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(Reaffirmed 2014) 
(Reaffirmed 2018) IS 4460 ( Parts 1 to 3 ) : 1995
  2006 )
( Reaffirmed

(Reaffirmed 2013) 

(Reaffirmed 2012) 

Indian Standard (Reaffirmed 2011) 

 
GEARS – SPUR AND HELICAL GEARS —
CALCULATION OF LOAD CAPACITY (Reaffirmed 2010) 

 
( First Revision ) (Reaffirmed 2009) 

UDC 621.833.1 : 620.172.21 (Reaffirmed 2008) 

(Reaffirmed 2007) 

(Reaffirmed 2006) 

(Reaffirmed 2005) 

© BIS 1995

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

August 1995 Price Group 12

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Gears Sectional Committee, LM 13

FOREWORD

This Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards, after the draft
finalized by the Gears Sectional Committee had been approved by the Light Mechanical Engineering
Division Council.
This standard was first published in 1967 and an amendment was issued in 1978 to give additional
information regarding properties of materials recommended for manufacture of cylindrical gears. This
first revision has been issued to align the standard with the International practices taking into account
the work done by ISO technical committee ISO/TC 60 'Gears'. The standard is based on the
corresponding ISO documents for cylindrical gears and presents the data and calculation formulae in
more rational manner.
In line with the International practices for designing of gears, load capacity of cylindrical gears is
evaluated based on limitation by contact stresses and bending stresses. Accordingly, the revision is
being presented in three parts so that the standard may be utilised more effectively. The Part 1
of this standard deals with the introduction, symbols and general influence factors for design of gears.
Detailed step by step calculation procedures for calculation of load factors taking into account the
effect of surface durability ( pitting ) is given in Part 2. There is appropriate reference to tables
and graphs for arriving at various factors. Part 3 covers the calculation procedure for calculating
the load factors with respect to bending strength. These parts have been presented in such a format
that the standard may be directly used for arriving at various factors relevant for calculations. In order
to help the designer, examples of use of the two sections have been included in the Annex A and B
to the standard.
The formulae and tables given in this standard apply to the calculation of load capacity of cylindrical
external gears — spur, helical and double-helical; with peripheral speeds less than 50 m/s.
IS 9466 : 1980 'Viscosity classification of industrial liquid lubricants' or ISO 3448 : 1975 'Industrial
liquid lubricants — ISO viscosity classification' may be referred for viscosity grade.
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IS 4460 ( Parts 1 to 3 ) : 1995

CONTENTS

Clause Title Page

PART I INTRODUCTION AND GENERAL INFLUENCE FACTORS

1 SCOPE. .. . .. ... ... 3
2 SYMBOLS, NOMENCLATURE AND UNITS ... ... ... 3
3 GENERAL INFLUENCE FACTOR ... ... ... 5
3.1 Application Factors, KA ... ... .. . 5
3.2 Dynamic Load, Factor, Kv ... ... ... 5
3.3 Longitudinal Load Distribution Factors, KHβ and KFβ ... ... 6
3.4 Transverse Load Distribution Factors, KHα and KFα ... ... 7
3.5 Zone Factor for Contact Stress, ZH ... ... 7
3.6 Elasticity Factor for Contact Stress, ZH ... ... ... 8
3.7 Contact Ratio Factor for Contact Stress. Zt ... ... 8
3.8 Helix Angle Factor for Contact Stress, Zβ ... ... ... 8
3.9 Life Factor for Contact Stress, ZL ... ... ... 8
3.10 Lubricant Factor for Contact Stress, Z1 ... ... ... 8
3.11 Velocity Factor for Contact Stress, Zv ... ... ... 9
3.12 Work Hardening Factor for Contact Stress, Zw ... ... 9
3.13 Size Factor for Contact Stress, Za ... ... 9
3.14 Roughness Factor for Contact Stress, ZH ... ... .. . 11
3.15 Reliabilit
y Factor , K..R . ... ... 11
3.16 Life Factor for Bending Stress, YN ... ... 11
3.17 Form Factor for Bending Stress, YFa ... .. 11
3.18 Stress Concentration Factor for Bending Stress, YK ... ... 12
3.19 Contact Ratio Factor for Bending Stress, Ys ... ... ... 12
3.20 Helix Angle Factor for Bending Stress, Yβ ... ... 12
3.21 Factor of Notch Sensitivity for Bending Stress, Yn ... ... 12
3.22 Factor of Relative Surface Roughness for Bending Stress, Yn ... ... 12
3.23 Size Factor for Bending Stress, Ya ... ... 12
3.24 Endurance Limit for the Contact Stress, σHlim ... ... 12
3.25 Nominal Bending Endurance Limit of an Un-notched Specimen at
Full Elasticity of the Material, σFE ... 13

PART 2 METHOD OF CALCULATION OF LOAD FACTORS FOR

SURFACE DURABILITY ( PITTING )
... ... 15
1 SCOPE ... ... ... 15
2 ... 15
DATA ... ...
2.1 Basic Data ... ... ... 15
... 15
2.2 Supplementary Data ... ...
3 FORMULAS ...

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IS 4460 ( Parts 1 to 3 ) : 1995

PART 3 METHOD OF CALCULATION OF LOAD FACTORS FOR
BENDING STRENGTH

1 SCOPE ... ... ... ... 19

2 DATA ... ... ... ... ... 19
2.1 Basic Data ... ... ... ... ... 19
2.2 Supplementary Data ... ... ... ... 19
3 FORMULAE ... ... ... ... — 19
ANNEX A EXAMPLE FOR CALCULATION OF LOAD FACTORS FOR SURFACE
DURABILITY ( PITTING ) ... ... ... 22
A-1 BASIC DATA ... ... ... 22
A-2 SUPPLEMENTARY DATA ... ... ... 23
A-3 FORMULAE ... ... ... ... 23
ANNEX B EXAMPLE FOR CALCULATION OF LOAD FACTORS FOR BENDING STRENGTH ... 25
B-l BASIC DATA ... ... ... ... ... 25
B-2 SUPPLEMENTARY DATA ... ... 26
B-3 FORMULAE ... ... ... ... ... 26

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IS 4460 ( Parts 1 to 3 ) : 1995

Indian Standard
GEARS — SPUR AND HELICAL GEARS —
CALCULATION OF LOAD CAPACITY
PART 1 INTRODUCTION AND GENERAL INFLUENCE FACTORS

( First Revision )

1 SCOPE capacity, factors of safety, and the relevance of each

factor in the design of spur and helical gears in relation
1.1 This Part 1 of the standard covers the symbols, to speed, applications, materials, manufacturing
general influence factors for calculation of load process, heat-treatment and lubrication.

