1、| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | BRITISH STANDARD BS ISO 14635-1:2000 ICS 2
2、1.200 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW Gears FZG test procedures Part 1: FZG test method A/8, 3/90 for relative scuffing load-carrying capacity of oilsThis British Standard, having been prepared under the direction of the Engineering Sector Committee, was publis
3、hed under the authority of the Standards Committee and comes into effect on 15 August 2000 BSI 08-1999 ISBN 0 580 36084 9 BS ISO 14635-1:2000 Amendments issued since publication Amd. No. Date Comments National foreword This British Standard reproduces verbatim ISO 14635-1:2000 and implements it as t
4、he UK national standard. The UK participation in its preparation was entrusted to Technical Committee MCE/5, Gears, which has the responsibility to: aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposals for
5、 change, and keep the UK interests informed; monitor related international and European developments and promulgate them in the UK. A list of organizations represented on this committee can be obtained on request to its secretary. Cross-references The British Standards which implement international
6、or European publications referred to in this document may be found in the BSI Standards Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Find” facility of the BSI Standards Electronic Catalogue. A British Standard does not purport to include all t
7、he necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, the ISO title
8、page, pages ii to v, a blank page, pages 1 to 17 and a back cover. The BSI copyright notice displayed in this document indicates when the document was last issued.Referencenumber ISO14635-1:2000(E) INTERNATIONAL STANDARD ISO 14635-1 Firstedition 2000-06-01 GearsFZGtestprocedures Part1: FZGtestmethod
9、A/8,3/90forrelative scuffingload-carryingcapacityofoils Engrenages Mthodes dessai FZG Partie 1: Mthode FZG A/8,3/90 pour valuer la capacit de charge au grippage des huilesISO14635-1:2000(E) ii ISO14635-1:2000(E)iii Contents Page Foreword.iv Introduction.v 1 Scope1 2 Normativereferences1 3 Termsandde
10、finitions.2 4 Briefdescriptionofmethod2 4.1 Generalprinciple2 4.2 Precision.4 5 Testmaterials.4 5.1 Testgears.4 5.2 Cleaningfluid.4 6 Apparatus.6 6.1 FZGspur-geartestrig.6 6.2 Heatingdevice8 6.3 Revolutioncounter8 7 Preparationofapparatus8 8 Testprocedure.8 9 Reportingofresults.9 AnnexA(informative)
11、TypicalFZGtestreportsheet11 AnnexB(informative)ChecklistformaintenanceofFZGgeartestrig.12 Bibliography17ISO14635-1:2000(E) iv Foreword ISO(theInternationalOrganizationforStandardization)isaworldwidefederationofnationalstandardsbodies(ISO memberbodies).TheworkofpreparingInternationalStandardsisnormal
12、lycarriedoutthroughISOtechnical committees.Eachmemberbodyinterestedinasubjectforwhichatechnicalcommitteehasbeenestablishedhas therighttoberepresentedonthatcommittee.Internationalorganizations,governmentalandnon-governmental,in liaisonwithISO,alsotakepartinthework.ISOcollaboratescloselywiththeInterna
13、tionalElectrotechnical Commission(IEC)onallmattersofelectrotechnicalstandardization. InternationalStandardsaredraftedinaccordancewiththerulesgivenintheISO/IECDirectives,Part3. DraftInternationalStandardsadoptedbythetechnicalcommitteesarecirculatedtothememberbodiesforvoting. PublicationasanInternatio
14、nalStandardrequiresapprovalbyatleast75%ofthememberbodiescastingavote. AttentionisdrawntothepossibilitythatsomeoftheelementsofthispartofISO14635maybethesubjectof patentrights.ISOshallnotbeheldresponsibleforidentifyinganyorallsuchpatentrights. InternationalStandardISO14635-1waspreparedbyTechnicalCommi
