risk was not
calculated for gear tooth ratings for through hardened gears. Now, case hardened gears allow higher tooth loads
making it necessary to calculate scuffing risk. AGMA and ISO application standards rate only macropitting and
bending fatigue resistance. Both AGMA and ISO provide information sheets and technical specification reports,
but neither provides a specific design standard for assessing scuffing risk.
Scuffing is severe adhesive wear occurring on gear tooth flanks when oil film thickness is insufficient to prevent
transfer of metal from one gear tooth surface to the mating gear tooth due to welding and tearing. It usually occurs
during startup of new gears thereby requiring design modification, load adjustment, or lubricant change.
Nevertheless, it can occur after years of service if the oil deteriorates or load distribution across gear tooth flanks
changes.
This paper compares three methods for calculating scuffing risk using performance data for real gears and
presents a simplified method that assures accurate prediction of scuffing risk.
ISBN: 978-1-64353-063-5

19FTM25. Optimum Carburized and Hardened Case Depth

Author: Robert Errichello, and Andrew Milburn
The optimum carburized and hardened case depth for each gear failure mode is different and must be defined at
different locations on the gear tooth. Current gear rating standards do not fully explain the different failure modes
and do not clearly define the different locations that must be considered. Furthermore, they use different hardness
values to define effective case depth and provide different values for recommended case depth. This paper
explains why case hardening is beneficial; the risks involved and compares the methods for calculating and
specifying case depth per the ISO 6336-5 and ANSI/AGMA 2101-D04 gear rating standards, and guidelines
presented in the MAAG Gear Handbook. The paper shows the three locations that the case depth needs to be
specified and presents separate calculation methods to determine the optimum case depth to avoid the failure
modes of macropitting, subcase fatigue, bending fatigue, and case/core separation. For each failure mode there is
a minimum case depth below which the load capacity drops off. On the other hand, an excessively deep case
decreases load capacity, increases cost, and has other detrimental effects that are explained.
ISBN: 978-1-64353-064-2

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AGMA Publications Catalog 41 April 2020