2 SYMBOLS, NOMENCLATURE AND UNITS

Symbol Description Unit

a' Working centre distance mm

b Face width mm
d Pitch circle diameter mm
da Outside diameter mm
db Base circle diameter mm
hao Basic rack addendum of tool mm
hFa Bending moment arm tor root stress mm
hk Buckling height at protuberance profile mm
m Module mm
mn Normal module mm
mt Transverse module mm
n Speed of the pinion or gear min-1
PF Probability of failure
qn Notch parameter –
Sfn Tooth root chord in the critical section mm
H Ratio of gearing (z2/z1) —
v Linear speed at reference circle m/s
x Profile correction factor –
z Number of teeth –
Zv Virtual number of teeth
A, B, C Auxiliary values –
Cz1 Factor for calculating Z1
Czv Factor for calculating Zv —
D Auxiliary value —
EA Auxiliary value mm
E Modulus of elasticity MPa
F1 Tangential load at the reference circle N
G Auxiliary value –
H Auxiliary value —
3
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IS 4460 ( Parts 1 to 3 ) : 1995

Symbol Description Unit

HB Brinell hardness of the material *

HRC Rockwell hardness of the material —
HV1 Vickers hardness measured at 9.81N —
HV10 Vickers hardness measured at 98.1N —
KA Application factor —
KHα Transverse load distribution factor for contact stress —
KHβ Longitudinal load distribution factor for contact stress —
KFα Transverse load distribution factor for bending stress —
KFβ Longitudinal load distribution factor for bending stress —
KR Reliability factor —
Kv Dynamic load factor —
Kvα Factor for calculating Kv —
Kvβ Factor for calculating Kv —
LA Auxiliary value —
LH Life in hours hours
LN Life in cycles cycles
P Transmitted power W
Rz Mean roughness μm
sH Factor of safety for contact stress —
sB Factor of safety for bending stress —
Yn Notch sensitivity factor —
YFa Form factor —
YN Life factor for bending stress —
YK Stress concentration factor —
YS Size factor for bending stress —
YR Factor of relative surface roughness —
Yc Contact ratio factor for bending stress —
Yβ Helix angle factor for bending stress —
Z1 Lubricant factor for contact stress —
ZE Elasticity factor for contact stress √MPa
ZH Zone factor for contact stress —
Life factor for contact stress
ZR Roughness factor for contact stress —
Zs Size factor for contact stress —
Zv Velocity factor for contact stress —
Zw Work hardening factor for contact stress —
Zr Contact ratio factor for contact stress —
Zβ Helix angle factor for contact stress —
α Pressure angle deg
αa Tip pressure angle deg
αn Normal pressure angle deg
αan Normal pressure angle at the tooth tip deg
αpro Protuberance angle deg

*The unit for Brinell hardness is kgf/mm2. It is usually specified as a number without units.

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Symbol Description Unit

α1 Transverse pressure angle deg

αta Transverse pressure angle at the tooth tip deg
αw1 Transverse working pressure angle deg
β Helix angle deg
βa Helix angle at the tip circle deg
βb Base helix angle deg
τ Auxiliary angle deg
εα Transverse contact ratio —
εαn Normal contact ratio —
εβ Overlap ratio —
v50 Viscocity of the lubricant at 50°C mm2/s
v40 Viscosity of the lubricant at 40°C mm2/s
ø Auxiliary angle rad
μ Poisson's ratio —
pao Tip radius of the basic rack mm
PF Fillet radius at contact point of the 30° tangent mm
σF Maximum working tensile stress MPa
σFE Nominal endurance limit of an un-notched specimen at full MPa
elasticity of the material
σFO Maximum nominal static stress calculated at the tooth root MPa
σFP Permissible stress for the material at the tooth root MPa
σHO Calculated contact stress MPa
σH Working contact stress MPa
σHP Permissible contact stress MPa
σHlim Endurance limit for contact stress MPa
Suffix 1 — For the pinion.
Suffix 2 — For the gear.

3 GENERAL INFLUENCE FACTORS e) lubrication,

3.1 Application Factor, KA f) damping characteristics of the gear system,
The application factor, KA accounts for dynamic over­ g) shaft and bearing stiffnesses, and
loads from sources external to the gearing. The over­ h) load bearing partem on tooth flanks.
loads depend on characteristics of driving and driven Method of calculating the dynamic load factor fur­
machines, the ratio of masses, the couplings and operat­ nished in this standard is suitable for:
ing conditions. If possible, the application factor should 1) steel gears of heavy rim section,
be determined by precise measurement or by a com­
prehensive system analysis. In case neither one of these 2) gears of average to heavy loading,
two is practicable, application factor shall be selected
as per the guidelines furnished in Tables 1, 2 and 3.
3.2 Dynamic Load Factor, KV 3) gears involving pinions with relatively small
The dynamic load factor, KV is defined as the ratio numbers of teeth,
between the maximum force which occurs at the mesh
4) Running speed in the sub-critical range:
of an actual gear pair and the corresponding load due
to the externally applied load. The dynamic load factor
is mainly influenced by: For helical gears :
a) transmision errors,
b) polar moments of inertia of pinion and gear, For spur gears:
c) mesh stiffness,
5) All types of gears,
d) transmitted load including application factor,

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Table 1 Application Factor for Speed Reducing Gears, KA
( Clause 3.1 )

Working Characteristics of Working Characteristics of Driven Machine (Refer Table 3)

Driving Machine
(Refer Table 2 ) Uniform Moderate Shock Heavy Shock

Uniform 1.00 1.25 1.75

Light shock 1.25 1.50 2.00

Medium shock 1.50 1.75 2.25
NOTES
1 The values in the table are valid for the gears not running at resonance speed.
2 For step-up drives, multiply the data by 1.1.