15、tteeISO/TC60, Gears, Subcommittee SC2, Gear capacity calculation. ISO14635consistsofthefollowingparts,underthegeneraltitle Gears FZG test procedures: Part 1: FZG test method A/8,3/90 for relative scuffing load-carrying capacity of oils Part 2: FZG test method A10/16,6R/90 for relative scuffing load-
16、carrying capacity of lubricants with high EP performance 1) AnnexesAandBofthispartofISO14635areforinformationonly. 1)Currentlyanewworkitemproposalavaitingapproval.ISO14635-1:2000(E)v Introduction Thetypesofgearfailureswhichmaybeinfluencedbythelubricantinusearescuffing,low-speedwearandthe gear-surfac
17、efatiguephenomenaknownasmicropittingandpitting.Inthegeardesignprocess,thesegear damagesaretakenintoconsiderationbytheuseofspecificlubricantandservice-relatedcharacteristicvalues.For anaccurate,field-relatedselectionofthesevalues,adequatelubricanttestproceduresarerequired.TheFZGtest proceduresdescrib
18、edinthisandotherpartsofISO14635canberegardedastoolsforthedeterminationofthe lubricant-relatedcharacteristicvaluestobeintroducedintotheload-carryingcapacitycalculationofgears. FZGtestmethodA/8,3/90fortherelativescuffingload-carryingcapacityofoilsdescribedinthispartofISO14635 istypicalforthemajorityof
19、applicationsinindustrialandmarinegears.ISO14635-2willberelatedtotherelative scuffingload-carryingcapacityofoilsofveryhighEPproperties,asusedforthelubricationofautomotivedriveline components.OtherFZGtestproceduresforthedeterminationoflow-speedwear,micropittingandpittingload- carryingcapacityofgearsar
20、ealreadyinalatestateofdevelopment.TheymaybeaddedlatertoISO14635as furtherparts.INTERNATIONALSTANDARD ISO14635-1:2000(E)1 GearsFZGtestprocedures Part1: FZGtestmethodA/8,3/90forrelativescuffingload-carrying capacityofoils 1 Scope ThispartofISO14635specifiesatestmethodbasedonanFZG 2 four-squaretestmach
21、inetodeterminethe relativeload-carryingcapacityoflubricatingoilsdefinedbythegear-surfacedamageknownasscuffing.High surfacetemperaturesduetohighsurfacepressuresandslidingvelocitiescaninitiatethebreakdownofthe lubricantfilms.Thistestmethodcanbeusedtoassesssuchlubricantbreakdownunderdefinedconditionsof
22、 temperature,highslidingvelocityandstepwiseincreasedload. NOTE ThismethodistechnicallyequivalenttoASTMD5182-97,DIN51354-1andDIN51354-2,IP334/90and CECL-07-A-95. 2 Normativereferences Thefollowingnormativedocumentscontainprovisionswhich,throughreferenceinthistext,constituteprovisionsof thispartofISO1
23、4635.Fordatedreferences,subsequentamendmentsto,orrevisionsof,anyofthesepublications donotapply.However,partiestoagreementsbasedonthispartofISO14635areencouragedtoinvestigatethe possibilityofapplyingthemostrecenteditionsofthenormativedocumentsindicatedbelow.Forundated references,thelatesteditionofthe
24、normativedocumentreferredtoapplies.MembersofISOandIECmaintain registersofcurrentlyvalidInternationalStandards. ISO1328-1, Cylindrical gears ISO system of accuracy Part 1: Definitions and allowable values of deviations relevant to corresponding flanks of gear teeth. ISO4287, Geometrical Product Speci
25、fications (GPS) Surface texture: Profile method Terms, definitions and surface texture parameters. ISO4964, Steel Hardness conversions. ISO5725-2, Accuracy (trueness and precision) of measurement methods and results Part 2: Basic method for the determination of repeatability and reproducibility of a
26、 standard measurement method. ASTMD235, Specification for Mineral Spirits (Petroleum Spirits) (Hydrocarbon Dry Cleaning Solvent). 2 FZG=ForschungsstellefrZahnrderundGetriebebau,TechnischeUniversittMnchen(GearResearchCentre, TechnicalUniversity,Munich),Boltzmannstrae15,D-85748Garching,Germany.ISO1463
