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User`s Manual of GEARCALC

1. 1 X1 hk Paa 1 T2 lino a Tr CAUTION Option may leave insufficient tip to root clearance if the oper ating center distance is much larger than the standard center distance Standard working depth 1 z k 2 ha Bad 1 27 k 2 haz af Pag CAUTION Option may leave insufficient tip to root clearance if the oper ating center distance is much larger than the standard center distance Standard tip to root clearance This represents the safest calculation option but the contact ratio is reduced 1 x1 k ha AL Paa 1 25 k hy pa curi Td CHAPTER 11 CALCULATION SETTINGS 2 34 11 1 3 Manufacturing tolerance The tolerance method can be defined for the calculation A choice of AGMA 2000 A88 or AGMA 2015 1 A01 is available from the drop down menu The scale runs from 15 best to 3 worst according to AGMA 2000 or from 2 best to 11 worst according AGMA 2015 In ISO 1328 also the low numbers are for better quality like in AGMA 2015 11 1 4 Calculate ratio face width to pitch diameter There are two alternatives for establishing the ratio face width to pitch di ameter m which ar toggled using the radio buttons The upper option activates the three cells directly under the radio button Then factors C4 and Cs can be entered to define the ratio as follows ma ma ma C3 Ci where C 1 0 for spur helical gears C 2 0 for double helical 0 lt C2 lt
2. Low pressure angle Requires more pinion teeth N 21 to avoid under cut Gives larger topland for same addendum modification coefficient High pressure angle Allows fewer pinion teeth without undercut Gives smaller topland for same addendum modification coefficient CHAPTER 12 AGMA 2001 2101 2 43 12 4 Helix angle v G is the standard or generating helix angle The helix angle of a gear varies with the diameter at which it is specified The standard helix angle is measured on the generating pitch cylinder For hobbed gears the helix angle may be freely chosen because the hobbing machine can be adjusted to cut any helix angle For pinion shaped gears the helix angle must correspond to the helical guides that are available for the gear shaping machine v deg Application 0 spur 10 20 single helical 20 40 double helical Low helix angle provides low thrust loads but results in fewer teeth in contact smaller face contact ratio mp and higher noise generation For the full benefit of helical action mpr eg should be at least 2 0 If mp lt 1 0 the gear is a low contact ratio LACR helical gear and is rated as a spur gear Maximum bending strength is obtained with approximately 15 degree helix angles High helix angle provides smooth running quiet gearsets but results in higher thrust loads unless double helical gears are used to cancel internally generated thrust loads The plus button l at the
3. O ed N N N nj number of cycles at the it stress level where N number of cycles to failure correspontiing to the 1 stress level n N damage ratio at the i stress level Instead of load cycles we can alo use lifetimes d suu qe mu red L4 Isa Li l time at a the i stress level where Li permissible lifetime at the it stress level l L damage ratio at the i stress level Assuming the fraction of time at each stress level is known rather than the actual number of cycles or times then 2 66 CHAPTER 13 LIFETIME MINER RULE 2 67 li amp Zb lb oL lL L where a fraction of time at the i stress level L Resultant number of cycles to failure under the applied load spectrum Defining the time ratio as Miner s Rule may be rewritten as Q1 Q2 F F Qi li i De a1 Q2 Qi Ty Doo The load spectrum is defined by the time ratio a and the load ratio 8 and additionally a speed ratio w is needed for the calculation of the permissible lifetimes L Bi instantaneous load baseline load where wi instantaneous speed nominal load The baseline load is entered with the Load Data input screen by specifying the transmitted horsepower and speed of the pinion The load spectrum is entered on the page Lifetime CHAPTER 13 LIFETIME MINER RULE 2 68 13 2 Define a lifetime calculation GearCalc AGMA 2001 Lifetime Miner Rule AGMA 925
4. 1 2 1 The Module Tree All of the KISSsoft calculation modules are logically listed in the Module Tree Calculation modules for which there is no current licence are greyed out A calculation module can be opened by a double click of the left mouse button The active calculation module is shown in bold print CHAPTER 1 USER INTERFACE 1 5 Results LU Geometry Strength Gear 1 Gear 2 Contact ratio eleste 1 73 3 11 4 85 Safety Flank 1 02 1 09 Backlash 0 0019 0 0019in Safety root 1 09 1 21 Tip diameter d 4 964 in 15 411 in Root diameter d 4 395 4 395 in 14 842 14 842 in Figure 1 2 The KISSsoft results window 1 2 2 The Project Tree The Project Tree gives a overview of opened projects and the files contained within and also shows the active working project in bold print The operation of the project management see 3 is carried out from the main menu under Project as well as from a context menu see 1 1 1 2 3 The Explorer The directory structure of the Explorer corresponds to the structure in the Windows Explorer and offers the same functionality The Explorer will be available from Release 02 2007 1 2 4 The Results Windows The KISSsoft Results Window shows the results of the latest calculation 1 2 5 The Message Window The Message Window information warnings and errors occured during the latest calculation see 4 2 A yellow exclamation mark in the Tab Message signals that messages exist that have