Table 2 Examples of Driving Machines with Different Working Characteristics

( Clause 3.1 )

Character of Operation Driving Machines

Uniform Electric motor, steam turbine, gas turbine

Light shock Multi-cylinder combustion engine

Medium shock Single-cylinder combustion engine

Table 3 Examples of Driven Machines with Different Working Characteristics

( Clause 3.1 )

Character of Operation Driven Machines

Uniform Generator, belt conveyor, platform conveyor, light elevator, electric hoist, feed gears of machine
tools, ventilators, turboblower, mixer for constant density material
Medium shock Main drive to machine tool, heavy elevator, turning gears of crane, mine ventilator, mixer for
variable density material, multi-cylinder piston pump, feed pump
Heavy shock Press shear, rubber dough mill, rolling mill drive, power shovel, heavy centrifuge, heavy feed
pump, rotary drilling apparatus, briquette press, pug mill.

3.3 Longitudinal Load Distribution Factors, KHβ h) surface irregularities caused by loading,
and KFβ j) thermal deformation for high speed gears,
The longitudinal load distribution factor, KHβ is to k) tangential and axial loads,
account for the non-uniform distribution of load across m) lapping effects,
the face-width. This depends on the mesh alignment
n) longitudinal corrections done on the teeth, and
error of the loaded gear pair and the mesh stiffness. The
main influeucing factors are: p) overhung loads on shafts.
The factor KHβ can be analysed by a complete evalua­
a) errors in the manufacture of teeth,
tion of all the. elements of influence, and can be
b) errors in mounting due to bore errors,
inspected, for example, by measuring the stress at the
c) bearing allowances, tooth root in actual operation or by a critical examina­
d) stiffness of teeth, tion of the meshing pattern on the teeth at full load.
e) stillness of the gear core,
In case, the influencing elements are not sufficiently
f) stiffness of the housing, known for a precise calculation of KHβ, the approximate
g) deformation of bearings, method described in this standard can be used.

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Longitudinal load distribution factor for bending stress, The main influencing factors are:
K Fβ enables to take into account the effects of uneven a) the overall rigidity of the gear mesh,
distribution of load along the length of the tooth. b) the total tangential load,
For gears in general mechanical use with the teeth cut
c) the base pitch error,
directly from through hardened steel, the value of K Fβ
is very close to KHβ. But, in case of surface hardened d) tip relief of the teeth,
teeth, KFβ is marginally less than KHβ (about 5%). In e) face width of the teeth,
general, same value can be taken for K Hβ and K Fβ f) influence of lapping, and
Formulae for the calculation of K Hβ and K Fβ are given g) the dimensions of the gear.
in Table 4. As far as general mechanical use is concerned, factor
K Hα can be selected from Table 5.
3.4 Transverse Load Distribution Factors, KHα and
KFα The transverse load distribution factor for bending
stress, KFα takes into account the effect of transverse
The distribution of the total tangential load on several distribution of loads during the tooth meshing. For the
pairs of teeth in contact depends on the dimensions gears of general mechanical use, factor K Fα can be
given to the gears, the precision and the value of the taken as equal to K Hα .
tangential force. Transverse load distribution factor
takes into account the distribution of actual load during 3.5 Zone Factor for Contact Stress, Z H
the gear mesh. The zone factor, Z H accounts for the influence on the

Table 4 Calculation of Factors, KHβ, KFβ

KHβ = KFβ
( Clause 3.3 )

Gear Quality With No Post Assembly Adjustment With Post Assembly Adjustment

6 and better 1.135 + 0, 18 (b/d 1 ) 2 + 0,23 × l 0 - 3 . b 1,1 +0, 18(b/d 1 ) 2 + 0, 115 × 10 -3 .b

7 1.15 + 0, 18 (b/d1)2 + 0,3 × 10 - 3 .b 1.11 + 0, 18 (b/d 1 ) 2 + 0,15 × 10-3.b

8 1.17 + 0, 18 (b/d1)2 + 0,47 × 10-3.b 1.12 + 0, 18 (b/d1)2 + 0,23 × 10-3.b

9 1.23 + 0, 18 (b/d1)2 + 0,61 × 10-3.b 1.15 + 0, 18 (b/d1)2 + 0,31 × 10-3.b

Table 5 Determination of Transverse Load Distribution Factors, K Hα and K Fα

KHα = KFα
( Clause 3.4 )

≥ 100 N/mm < 100

Specific Loading N/mm

Gear quality grade 6 and 7 8 9 10 11 12 6 and

better worse

Hardened: Spur gears KHα 1.0 1.1 1.2 1/Z2 ≥ 1.2

KFα
Hardened: Helical gears KHα 1.0 1.1 1.2 1.4 εαn ≥ 1.2
KFα

Unhardened: Spur gears KHα 1.0 1.1 1.2 1/Z2 ≥ 1.4

KFα
Unburdened: Helical gears KHα 1.0 1.1 1.2
KFα
1.4
tan ≥ 1.4

NOTE — For specific loading less than 100 N/mm and quality grade 5 and better, KHα and KFα may be taken as 1.0.

