Chapter 1. Reducer Manufacturing Specification

1.A reducer is designed in accordance with the AGMA 2001.

2. Materials and Manufacturing

• 1) Toothed gear's used materials, heat treatment, and hardness of tooth surface

Quality of the material	Method of heat treatment	Hardness of tooth surface
SCM415	HC	75-80
SCM440	HQI	60-70
SCM440	HQ & HT	40-45
S45C	HQI	55-65
S45C	HQ & HT	35-40

HC : Carburizing   HQI : High Frequency   HQ & HT : Tempering

• 2) The hardness differential of a toothed gear's pinion and a gear shall be HS4-5.
• 3) In the hardness of tooth surface, the quenching of HQI shall be a toothed hardness (ACMA type) and the hardness differential of the tooth line and the root shall not be above HRC8.
• 4) The case shall have the molding and welding structure and receive annealing to remove stress.
• 5) With respect to the bearing, It is a principle to use the spherical roller bearing, ball BRG, and taper roller BRG.
• 6) The precision machining shall be applied to the head shaft, the shaft and the coupling, etc. with the precision degree of the machining being based on the KS B 0401 gear tolerances and fits.

• 3. The type of the gear shall be the single helical gear and the meshing degree shall be the JIS B 1702 Class 2 or above ( 70% or more).
• 4. Gear Grade and Finishing When the circumferential speed is 10m/Sec or above : Grinding Class 3 .
• 5. The reducer-applied service factor is based on Table 1 and 2 and the bearing's standard lifespan shall be 25,000hrs or above.
• 6. It is a principle to used the lubricating method with respect to the lubricating method. When the heat capacity is short of the use capacity, the forced circulation cooling system is used.

1) Method of the reducer's heat capacity calculation

P = (A x K x ∇ t)/ {(1 x ∂) x 860} (KW)

A : Reducer's surface area

K : Ambient temperature

∇ t : 13(heat loss coefficient)

∂ : Reducer efficiency

• 2) Reducer's deceleration ratio and efficiency

No. of the stage of the reducer	Deceleration ratio	Tolerance of deceleration ratio	Efficiency
First-stage	1/6	±3%	97%
Scond-stage	1/30	±4%	94%
Third-stage	1/120	±4%	92%

7. It is a principle to base the reducer's no-load performance as the following standards.

Noise : 85dB or less (measured 1 meter away from the reducer in all directions)

Vibration : 22㎛ or less

Generated heat : ±50℃ or less than the ambient temperature