5. For metric units also the normal module can be shown instead The normal diametral pitch defines the size of a tooth It is v divided by the normal pitch Paa m p So the tooth thickness increases with a decreasing normal diametral pitch The value can be directly entered by checking the box by the side of the field So you have the possibility to select a standard value 10 4 5 Normal module The normal module m is only shown if metric units are selected see 1 3 3 For US customary units you see the normal diametral pitch instead The normal diametral pitch defines the size of a tooth It is the normal pitch divided by 7 M p 7 So the tooth thickness increases with an increasing CHAPTER 10 GEARCALC WIZARD 2 29 module The value can be directly entered by checking the box by the side of the field So you have the possibility to select a standard value with are normally given in millimeters 10 5 GEARCALC page 5 GearCalc AGMA2001 Lifetime Miner Rule AGMA 925 Den Result overview NP lt NG ratio Aratio hunting Pr Pr wr Several solutions with different combinations of tooth 15 77 5 133 2 667 YES 19 99 19 99 0 numbers are shown Additional results for each 15 76 5 067 1 333 YES 21 637 21 637 solution can be shown using the right mouse button 15 75 5 D NO 23 172 23 172 15 74 4 933 1 333 VES 24 617 24 617 0 You should select a solution and continue with the 16 76 4 75 5 NO 19 99 19
6. K 1 9400 K 1 0000 Pinion O Gear O Pinion U Gear li E Ml Steel Grade 2 HRC58 64 AGMA Case carburized steel case hardened Steel Grade 2 HRC58 64 AGMA Case carburized steel case hardened Calculation of tooth Form factor For spur and LACR gears with Application of Force at tip Figure 12 1 GEARCALC AGMA 2001 2101 instead of the normal module CHAPTER 12 AGMA 2001 2101 2 42 12 1 Normal module The normal module m is only shown if metric units are selected see 1 3 3 It is defined as m p r and standard values are usually given in millimeters and can be found in ISO 54 or DIN 780 The size of the gears is increasing with the module The transverse module m is the normal module divided by the cosine of the helix angle m m cos v 12 2 Normal diametral pitch The normal diametral pitch Ppa defines the size of a tooth It is m divided by the normal pitch Paa m p So the tooth thickness increases with a decreasing normal diametral pitch 12 3 Normal pressure angle On an is the standard or generating pressure angle For hobbed or rack generated gears it is the pressure angle of the tool For helical gears is measured on the generating pitch cylinder in the normal plane amp is stan dardized to minimize tool inventory On deg Application 14 5 Low Noise 17 5 20 General Purpose 22 5 25 High load Capacity
7. 1 0000 Factor C1 double helical 2 0000 Factor C2 1 0000 Use fixed ratio width to pitch diameter b d Ratio width to pitch diameter b d Range for pressure angle Kell Tool tip radius 2 E E Finish Cut Shaved Ground z ES a 16 1 3500 1 4500 1 5000 0 4500 16 lt a lt 19 1 3000 1 4000 1 4500 0 4000 19 o s 21 1 2500 1 3500 1 4000 0 3500 21 lt a lt 24 1 2500 1 3000 1 3500 0 3000 a 24 1 2500 1 2500 1 3000 0 2500 O Use full radius calculated at run time Figure 11 1 GEARCALC settings page GEARCALC 2 32 CHAPTER 11 CALCULATION SETTINGS 2 33 11 1 1 Permissible deviation of ratio There are often several designs which will achieve the required criteria but be outside the exact ratio A permissible deviation as a percentage of the nominal ratio can be entered to allow the assessment of such designs 11 1 2 Tip shortening The sum of profile shift factors not equal to zero will decrease the tip clearance for external gear sets To avoid this decrease of tip clearance a tip shortening is often made For internal gear sets the sum of profile shift factors not equal zero will result in an increase of tip clearance Therefore no automatic tip shortening is made for internal gear sets There is a choice of three tip treatment methods from drop down list Full length teeth The addenda of the gear and pinion are calculated with out tip shortening
