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Please login with your username and your password. Select the module through the tree structure of the project manager by double-clicking on the module or clicking on the button ‘New calculation’.
Please note: You can get into the calculation module either through the entry ‘Involute splines’, ‘Serrated
shaft’ or ‘Splined shaft’. The module starts then with the selected profile type as default. You can
change the profile type by clicking the button ‘Selection’ anytime you want. The profile geometry
selection allows you to switch between involute splines, serrated shaft connections and splined shaft
connections.
All input options are the same for every profile type. Only the profile geometry selection provides some profile specific input options. Each profile type gets a graphical representation.
In order to select the profile, click the button ‘Selection’.
The profile geometry selection is opened.
Click the listbox ‘Kind of profile geometry’ and select the profile type - either involute spline, serrated shaft or splined shaft. The selection parameters automatically adjust to the profile type.
The calculation module ‘Involute splines’ allows the strength calculation of splined connections with involute splines according to DIN 5480. The calculation is based on Niemann „Maschinenelemente“ Vol. 1, 2001. Involute splines are widely used. The splines are usually made with straight sides or cut with an involute. But involute splines are favoured over straight sided splines because of their greater strength. Involute splines can be moved axially, they are strong and are easy to cut and fit. The major advantage of involute splines is that no special machines are required in order to produce involute splines. Involute splines are especially suitable for the transmission of high torques. You can decide between the DIN 5480 standard or the preferred series of the DIN 5480. All dimensions can be easily selected from the database or identified with the profile search function.
You can refine the profile geometry selection by including specific parameters to find the right profile quicker. The following parameters can be defined for a certain range:
Please enter your values. Use the Tab key to jump from field to field. All the inputs are applied. Click on the button ‘Search’ to start the profile selection search. The number of found profiles will be displayed below the ‘Search’ button.
Please note: To narrow your search, type more values in the search box. This way, you have to decide between
a few profiles and you will find the right profile faster. If you have already entered values into the input fields and
want to change your entry for any reason (e.g., any reference diameter again), please delete the value and click
into another input field or use the Tab key. The option ‘Any’ is used again in the input field. This applies also for
the input of data of the other profile types.
Select the profile from the database and confirm with the button ‘OK’.
Please note: You can sort the selection list in the database by clicking on the column header. To sort the
profiles in reverse order, click on the column header again. A black arrow appears. The arrow makes the
orientation much easier for you.
In case you cannot find the right profile you are looking for in our extensive database, simply define your individual profile. Activate the option ‘User-defined’. If you select this option, the input fields will be enabled, so that you can enter your own input values.
Please confirm these inputs with the button ‘OK’ and the profile, including your own values, will be applied.
The calculation module ‘Serrated shafts’ allows the strength calculation of serrated shafts according to DIN
5481. The calculation is based on Niemann „Maschinenelemente“ Vol. 1, 2001. The teeth of this profile are in
the form of adjacent triangular teeth. Serrated shaft usually have 
and can be easily created using
broaching.
You can refine the profile geometry selection by including specific parameters to find the right profile quicker. The following parameters can be defined for a certain range:
Please enter your values. Use the Tab key to jump from field to field. All the inputs are applied. Click on the button ‘Search’ to start the profile selection search. The number of found profiles will be displayed below the ‘Search’ button.
Please note: To narrow your search, type more values in the search box. This way, you have to decide between
a few profiles and you will find the right profile faster. If you have already entered values into the input fields and
want to change your entry for any reason (e.g., any tip circle diameter again), please delete the value
and click into another input field or use the Tab key. The option ‘Any’ is used again in the input
field.
Select the profile from the database and confirm with the button ‘OK’.
Please note: You can sort the selection list in the database by clicking on the column header. To sort the
profiles in reverse order, click on the column header again. A black arrow appears. The arrow makes the
orientation much easier for you.
In case you cannot find the right profile you are looking for in our extensive database, simply define your individual profile. Activate the option ‘User-defined’. If you select this option, the input fields will be enabled, so that you can enter your own input values.
Please confirm these inputs with the button ‘OK’ and the profile, including your own values, will be applied.
Splined shafts has equally spaced teeth around the circumference parallel to the shafts axis of rotation. This type of profile is used in case of transmission of large forces, especially in case of alternating forces or impact forces. Splined shaft are replaceable and centers the hub on the shaft very accurately. The manufacturing cost of splined shafts is low. Splines are cut on the shaft by milling and on the hub by broaching. Select the splined shaft connection. The calculation module ‘Splined shaft’ allows the strength calculation of serrated shafts according to DIN ISO 14 light and medium series, DIN 5464 heavy series, DIN 5471 and DIN 5472 for machine tools. The calculation is based on Niemann „Maschinenelemente“ Vol. 1, 2001.