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Hertzian pressure, of tooth flank curvature at pitch of helix angle on surface durability and distribution of
point and converts the tangential force at the reference load along the line of contact Helix angle factor
cylinder to the normal force. depends only on the helix angle and is independent of
ZH is given by the formula: the influence of helix angle on the length of contact
Zβ can be calculated from the following formula:

3.6 Elasticity Factor for Contact Stress, ZE 3.9 Life Factor for Contact Street, ZL

The elasticity factor accounts for the influence of the The life factor, ZL takes into account a higher permis­
material properties, modulus of elasticity (E) and Poisson's sible Hertzian stress if only limited life is required.
ratio (μ) on the Hertzian pressure (see Table 6). The main influencing factors are:
ZE can be calculated from the formula: a) material and hardness,
b) number of cycles, and
c) factors Z R , Z V , Z L , Z W and Z s .
The formulae furnished in Table 7 can be used for the
calculation of ZL.
3.7 Contact Ratio Factor for Contact Stress, Zc 3.10 Lubricant Factor for Contact Stress, Z1
The contact ratio factor, Zs accounts for the influence The lubricant factor, Z1 accounts for the influence of the
of the transverse contact ratio and the overlap ratio on type of lubricant and its viscosity on the load bearing
the specific surface load of gears. capacity of the surface. Z1 can be calculated by using
Zε can be calculated from the following formulae: the following formulae:
For spur gears:

For helical gears:

if εβ < 1

if εβ ≥ 1

3.8 Helix Angle Factor for Contact Stress, Zβ

The helix angle factor, Zβ accounts for the influence

Table 6 Modulus of Elasticity and Poisson's Ratio

Material Modulus of Elasticity, MPa (N/mm2) Poisson's Ratio

Steel 206 000 0.3

Cast steel 202 000 0.3
Spheroidal cast iron 173 000 0.3
Cast tin bronze 103 000 0.3
Tin bronze 113 000 0.3
Grey cast iron 118 000 0.3

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if σHim > 1 200 MPa, Cz1 = 0.91 The increase of surface durability of the soft gear is
v 50 and v 40 may be obtained from Table 8. dependent not only on the work-hardening of the soft
gear but also on the other factors such as alloying
3.11 Velocity Factor for Contact Stress, Z v elements of the soft material, Hertzian stress, hardening
The velocity factor, Z v accounts for the influence of the process and surface roughness of the hard pinion.
pitch line velocity on the surface load capacity. Z v can The work hardening effect should be evaluated from
be calculated by using the following formulae: results of tests or field experiences with gears. In the
absence of such data, the following formula can be used
for the evaluation of the approximate value of Zw:

if 850 ≤ σ Hlim ≤ 1 200 MPa for 130 < HB < 400, Z w can be taken as unity.

3.13 Size Factor for Contact Stress, Z s

The size factor, Z s accounts for the influence of tooth
if σ Hlim < 850 MPa, Czv = 0.85 dimensions on allowable contact stress. In principle,
if σHlim > 1 200 MPa, Czv = 0.93. the flank curvature/radius is suitable as dimension for
the size. However, for surface hardened gears, the
3.12 Work Hardening Factor for Contact Stress, Z w
hardness depth as compared to the tooth size plays
Work hardening factor takes into account the increase a role. Further, as larger modules are found for
of surface durability due to meshing of gear with a larger diameters, the module can be taken as basis for
hardened pinion with smooth tooth surfaces. size.

Table 7 Life Factor for Contact Stress, Z L

LN = 60 × n × LH
( Clause 3.9 )
ZL
Sl N o . Material Condition

Through hardened steals, SG iron LN ≤ 6 × 105 1.6

castings, Malleable iron castings,
1 Surface hardened steels (with a permitted
level of pitting)
6 × 105 ≤ LN ≤ 107 (3 × l08/LN)0.0756
LN ≥ 109 1.0

Through hardened steels, SG iron LN ≤ 10

5 1.6
castings, Surface hardened steels (with
2 no permitted level of pitting)
105 ≤ LN ≤ 107 (5 × l07/LN)0.0756

LN ≤ 5 × 1 0 7 1.0

Nitriding steels - LN ≤ 1 0 5 1.3

G a s nitrided
3 Grey cast iron
105 ≤ LN ≤ 2 × 106 (2 × 106/LN)0.0875

LN ≥ 2 × 106 1.0

Nitriding steels - LN ≤ 105 1.1

Liquid nitrided
4 105 ≤ LN ≤ 2 × 106 (2 × l06/LN)0.0318

LN ≥ 2 × 106 1.0
NOTES
1 For a single tooth mesh, LN = LN
2. For an intermediate gear, LN = 2 LN
3 For a motor pinion with double mesh, LN = 2 LN
4 For a planetary train with q satellites
Sun Gear, LN = q. LN
Ring Gear, LN = q. LN
Satellites, LN = 2. LN

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Table 8 Values of Viscosity for Lubrication Oils in mm2/s
( Clause 3.10 )

ISO Viscosity Grade v40 v50

Kinematic Viscosity Range at 40°C Kinematic Viscosity Range at 50°C
ISO VG 2 1.96 - 2.42 1.60 - 2.03
ISO VG 3 2.88 - 3.52 2.37 - 2.83
ISO VG 5 4.14 - 5.06 3.27 - 3.01
ISO VG 7 6.12 - 7.48 4.63 - 5.52
ISO VG 10 9.0 - 11.0 6.53 - 7.83
ISO VG 15 13.5 - 16.5 9.43 - 113
ISO VG 22 19.8 - 24.2 13.3 - 16.0
ISO VG 32 28.8 - 35.2 18.6 - 22.2
ISO VG 46 41.4 - 50.6 25.5 - 30.3
ISO VG 68 61.2 - 74.8 35.9 - 42.8
ISO VG 100 90.0 - 110 50.4 - 60.3
ISO VG 150 135 - 165 72.5 - 86.9
ISO VG 220 198 - 242 102 - 123
ISO VG 320 288 - 352 144 - 172
ISO VG 460 414 - 506 199 - 239
ISO VG 680 612 - 748 283 - 339
ISO VG 1 000 900 - 1 100 400 - 470
ISO VG 1 500 1 350 - 1 650 575 - 688
NOTE — IS 9466 : 1980 can be referred for viscosity grade.