8. Lapping is done by either running the gear in mesh with a gear shaped lapping tool or by running the two mating gears together while an abrasive lapping compound is added to the gear mesh to promote removal of the high points of the gear tooth working surface 12 21 5 Double Helical For double helical gears the mesh alignment factor is calculated based on one helix one half of the net face width 12 21 6 Transverse load distribution factor Since no information about the transverse load distribution factor C4 KHa is given in AGMA 2001 the load distribution factor is equal to the face load distribution factor Km Caf gj 12 21 7 Notes It usually is not possible to obtain a perfectly uniform distribution of load across the entire face width of an industrial gearset Misalignment between CHAPTER 12 AGMA 2001 2101 2 58 the mating gear teeth causes the load and stress distribution to be non uniform along the tooth length The load distribution factor is used to ac count for the effects of the non uniform loading It is defined as the ratio of the maximum load intensity along the face width to the nominal load intensity 1 e Km Cm Maximum Load Intensity W F Variations in the load distribution can be influenced by Design Factors Ratio of face width to pinion diameter Bearing arrangement and spacing Internal bearing clearance Geometry and symmetry of gear blanks Material hardness of gear teeth Manufacturing
9. Many high speed CHAPTER 12 AGMA 2001 2101 2 56 gears are through hardened hobbed and shaved Usually the gear member is shaved to improve the surface finish profiles and spacing but the helix lead is not changed significantly The pinion and gear are then installed in the housing and a contact pattern is obtained by rolling the gears together under a light load with marking compound applied to the gear teeth Based on the contact pattern obtained from this test the pinion is shaved to match the lead of the gear The process is repeated until the desired no load contact pattern is obtained 12 21 2 Pinion proportion modifier Cpm This setting allows consideration of the degree of alignment change as the pinion is offset under a defelction of the bearings The Cpm value alters the pinion proportion factor Cp based on the location of the pinion relative to its bearing center line 12 21 3 Mesh alignment factor Cia The mesh alignment factor Cma accounts for the misalignment of the axes of rotation of the pitch cylinders of the mating gear elements from all causes other than elastic deformation The factor is dependend on the face width and the follwing options e Open This type of gearing is used in such applications as rotary grinding mills kilns dryers lifting hoists and winches These gears are frequently of low accuracy because their large size limits the practicable manufacturing methods The gear shafts are usually supp
10. Time ratio Power Factor Speed factor Power hp Torque ft IbF Speed rpm 1 1 1 1 10 41 6832 1260 pn Sum of time ratio 100 0000 x Read load spectrum from file Save load spectrum to file Figure 13 1 Gearcalc Lifetime calculation 13 2 1 Create a load spectrum element On this screen is a table containing at least one row Each row element is used to define the individual characteristics for a proportion of running time at a specified load A collection of more than one elements for multiple operating levels represents a load spectrum Each element entry contains six characteristics Time Ratio Power Factor Speed Factor Power Torque Speed Three buttons at the bottom right of the table control the construction of the elements in the load spectrum The button adds another row element to the table The button will delete the any row currently selected in the table The x button will clear the table of all but one row entry CHAPTER 13 LIFETIME MINER RULE 2 69 13 2 2 Sum of time ratio This represents the total operating time as a percentage defined by the sum of the ratios in the first column of the table The time ratio column is summed and multiplied by 100 13 2 3 Save spectrum An table which has been defined can be stored for future use or in association with other designs On pressing the button indicated under the table a direc tory window opens to allow the user to specify the f
11. is the axial length over which the tooth of a gear is formed This can be entered independently for both gears The width should CHAPTER 12 AGMA 2001 2101 2 45 be smaller then the pinion diameter as a default because the load distribution over the width is affeced by a large width of the gear 12 8 Profile shift coefficient A profile shift or addendum mofification can be made to have an influence on tooth shape and tooth thickness According AGMA 908 the factor is called addendum modification coefficient according AGMA 913 and newer ISO standards profile shift coefficient is used 12 8 1 Gears with standard addenda For gears with standard addenda the profile shift coefficients or addendum modification coefficients are zero i e 21 29 0 The standard outside diameters may be calculated from the following equa tions using the gear ratio mg Na Np Standard pitch radii Np 2 Paa cos 11 R remo Standard addenda hai Pra ha Ps Standard outside diameters d 2 r ha D 2 R ha2 Standard inside diameter internal gears Di 2 R haz NOTE The inside diameter of an internal gear is frequently made larger than that given by the above equation to avoid interference between the tips of the pinion and gear teeth CHAPTER 12 AGMA 2001 2101 2 46 12 8 2 Gears with addendum modification Gear teeth may have modified addenda in order to avoid undercut to balance the bending stre