A centric position of the hub on the shaft is achieved by:
You can refine the profile geometry selection by including specific parameters to find the right profile quicker. The following parameters can be defined for a certain range:
Please enter your values. Use the Tab key to jump from field to field. All the inputs are applied. Click on the button ‘Search’ to start the profile selection search. The number of found profiles will be displayed below the ‘Search’ button. You can sort the selection list in the database by clicking on the column header. To sort the profiles in reverse order, click on the column header again. A black arrow appears. The arrow makes the orientation much easier for you.
Please note: To narrow your search, type more values in the search box. This way, you have to decide between
a few profiles and you will find the right profile faster. If you have already entered values into the input fields and
want to change your entry for any reason (e.g., any tip circle diameter again), please delete the value
and click into another input field or use the Tab key. The option ‘Any’ is used again in the input
field.
In case you cannot find the right profile you are looking for in our extensive database, simply define your individual profile. Activate the option ‘User-defined’. If you select this option, the input fields will be enabled, so that you can enter your own input values.
Please confirm these inputs with the button ‘OK’ and the profile, including your own values, will be applied.
Use this function if you want to change the unit of measurement quickly. Just a right-click on the input field where you want to change the unit. The context menu contains all available units. The two arrows mark the current setting. As soon as you select a unit, the current field value will be converted automatically into the chosen unit of measurement.
The application factor 
evaluates the external dynamic forces that affect the gearing. These additional
forces are largely dependent on the characteristics of the driving and driven machines as well as the masses
and stiffness of the system, including shafts and couplings used in service.
| Application Factors
 According to DIN 3990-1: 1987-121 | ||||
| Working Characteristics | Working Characteristics of the Driven Machine
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| of the Driving Machine | Uniform | Light Shocks | Moderate Shocks | Heavy Shocks |
| Uniform | 1,0 | 1,25 | 1,5 | 1,75 |
| Light Shocks | 1,1 | 1,35 | 1,6 | 1,85 |
| Moderate Shocks | 1,25 | 1,5 | 1,75 | 2,0 |
| Heavy Shocks | 1,5 | 1,75 | 2,0 | 2,25 or higher |
| 1 from: DIN 3990 Part 1, December 1987, p. 55, table: A1
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| Examples for Driving Machines with Various Working Characteristics
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| according to DIN 3990-1: 1987-12
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| Working | Characteristics |
| Uniform | Electric motor (e.g. d.c. motor), steam or gas turbine with uniform operation1 and small rarely occurring starting torques |
| Light shocks | Steam turbine, gas turbine, hydraulic or electric motor (large, frequently occurring starting torques) |
| Moderate shocks | Multiple cylinder internal combustion engines |
| Heavy shocks | Single cylinder internal combustion engines |
| 1 Based on vibration tests or on experience gained from similar installations.
| |
| Examples of Working Characteristics of Driven Machines
| |
| according to DIN 3990-1: 1987-12
| |
| Working Characteristics | Driven Machines |
| Uniform | Steady load current generator; uniform loaded conveyor belt or platform conveyor; worm conveyor; light lifts; packing machinery; feed drives of machine tools; ventilators; lightweight centrifuges; centrifugal pumps; agitators and mixers for light liquids or uniform density materials; shears; presses; stamping machines1; vertical gear; running gear2 |
| Light Shocks | Non-uniformly (i.e. with piece or batched components) loaded conveyor belts or platform conveyors; machine tool main drives; heavy lifts; crane slewing gear; industrial and mine ventilator; heavy centrifuges; centrifugal pumps; agitators and mixers for viscous liquids or substances of non-uniform density, multi-cylinder piston pumps, distribution pumps; extruders (general); calenders; rotating kilns; rolling mill stands3 (continuous zinc and aluminium strip mills, wire and bar mills) |
| Moderate Shocks | Rubber extruders; continuously operating mixers for rubber and plastics; ball mills (light); wood-working machine (gang saw, lathes); billet rolling mills3,4; lifting gear; single cylinder piston pumps |
| Heavy Shocks | Excavators (bucket wheel drives), bucket chain drives; sieve drives; power shovels; ball mills (heavy); rubber kneaders; crushers (stone, ore); foundry machines; heavy distribution pumps; rotary drills; brick presses; debarking mills; peeling machines; cold strip3,5; briquette presses; breaker mills |
| 1 Nominal torque: maximum cutting, pressing or stamping torque
| |
| 2 Nominal torque: maximum starting torque
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| 3 Nominal torque: maximum rolling torque, 4 Torque from current limitation
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| 5
 up to 2,0 because of frequent strip cracking | |
The calculation module allows you to consider a number of load peaks for your calculation. If you want to use this option, just activate ‘Consider load peaks’.
Click the listbox to select the number of load peaks. It is also possible to define an own number of load peaks. Select the entry ‘User-defined input’. The input field next to the listbox is enabled and you can add your value.