Table 9 Size Factor, Zs

( Clause 3.13 )

Material Zs Limiting Conditions

Case hardened flame or induction hardened 1.05 - 0.005 mn 0.9 ≤ Zs ≤ 1

???

??? 1.08 - 0.011m n 0.75 ≤ Z s ≤ 1

Structural or annenled g e a r s 1 —

Table 10 Roughness Factor, ZR

(Clause 3.14)

Material ZR
Hardened a n d ground g e a r s 1.0
Finish cut g e a r s 0.85

Gears lapped after generation 0.9

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Normally, Zs has the value of unity. This can be applied, KR = 0.79 - 0.105 log (pf)
if the appropriate heat treatment and case depth are pf = probability of failure.
chosen. Table 9 can be referred to for the values of size 3.14 Life Factor for Bending Stress, YN
factor depending on module and material hardness The life factor for bending stress, Y takes into account
N
condition.
the case of limited life (3 × 106 cycles) where a higher
3.14 Roughness Factor for Contact Stress, ZR root stress can be permitted. The main influencing
The roughness factor, ZR accounts for the influence of factors are:
surface texture of tooth flanks on surface load capacity. a) material and hardness,
Depending on the surface condition of the gears, the b) number of cycles (required life), and
value of ZR can be selected from Table 10. c) influence factors Ya, YR and Ys.
3.15 Reliability Factor, KR The life factor YN can be taken as unity for a required
life of more than 3 × 106 cycles. For other cases, the
The reliability factor is introduced to allow the design formulae furnished in Table 11 can be used for the
of gears with a calculated risk and higher reliability. calculation of YN.
KR = 1.0, corresponds to a probability of failure
3.17 Form Factor for Bending Stress, YFa
of one in 100 at the rated load and required
life ( ρF = 0.01). The tooth form factor, YFa, takes into account the
For some applications, there may be a requirement for influence of the tooth form on the nominal bending
a greater or a smaller reliability factor. For such cases, stress for the application of load at the tooth tip. The
procedure and the formulae for the calculation of tooth
KR can be calculated using the following formula: form factor, YFa is given in detail in Part 3 of this
Table 11 Life Factor for Bending Stress, YN
LN = 60 × n × LH
( Clause 3.16 )

Sl N o . Material Condition YN

LN ≤ 1 0 4 2.5
T h r o u g h hardened steels,
1 SG iron castings,
Malleable iron castings
1 0 4 < LN ≤ 3 × 1 0 6 (3 X 106/LN)0.115

LN > 3 × 106 1.0

LN ≤ 103 2.5
2 Carburising steels,
Surface hardened steels
103 < LN ≤ 3 × 106 (3 × 106/LN)0.115

LN > 3 × l0 6 1.0

LN ≤ 103 1.6
3 T h r o u g h hardened steels
- Gas nitrided
103 < LN ≤ 3 × 106 (3 × 106/LN)0.059
Grey cast iron
LN > 3 × 106 1.0

LN ≤ 103 1.2
4 Through hardened steels - Liquid nitrided 103 < LN ≤ 3 × 106 (3 × 106/LN)0.012

LN > 3 × l0 6 1.0

NOTES
1 For a single tooth mesh, LN = LN.
2 For an intermediate gear, LN = 2 LN.
3 For a motor pinion with double mesh, LN = 2 LN.
4 For a planetary train with q satellites
Sun gear, LN = q. LN
Ring gear, LN = q. LN
Satellites, LN = 2. LN

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standard. The calculation method is based on the dis­ are rarely less than 3 × 10 6 cycles.
tance between the contact points of the 30° tangents at The notch sensitivity factor Yn can be determined from
the root fillet of the tooth profile. Table 12 depending on the material condition.
3.18 Stress Concentration Factor for Bending 3.22 Factor of Relative Surface Roughness for
Stress, Y K Bending Stress, YR
The stress concentration factor, Y K takes into account A fatigue fracture has its origin in a small crack and it
the conversion of the nominal bending stress to the local is evident that the endurance of a test piece would
tooth root stress. Thereby Y K covers the stress increas­ diminish in case of a roughly machined surface. For the
ing effect of the fillet (notch) and the bending stresses materials very susceptible to concentration of stress, the
arising at the tooth root. A part of the local stress is influence of surface condition is more important The
independent of the bending moment arm and as it surface roughness factor enables to take into account
increases, the point of application of load approaches the influence of profile roughness on the fatigue life of
the gear. The relative surface roughness factor is the
the critical tooth root section.
ratio between the surface roughness factor of the gear
Therefore, in addition to its dependence on the notch to be determined and a test gear. This value can be
radius, the stress correction is also dependent on the calculated from the formulae given in Table 13.
p o s i t i o n on the load application, that is, the size of the
bending moment arm. Y K applies to the application of 3.23 Size Factor for Bending Stress, Y s
the load at the tooth tip. The size factor, Y s takes into account the decrease of
Y K can be calculated as per the procedure given in the strength with increasing size (size effect). The main
Part 3 of this standard. influencing factors are:
a) material and hardness, and
3.19 Contact Ratio Factor for Bending Stress, Y c b) size of the gear.
The contact ratio factor Yc is necessary for the deter­ Ys as a function of normal module and the material can
mination of tooth root stress Σ F O . W i t h Y ε , the conver­ be approximately determined from formulae given in
sion of applied load at the tip, to the decisive point of Table 14.
load application is carried out for approximate calcula­
3.24 Endurance Limit for the Contact Stress,
tion of maximum tooth root stress arising during the
meshing of the teeth. σH lim
Yε can be calculated from: For a given material σH lim is the limit of repeated
Hertzian stress which can be permanently endured. The
value of σH lim for a material can be regarded as the level
of Hertzian stress which the material will endure
3.20 Helix Angle Factor for Bending Stress, Y β without damage for at least 50 × 10 6 load cycles.
The helix angle factor Y β takes into account the dif­ The main influencing factors are:
ference between the helical gear and the virtual spur a) material composition;
gear in the normal section on which the calculation is b) mechanical properties;
based. Y β can be calculated as given below: c) hardening process, depth of hardened zone,
hardness gradient;
d) structure;
≥ 1 – 0.25 εβ e) residual stresses; and
f) material cleanliness and defects.
≥.75
σH lim can be established for any material in any condi­
3.31 Factor of Notch Sensitivity for Bending Stress, Yn tion, by running load tests on gears, made of the
Actual reduction of resistance to fatigue due to notch material in question. It is essential that when test results
sensitivity is often less than the value of the stress or data from service are interpreted, allowances are
concentration factor Y K . The main influencing made on the influences on permissible stresses of such
parameters of notch sensitivity factor are the material, variables as lubricant viscosity, surface roughness,
heat treatment and the rate of loading. material combination, etc.
Two value aspects are to be considered for this coeffi­ Figures 3 to 7 give fields relative to flank hardness for
cient. They are: the endurance limits of given material groups, with
— value relative to the endurance limit, and nonnal heat treatment method. These graphs can be
— value relative to the static limiting stress. used, if the requisite data from load tests or service
conditions are not available.
In this standard only the value of notch sensitivity factor
relative to endurance limit is considered because the The values furnished in Fig. 3 to 7 correspond to a
number of working cycles for general mechanical use failure probability of 0.01.