27、5-1:2000(E) 2 3 Termsanddefinitions ForthepurposesofthispartofISO14635,thefollowingtermsanddefinitionsapply. 3.1 scuffingload-carryingcapacity ofalubricant maximumloadwhichcanbesustainedunderadefinedsetofconditions NOTE1 ForexamplesoffailureseeFigure1. NOTE2 Scuffingisaparticularlysevereformofdamage
28、tothegear-toothsurfaceinwhichseizureorweldingtogetherof areasoftoothsurfaceoccur,duetoabsenceorbreakdownofalubricantfilmbetweenthecontactingtoothflanksofmating gears,typicallycausedbyhightemperatureandhighpressure.Scuffingismostlikelywhensurfacevelocitiesarehigh.Scuffing mayalsooccuratrelativelylows
29、lidingvelocitieswhentooth-surfacepressuresarehighenougheithergenerallyor,becauseof unevensurfacegeometryandloading,indiscreteareas. NOTE3 Riskofscuffingdamagevarieswiththepropertiesofgearmaterials,thelubricantused,thesurfaceroughnessof toothflanks,theslidingvelocitiesandtheload.Consequencesofscuffin
30、gofhigh-speedgearsincludeatendencytohighlevels ofdynamicloadingduetoincreaseofvibrations,whichusuallyleadstofurtherdamagebyscuffing,pittingortoothbreakage. 3.2 FZGtestconditionA/8,3/90 testconditionwhereAistheparticulartoothformofthetestgears,accordingtoTable1;8,3isthespeedatthe pitchcircle,inmetres
31、persecond,and90istheinitialoiltemperature,indegreesCelsius,fromloadstage5and onwardintheoilsump NOTE ThedirectionoftherotationofthegearsisshowninFigure3. 3.3 failureloadstage loadstageinwhichthesummedtotalwidthofscuffingdamageontheactiveflankareaofthe16pinionteeth exceedsonegear-toothwidth,i.e.20mm
32、NOTE ExamplesofflankdamagesforthepurposeofthetestmethodareshowninFigure1. 4 Briefdescriptionofmethod 4.1 Generalprinciple Asetoftestgearsasdefinedinclause5,Tables1and2,isrunwiththetestlubricantatconstantspeedforafixed numberofrevolutionsusingdip-lubricationmode.Loadingofthegearteethisincreasedinstep
33、soutlinedin Table3.Beginningwithloadstage5,theinitialoiltemperatureiscontrolledbetween(90 3)C.Duringthetest runofeachloadstage,theoiltemperatureisallowedtorisefreely.Afterloadstage4,thepiniontoothflanksare inspectedforsurfacedamageattheendofeachloadstageandanychangesinappearancearenoted.Atestis cons
34、ideredcompletewheneitherthefailurecriteriahasbeenmetorwhenloadstage12isrunwithoutmeetingthe failurecriteria. Itistheresponsibilityoftheoperatortoensurethatalllocallegislativeandstatutoryrequirementsaremet. NOTE Ithasbeenassumedbythecompilersofthistestmethodthatanyoneusingthemethodwilleitherbefullytr
35、ained andfamiliarwithallnormalengineeringandlaboratorypractice,orwillbeunderthedirectsupervisionofsuchaperson. WARNINGWhentherigisrunning,therearelongloadedshaftsandhighlystressedtestgearsturning athighspeedandprecautionsshallbetakentoprotectpersonnel. Protectionfromnoiseisalsohighlyrecommended.ISO1
36、4635-1:2000(E)3 a) Nofailuremarks b)Nofailuremarks c)Approx.5mmfailuremarks d)Approx.15mmfailuremarks e)20mmfailuremarks f) Approx.2mmfailuremarks g)Approx.6mmfailuremarks h)20mmfailuremarks NOTE ThisfiguredescribesthetypicalpiniontoothflankchangesoccurringinFZGtests.Changesintheoriginalsurface cond
37、ition(criss-crossgrinding)maybedescribedbytheirphysicalappearance.Oneandthesametypeofflankdamagemaybe describedindifferentplacesintheworldbyusingdifferentterminology(e.g.“scuffing“,“scoring“and“severewear“).Inorderto avoidmisinterpretationofthepiniontoothflankchangesoccurringduringthetest,typicalexa
38、mplesofnon-failureandfailureare given. PRODUCTIONNOTE ThecoloursrepresentedintheelectronicfileofthispartofISO14635canbeneitherviewednor printedastruerepresentations.OnlycopiesofthispartofISO14635printedbyISOcanbeguaranteedtorepresentthetrue colours. Figure1FZGA-typegear-toothfacechanges(flankdamages