Click the listbox to define the kind of load for your calculation. Decide between alternating torque with slow or fast increase or no alternating torque.
In case you have an alternating torque with a slow or fast increase, then the load direction change is automatically activated. You will find the entry ‘User-defined’ in the listbox. If you select this option, the input field will be enabled, so that you can enter your own input value for the load direction change.
A stepped hub can be taken into account. If you enable this option, you can define a smaller hub diameter 
,
the width 
as well as the axial distance 
. Use the graphical representation to make it easier to find these
parameters. With these inputs, the load distribution factor 
is determined for a different load in and
output according to DIN 6892.
Select an appropriate material for the shaft and hub directly from the listbox or click on the button ‘Material’ in order to open the material database.
Please select the material from the list.
Please note: The two cursor keys ‘Up’ and ‘Down’ of your keyboard allows you to navigate through the material
database, so you can compare the different material properties with each other.
To open the material dataabse, please click the button ‘Material’.
The material database provides some detailed information on the several kinds of material.
You will find the entry ‘User-defined’ in the listbox. If you select this option, the input fields will be enabled, so that you can enter your own input values or add a comment.
Add a comment, a source, kind of material, yield point, hardness factor as well as the support
factor. Please confirm your inputs with the button ‘OK’. In the main mask the entry ‘User-defined’ is
displayed.
Please note: In case you add a comment and own values for the ‘User-defined’ entry, confirm these with the
button ’OK’. Please be advised that changing the material will delete your defined inputs and you have to enter
the inputs again.
The calculation module provides a message window. This message window displays detailed information, helpful hints or warnings about problems. One of the main benefits of the program is that the software provides suggestions for correcting errors during the data input. If you check the message window carefully for any errors or warnings and follow the hints, you are able to find a solution to quickly resolve calculation problems.
The quick info feature gives you additional information about all input fields and buttons. Move the mouse pointer to an input field or a button, then you will get some additional information. This information will be displayed in the quick info line.
All important calculation results will be calculated during every input and will be displayed in the result panel. A recalculation occurs after every data input. Any changes that are made to the user interface take effect immediately. Press the Enter key or move to the next input field to complete the input. Alternatively, use the Tab key to jump from field to field or click the ‘Calculate’ button after every input. Your entries will be also confirmed and the calculation results will displayed automatically. If the result exceeds certain values, the result will be marked red.
After the completion of your calculation, you can create a calculation report. Click on the ‘Report’ button.
You can navigate through the report via the table of contents that provides links to the input values, results and figures. This calculation report contains all input data, the calculation method as well as all detailed results. The report is available in HTML and PDF format. The calculation report saved in HTML format, can be opened in a web browser or in Word for Windows.
You may also print or save the calculation report:
‘Save as’ from your browser menu
bar. Select the file type ‘Webpage complete’, then just click on the button ‘Save’.
When the calculation is finished, you can save it to your computer or to the eAssistant server. Click on the button ‘Save’.
Before you can save the calculation to your computer, you need to activate the checkbox ‘Enable save data local’ in the project manager and the option ‘Local’ in the calculation module. A standard Windows dialog for saving files will appear. Now you will be able to save the calculation to your computer.
In case you do not activate the option in order to save your files locally, then a new window is opened and you can save the calculation to the eAssistant server. Please enter a name into the input field ‘Filename’ and click on the button ‘Save’. Then click on the button ‘Refresh’ in the project manager. Your saved calculation file is displayed in the window ‘Files’.
The button for the dimensioning functions is marked by a calculator symbol and is located next to
the input fields. If you click on the dimensioning buttons, you get a suggestion for an appropriate
input value. The calculation of the value is carried out so that the given minimum safety is fulfilled.
The default value for the minimum safety is set to ‘1.2’. Clicking the button ‘Options’ allows you to
change this value. The following dimensioning functions (calculator button) provide you with optimal
support:
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Please determine the torque which fulfills the demanded safety of ‘1.2’. Click on the dimensioning button next to the input field for the torque.
Now the maximum torque is determined.
The minimum safety is displayed in the result panel. If you enter a higher value than ‘69648.0 Nm’, the safety
has fallen below. The result is marked in red. Click on the dimensioning function again and the value, which
fulfills the minimum safety for the maximum torque, is displayed.
The button ‘Undo’ allows you to reset your input to an older state. The button ‘Redo’ reverses the undo.