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IS 4460 ( Parts 1 to 3 ) : 1995

The selection of fatigue strength values at the upper ZR = 1.0, Zv = 1.0 and ZL = 1.0
limits of the fields demands a special consideration to
the selection, testing and heat treatment of the material 3.23 Nominal Bending Endurance Limit of an Un-
and the corresponding control processes. notched Specimen at Full Elasticity of the Material,
Normally the choice of endurance limits is from the σFE
middle of the fields.
The endurance limit takes into account the influence of
The endurance limits for Hertzian stress shown in the the material on the tooth root stress which can be
diagrams are valid for: permanently endured. For steels, the endurance limit is

Table 12 Notch Sensitivity Factor, Yn

( Clause 3.21 )

Material Ya
Cast iron 0 3 5 YK+ 0.38

Nitrided steels 0.22 YK +0.61

Soft steels 0.18 YK + 0.68

Through hardened steels 0.08 YK + 0.86

Case hardened steels 0.04 YK + 0.93

Table 13 Factor of Relative Roughness, YR

(Clause 3.22)

Material Condition YR

1 μ m ≤ Rz ≤ 40 μm 1.674 - 0.529 (Rz + l)0.1

Through hardened and case hardened steels
Rz < 1 μm 1.12

1 μ m ≤ Rz ≤ 40 μm 5.306 - 4.203 (R z + 1) α 0 1
Soft steels
Rz < 1 μm 1.07

1 μ m ≤ Rz ≤ 40 μm 4.299 - 3.259 (Rz+ 1 )0.005

Grey cast iron and nitrided steels
Rz < 1 μm 1.025

Manufacturing Process for Gears Mean Roughness, Rz, μm

Lapping 0.5 - 4.8

Grinding 2.4 - 4.8

Grinding - Criss Cross 4.8 - 9.6

Shaving 4.8 - 19.2

Shaping 9.6 - 75.0

Hobbing 19.2 - 75.0

Milling with formed cutters 19.2 - 75.0

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IS 4460 ( Parts 1 to 3 ) : 1995

taken as 3 × 10 6 cycles. The main influencing factors The values of σFE given in the figures correspond to a
are: test gear with stress concentration factor 2.0.
a) material composition; The values indicated correspond to a probability of
b) mechanical properties; failure of 0.01.
c) beat treatment, case depth and hardness value; The selection of fatigue strength values at the upper
d) structure; limits of the fields demand a special consideration to
the selection, testing and heat treatment of the material
e) residual stresses; and and the corresponding control process. Normally the
f) impurities. choice of the endurance limits is from the middle of the
σ FE can be found by pulsating tests or running tests for fields.
any material and any state of that material. σFE can also The values indicated in the diagrams apply to gears with
be found by using the limiting values obtained by field constant load direction. In case of idler gears, 0.7 times
experience. During the evaluation of such results, the the given values are permitted.
influence of other factors such as module, fillet and
The endurance limits indicated for surface hardened
roughness of tooth root on limiting values is to be
test gears apply to case depths of 0.15 mn and above.
checked.
In the absence of such data, guide values furnished in The endurance limits indicated for nitrided test gears
Figures 9 to 13 can be used to assess the value of σFE. apply to a depth of nitration of 0.4 to 0.6 mm.

Table 14 Size Factor, Ys

( Clause 3.23 )

Sl No. Material Condition YS

Through hardened steels, spheroidal 5 < ma < 30 1.03 - 0.006 ma
1 graphite castings and malleable steel
castings 30 ≤ ma 0.85
5 < ma < 30 1.05 - 0.01 mn
2 Surface hardened steels
304 ≤ ma 0.75
5 < ma < 25 1.075 - 0.015 ma
3 Cast material
ma ≥ 25 0.7

4 For all materials under static load and – 1.0

ma ≤ 5

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IS 4460 ( Parts 1 to 3 ) : 1995

Indian Standard
GEARS — SPUR AND HELICAL GEARS –
CALCULATION OF LOAD CAPACITY
PART 2 METHOD OF CALCULATION OF LOAD FACTORS FOR
SURFACE DURABILITY (PITTING)