39、)ISO14635-1:2000(E) 4 4.2 Precision TheprecisionofthemethodhasbeenevaluatedaccordingtoISO5725-2withthreeoils(tworeferenceoilsand oneoilfromthemarket).Thefailureloadstageoftheseoilscoveredtherange5to12inclusive. Valuesofrepeatability(r)andreproducibility(R),asdefinedinISO5725-2,forthistestprocedurear
40、e: r=1loadstage R=2loadstages NOTE Theaboveprecisionresultsapplytotherangeoffailureloadstages5to12. 5 Testmaterials 5.1 Testgears Apairoftype“A”gearswithaspecificationaccordingtoTables1and2shallbeusedfortesting.Eachpairoftest gearsmaybeusedtwicefortesting,utilizingbothtoothflanksasload-carryingflank
41、s. 5.2 Cleaningfluid PetroleumspiritconformingtoASTMD235.ISO14635-1:2000(E)5 Table1DetailsofFZGtestgearstypeA Dimension Symbol Numerical value Unit Shaftcentredistance a 91,5 mm Effectivetoothwidth b 20 mm Workingpitchdiameter pinion d w1 73,2 mm wheel d w2 109,8 mm Tipdiameter pinion d a1 88,77 mm
42、wheel d a2 112,5 mm Module m 4,5 mm Numberofteeth pinion z 1 16 wheel z 2 24 Profile-shiftcoefficient pinion x 1 0,8532 wheel x 2 0,50 Pressureangle 20 Degrees Workingpressureangle w 22,5 Degrees Pitch-diametercircumferentialspeed w 8,3 m/s Addendumengagement pinion e a1 14,7 mm wheel e a2 3,3 mm Sl
43、idingspeedattoothtip pinion ga1 5,56 m/s wheel ga2 1,25 m/s Specificslidingattoothtip pinion E1 0,86 wheel A2 0,34 Specificslidingattoothroot pinion A1 0,52 wheel E2 5,96 Hertziancontactpressure p c 14,7 nt F a N/mm 2 a F nt =normaltoothloadinnewtons(seeTable3).ISO14635-1:2000(E) 6 Table2Manufacturi
44、ngdetailsofFZGtestgearstypeA Material Case-hardeningsteelwithrestrictedhardenabilityto2/3ofthelowerscatter band.Materialcomposition: C=0,13%to0,20% Mo=max.0,12% Si=max.0,40% Ni=max.0,30% Mn=1,00%to1,30% Al=0,02%to0,05% P=max.0,025% B=0,001%to0,003% S=0,020%to0,035% Cu=max.0,30% Cr=0,80%to1,30% Heatt
45、reatment Thetestgearsarecarburizedandcasehardened.Thecasedepthata hardnessof550HV10shallbe0,6mmto0,9mm.Thesurfacehardnessafter tempering:60HRCto62HRC,corestrengthintoothrootcentre:1000N/mm 2 to1250N/mm 2 (determinedinaccordancewithISO4964basedonBrinell hardness). Retainedausteniteshouldbenominally20
46、%. Gearaccuracygrade Q5accordingtoISO1328-1 Arithmeticroughnessof flanksRa Raisseparatelydeterminedforleftandrightflanks,measuredeachatthree flankspergearacrossthecentreofthetoothparalleltothepitchline;measuring parametersaccordingtoISO4287: measuredlengthl t =4,8mm,cut-offlength c =0,8mm; velocity=
47、0,5mm/s; usingaskid. Averageroughness(relatingtomanufacturebatchesofaminimumofa 100gearsets) Pinion: Ra=0,35m 0,1m Gear: Ra=0,30m 0,1m Maximumroughness(averageofthreemeasurementsaccordingtothe describedmethodandvalidfor95of100testedgears). Pinionandgear: Ra=0,5m Grinding Maagcriss-crossgrinding(15me
48、thod),154r/minofgeneratingstrokedrive Flankmodification None 6 Apparatus 6.1 FZGspur-geartestrig 6.1.1 TheFZGspur-geartestmachineutilizesarecirculatingpowerloopprinciple,alsoknownasafour-square configuration,toprovideafixedtorque(load)toapairofprecisiontestgears.Aschematicviewofthetestrigis showninF
49、igures2and3.Theslavegearboxandthetestgearboxareconnectedthroughtwotorsionalshafts. Shaft1containsaloadcouplingusedtoapplythetorquethroughtheuseofknownweightsdefinedinTable3 hungontheloadingarm. 6.1.2 Thetestgearboxcontainsheatingelementstomaintainandcontroltheminimumtemperatureoftheoil.A temperaturesensorlocatedinthesideofthetestgearboxisusedtocontroltheheatingsystemasrequiredbythe testoperatingconditions. 6.1.3 Thetestmachineispoweredbyanelectricmotorofminimum5,5kWataspeedofapproximately 1450r/min. 6.1