The eAssistant plugin for various CAD systems (e.g., SolidWorks, Solid Edge, Autodesk Inventor and Catia) enables you to combine calculation and design very easily and fast. Based on your eAssistant calculation, you can generateshafts as well hubs of splined shaft and serrated shaft connections as a 3D part within seconds. A single menu pick in the eAssistant software transfers the eAssistant calculation data to the CAD system. Based on these parameters, the automatic creation of a 3D parametric model starts in the CAD system. First you need to download and install the right CAD plugin for your CAD system. After installation, an integrated button called ‘eAssistant’ appears in the CAD system. Click the button ‘CAD’ and select the CAD plugin. Open the CAD system and start the generation by clicking the integrated button ‘eAssistant’. Do not forget to activate the option ‘Enable save data local’ in the project manager.
Please note: For further information, please visit our web site www.eAssistant.eu or read the CAD plugin
manual.
Click the button ‘Options’ in order to change the default settings.
You can change the minimum safety or number of the decimal places in the report. To make a permanent change to the calculation module, you can save your settings to a template file. For further details, please check the ‘General functions’ chapter.
We have prepared the following example to guide you through the calculation module. This calculation example
is based on: G. Niemann, H. Winter, B.-R. Hoehn: Maschinenelemente Band I: Konstruktion von
Verbindungen, Lagern, Wellen. Springer Verlag, 3rd Edition, 2001: p. 857 Example 4: Splined shaft for lifting
gear.
Please login with your user name and your password. Select the module ‘Splined shaft’ through the tree structure of the project manager by double-clicking on the module or clicking on the button ‘New calculation’.
A splined shaft connection with a splined shaft according to DIN ISO 14 is given. The safety against pressure is required. For our calculation example the following input values are given:
Diameter  | = 32 mm |
Diameter  | = 38 mm |
| Number of keys | = 8 |
| Key width | = 6 |
Supporting length  | = 40 mm |
| Manufacturing according to tolerance field | = H7/IT7 |
| Application factor | = 1 |
Nominal operation torque  | = 2400 Nm |
Maximum load peak torque  | = 2400 Nm with number of load peaks 
|
| No alternating torque |
Outer diameter of hub  | = 45 mm |
| Material shaft | = C45 hardened and tempered |
| Material hub | = C45 hardened and tempered |
In order to find the right profile, click the button ‘Selection’.
Select from the listbox ‘Standard geometry data’ the splined shaft profile according to DIN ISO 14 medium series.
You can narrow your search by entering certain parameters in order to find the right profile quicker. Just add the
diameter 
, the number of keys as well the key width. Click on the button ‘Search’.
After clicking the button ‘Search’, only one profile remains. Please select the profile and click the button ‘OK’.
Enter ‘40 mm’ for the supporting length 
.
Click the listbox in order to choose the tolerance field ‘H7/IT7’.
The field ‘Profile’ displays the previously selected tolerance field.
Please add the application factor as well as the nominal operation factor 
.
Activate the load peaks und enter ‘2400’ for the maximum load peak torque 
.
Select the number of load peaks from the listbox.
There is no change in load direction, so enter the default setting ‘No alternating torque’ for the ‘kind of load’.
Enter the value ‘45 mm’ for the outer diameter of the hub.
Select the material ‘C45 hardened and tempered’ for the shaft.
Please note: In case you need further information on the material, click on the button ‘Material’.
Select the hub material ‘C45 hardened and tempered’ from the listbox.
All results (safeties at operation load and maximum load, the pressures for shaft and hub) will be calculated during every input and will be displayed in the result panel. A recalculation occurs after every data input. Any changes that are made to the user interface take effect immediately.
For our calculation example the splined shaft is sufficiently dimensioned. In addition, the message window contains the hint that this shaft-hub-connection is suitable and can be used.
After the completion of your calculation, you can create a calculation report. Click on the ‘Report’ button. You can navigate through the report via the table of contents that provides links to the input values, results and figures. This calculation report contains all input data, the calculation method as well as all detailed results. The report is available in HTML and PDF format. The calculation report saved in HTML format, can be opened in a web browser or in Word for Windows.
You may also print or save the calculation report:
‘Save as’ from your browser menu
bar. Select the file type ‘Webpage complete’, then just click on the button ‘Save’.
When the calculation is finished, you can save it to your computer or to the eAssistant server. Click on the button ‘Save’.
Before you can save the calculation to your computer, you need to activate the checkbox ‘Enable save data local’ in the project manager and the option ‘Local’ in the calculation module. A standard Windows dialog for saving files will appear. Now you will be able to save the calculation to your computer.
In case you do not activate the option in order to save your files locally, then a new window is opened and you can save the calculation to the eAssistant server. Please enter a name into the input field ‘Filename’ and click on the button ‘Save’. Then click on the button ‘Refresh’ in the project manager. Your saved calculation file is displayed in the window ‘Files’.
Our manual is improved continually. Of course we are always interested in your opinion, so we would like to know what you think. We appreciate your feedback and we are looking for ideas, suggestions or criticism. If you have anything to say or if you have any questions, please let us know via phone +49 (0) 531 129 399-0 or email eAssistant@gwj.de.