( First Revision )
1 SCOPE Outside diameter (gear) d a2 =
1.1 This Part 2 of the standard covers the method of Working centre distance a =
calculating the load capacity taking into account sur­ Face width b =
face durability (pitting) of spur and helical gears. Probability of failure Pf =
1.2 The load factors are arrived at by calculating the
contact stress and factor of safety. The basic data is Accuracy grade for the pinion =
Accuracy grade for the gear =
provided to the designer. Supplementary data is arrived
Hardness of the pinion material =
at from the tables and figures which is used for calcula­ Hardness of the gear material =
tion of load factors. Viscosity grade of the lubricant =
2 DATA 2.2 Supplementary Data

2.1 Basic Data Ratio of gearing u =

Number of teeth (pinion) z1 =
Modulus of elasticity (pinion) E1 = (from Table 6)
Number of teeth (gear) z2 =
Modulus of elasticity (gear) E2 = (from Table 6)
Module m =
Poisson's Ratio (pinion) μ 1 = (from Table 6)
Normal pressure angle n =
Helix angle β = Poisson's Ratio (gear) μ1 = (from Tablc 6)
Transmitted power P = Viscosity of the lubricant at 50° C v50 =
Speed of pinion n1 = Viscosity of the lubricant at 40° C v40 =
PCD (pinion) d1 = (from Table 8)
PCD (gear) d2 = Endurance limit for contact stress —
Outside diameter (pinion) da1 = σ Hlim 1 = (from Fig. 3 - 7) (pinion)
σHlim 2 = (from Fig. 3 - 7) (gear)

3 FORMULAE

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IS 4460 ( Parts 1 to 3 ) : 1995

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As in the Original Standard, this Page is Intentionally Left Blank

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IS 4460 ( Parts 1 to 3 ) : 1995

Indian Standard
GEARS —SPUR AND HELICAL GEARS —
CALCULATION OF LOAD CAPACITY
PART 3 METHOD OF CALCULATION OF LOAD FACTORS FOR BENDING STRENGTH

( First Revision )
1 SCOPE Accuracy grade for the pinoin =
1.1 This Part 3 of the standard covers the method of Accuracy grade for the gear =
calculating the load capacity taking into account the Hardness of the pinion material =
bending strength for spur and helical gears. Hardness of the gear material =
1.2 Basic data is provided to the designer. The load
factors are arrived at by using the supplementary data Viscosity grade of the lubricant =
obtained from tables and figures. 2.2 Supplementary Data
2 DATA Nominal endurance limit of an unnotched specimen at
full elasticity of the material (pinion) σFE1 =
2.1 Basic Data
Number of teeth (pinion) z1 = (from Fig. 9 - 13)
Number of teeth (gear) z2 = Nominal endurance limit of an unnotched specimen at
Normal module mn = full elasticity of the material (gear) σFE2 =
Normal pressure angle αn = (from Fig. 9 - 13)
Helix angle β = Basic rack addendum of tool (pinion) llsol =
Transmitted power P =
(refer Fig. 8)
Speed of pinion n1 = Basic rack addendum of tool (gear) llso2 =
PCD (pinion) d1 = (refer Fig. 8)
PCD (gear) d2 = Buckling height at protuberance profile, (pinion) l1k1 =
Outside diameter (pinion) da1 = Buckling height at protuberance profile (gear) l1k2 =
Outside diameter (gear) da2 = Protuberance angle (pinion) αpro1 =
Working centre distance a' = Protuberance angle (gear) αpro2 =
Face width b = Tip radius of the basic rack (pinion) ρzol =
Profile correction factor (pinion) x1 = Tip radius of the basic rack (gear) ρzo2 =
Profile correction factor (gear) x2 = For standard gears llao = 1.25 mn or 1.167 mn
Pso = 0.2mn
Probability of failure pt =
For tools without protuberance αpro2 = αn
Mean roughness Rz1 (pinion) =
llk = 0
Mean roughness Rz2 (gear) =
3 FORMULAE

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IS 4460 ( Parts 1 to 3 ) : 1995

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IS 4460 ( Parts 1 to 3 ) : 1995

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IS 4460 ( Parts 1 to 3 ) : 1995

ANNEX A
( Foreword )
EXAMPLE FOR CALCULATION OF LOAD FACTORS
FOR SURFACE DURABILITY (PITTING)

A-1 BASIC DATA Speed of pinion n1 = 750 rev/min

Number of teeth (pinion) z1 = 16 PCD (pinion) d1 = 54.83 mm
Number of teeth (gear) z2 = 100 PCD (gear) d2 = 342.71 mm
Module m = 3.25 mm Outside diameter (pinion) da1 = 64.28 mm
Normal pressure angle αn Outside diameter (gear) da2 = 352.42 mm
= 20°
Working centre distance a' = 202.0 mm
Helix angle β = 18.5° Face width b = 45.0 mm
Transmitted power P = 7 350 W Probability of failure pf = 0.01
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IS 4460 ( Part 1 to 3 ) : 1995

The gear and pinion are made from case hardened steel Modulus of elasticity (gear) E2 = 206 000 MPa (from
and hardness after heat treatment shall be 627 HB and Table 6)
shall have an accuracy grade of 5. The lubricant used
has ISO viscosity grade of ISO VG 32 having a Poisson's ratio (pinion) μ1 = 0.3 (from Table 6)
kinematic viscosity of 20 mm 2 /s. Load factors relating Poisson's ratio (gear) μ2 = 0.3 (from Table 6)
to surface durability (pitting) are to be calculated. Viscosity of the lubricant at 50° C is
v50 = 20.0 mm2/s
A - 2 SUPPLEMENTARY DATA
Viscosity of the lubricant at 40° C is v40 = 32 mm2/s
Ratio of gearing u = = 6.25 (from Table 8)
Endurance limit for contact stress :
Modulus of elasticity (pinion) E1 = 206 000 MPa (from
Table 6) σHlim1 = 1 450.0 MPa (from Fig. 3 - 7) (pinion)
σHlim2 = 1 450.0 MPa (from Fig. 3 - 7) (gear)
A-3 FORMULAE

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IS 4460 ( Parts 1 to 3) : 1995

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IS 4460 ( Parts 1 to 3 ) : 1995

ANNEX B
( Foreword )

EXAMPLE FOR CALCULATION OF LOAD FACTORS FOR BENDING STRENGTH

B-1 BASIC DATA Transmitted power P = 7 350W

Number of teeth (pinion) z1 = 16 Speed of pinion n1 = 750 rev/min
Number of teeth (gear) z2 = 100 PCD (pinion) d1 = 54.83 mm
Normal module mn = 3.25 mm PCD (gear) d2 = 342.71 mm
Nonual pressure angle αn = 20° Outside diameter (pinion) da1 = 64.28 mm
Helix angle β = 18.5° Outside diameter (gear) da2 = 352.42 mm

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IS 4460 ( Parts 1 to 3 ) : 1995

Working centre distance a' = 202.0 mm Nominal endurance limit of an unnotched specimen at
Face width b = 45.0 mm full elasticity of the material (gear) Σ F E 2 = 820 MPa
(from Fig. 9 -13)
Profile correction factor (pinion) x1 = 0.5 Basic rack addendum of tool (pinion) hso1 = 4.06 mm
Profile correction factor (gear) x2 = 0.54 (see Fig. 8)
Basic rack addendum of tool (gear) hso2 = 4.06 mm
Probability of failure pr = 0.01 (see Fig. 8)
Mean roughness Rz1 (pinion) = 3.6 μm Buckling height at protuberance profile (pinion)
hk1 = 0.0 mm
Mean roughness Rz1 (gear) = 3.6 μm Buckling height at protuberance profile (gear)
The gear and pinion are made from case hardened steel hk2 = 0.0 mm
and hardness after heat treatment shall be 627 HB and Protuberance angle (pinion) αpro1 = 20.0°
shall have an accuracy grade of 5. The lubricant used
has ISO viscosity grade of ISO VG 32 having a Protuberance angle (gear) αpro1 = 20.0°
kinematic viscosity of 20 mm2/s. Load factors relating Tip radius of the basic rack (pinion) ρso1 = 0.65 mm
to surface durability (pitting) are to be calculated.
Tip radius of the basic rack (gear) ρso2 = 0.65 mm
B-2 SUPPLEMENTARY DATA For standard gears hao = 1.25 mn or 1.167 mn
Nominal endurance limit of an unnotched specimen at P s o = 0.2 . m n
full elasticity of the material (pinion) ΣFE1 = 820 MPa
(from Fig. 9-13) For tools without protuberance αpro = αn
l1k = 0
B-3 FORMULAE

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IS 4460 ( Parts 1 to 3 ) : 1995

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IS 4460 ( Parts 1 to 3 ) : 1995

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IS 4460 ( Parts 1 to 3 ) : 1995

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IS 4460 ( Parts 1 to 3 ) : 1995

FIG. 1 DETERMINATION OF FACTOR Kvα

FIG. 2 DETERMINATION OF FACTOR KVβ

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IS 4460 ( Parts 1 to 3 ) : 1995

FIG 3 DETERMINATION Of σHlim FOR NORMALISED STRUCTURAL STEEL AND CAST STEEL

F I G . 4 DETERMINATION OF σHlim FOR CAST IRON

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IS 4460 ( Parts 1 to 3 ) : 1995

FIG. 5 DETERMINATION OF σHlim FOR THROUGH HARDENED STEEL

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FIG. 6 DETERMINATION OF σHlim FOR STEELS

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IS 4460 ( Parts 1 to 3 ) : 1995

FIG. 7 DETERMINATION OF σnlim FOR NITRIDING STEELS

F I G . 8 BASIC RACK DIMENSIONS OF THE TOOL

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IS 4460 ( Parts 1 to 3 ) : 1995

NOTES
1 In case of idler gears, 0.7 times the given values can be used.
2 In case of change of load direction, 1.7 times the given values are permitted.
FIG. 9 DETERMINATION OF σFE FOR NORMALISED STRUCTURAL STEEL AND CAST STEEL

NOTES
1 In case of idler gears, 0.7 times the given values can be used.
2 In case of change of load direction, 1.7 times the given values are permitted.
FIG. 10 DETERMINATION OF σFM FOR CAST IRON

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IS 4460 ( Parts 1 to 3 ) : 1995

NOTES
1 In case of idler gears, 0.7 times the given values can be used.
2 In case of change of load direction, 1.7 times the given values are permitted.
3 The endurance limits indicated for surface hardened test gears apply to case
depths of 0.15 mn and above of the finished gear.
F I G . 11 DETERMINATION OF σFE FOR THROUGH HARDENED STEELS ( > 0.32% C )

NOTES
1 In case of idler gears, 0.7 times the given values can be used.
2 In case of change of load direction, 1.7 times the given values are permitted.
3 The endurance limits indicated for surface hardened test gears apply to case
depths of 0.15 mn and above of the finished gear.
F I G . 12 DETERMINATION OF σFE FOR SURFACE HARDENED STEELS
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NOTES
1 In case of idler gears, 0.7 times the given values can be used.
2 In case of change of load direction 1.7 times the given values are permitted.
3 The endurance limits indicated apply to a depth of nitration of 0.4 to 0.6 mm.
FIG. 13 DETERMINATION OF σFE FOR NITRIDING STEELS

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Bureau of Indian Standards

BIS is a statutory institution established under tbe Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

Copyright

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of implementing the standard, of necessary details, such as symbols and sizes, type or grade
designations. Enquiries relating to copyright be addressed to the Director ( Publications ), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also
reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that
no changes are needed; if the review indicates that changes are needed, it is taken up for revision.
Users of Indian Standards should ascertain that they are in possession of the latest amendments or
edition.

This Indian Standard has been developed from Doc No: LM 13 (4461)

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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