12. pe 1 f h istics of drivi i Pon ecd 1260 0000 rpm a of the characteristics of driving and driven Required Design Life L 132 0000 h The load distribution factor considers an unequal ma load distribution over the width of the gear It is Overload factor Ko 1 0000 calculated from the inputs selectable behind the plus ih button as a default It is also possible to overwrite the Load distribution Factor Km 1 9400 value using the toggle button behind Dynamic Factor K 1 0000 The dynamic factor is considering a load increase ae ah because of vibrations It is also calculated as default Driving Pinion O Gear but you may constrain it For special cases Reversed bending O Pinion O Gear Reversed bending reduces the strength of the ENEE AE EE 1 3 1 3 gear It occurs for example For a planet in a planetary gear set Also for planetary gear sets the number of contacts per revolution can be set The number of contacts for sun and internal gear would be equal to the number of planets Figure 10 4 GEARCALC Wizard page 3 10 3 1 Transmitted power P is the power transmitted per gear mesh For multiple power paths load sharing must be considered Branched offsets Ifthe pinion meshes with two or more gears or the gear meshes with two or more pinions use the power of the more highly loaded branch Epicyclic Gearboxes The degree of load sharing depends on the number of planets accuracy of the gears and mountings provisions
13. 18 q q z Number of contacts per revolution 12 25 P hp P kW Transmitted power 12 17 P 1 in Normal diametral pitch 122 Mn mm Normal module 12 1 SH SH Safety factor pitting 11 3 Sp Sr Safety factor bending 11 3 Sac lb in oyp N mm Allowable contact stress number Sat lb in opp N mm Allowable bending stress number Se lb in op N mm Contact stress number St lb in or N mm Bending stress number Y B P Helix angle at generating pitch diameter 12 4 On li On i Normal pressure angle 123 Chapter 10 GEARCALC Wizard 10 1 GEARCALC page 1 GearCalc Description AGMA2001 Lifetime Miner Rule AGMA 925 Normal pressure angle Helix type Helix angle Required ratio Profile modification Stress cycle factor For Calculation of tooth Form Factor For spur and LACR gears with Reliability Required safety Factor pitting Required safety Factor bending 20 0000 Spur y 0 0000 m 5 0000 For high load capacity Critical service YN gt 0 8 v v Application of force at tip v v 99 5H 1 0000 SF 1 0000 Startpage of GearCalc wizard The GearCalc wizard guides you through different steps needed for the sizing of a gear pair The pressure angle is usually 20 For high load capacity higher values For low noise or low backlash lower values can be used Helical gears provide smooth running
14. 2 Registry 1 32 Chapter 8 Additional KISSsoft Tools From Release 02 2007 the following tools are available 8 1 Licence Tool 8 2 Configuration Tool 8 3 Database Tool and Table Interface 1 33 Part II GEARCALC Chapter 9 GEARCALC in general The GEARCALC windows version has several parts First we have the GEARCALC wizard for the sizing of a new gear pair Then we have three pages for the analysis of a gear pair The input data of the wizard is indepen dent of the data for analysis Only if you accept the results from the wizard the data is transfered from the wizard to the analysis part of the software All the graphics displayed are for the data for the analysis part of the software Usually you will start a new design in the GEARCALC wizard see chap ter 10 The wizard will guide you with several pages to get a design that suits your purpose After accepting the result you can do further analysis on strength using the AGMA 2001 2101 page see chapter 12 you can do a lifetime analysis using a load spectrum on the page Lifetime see chapter 13 or an analysis for scoring or wear on the AGMA 925 page see chapter 14 If you want to modify the geometry afterwards you can either go through the wizard again This can be done quickly because all the inputs are saved Or you change the geometry directly on the AGMA 2001 2101 page if you know what you want to change For the analysis there are different reports for the
15. Accuracy Gear housing machining errors shaft axes not parallel Tooth errors lead profile spacing amp runout Gear blank and shaft errors runout unbalance Eccentricity between bearing bores and outside diameter Elastic Deflection of Gear tooth bending Gear tooth hertzian Pinion shaft bending and torsional Bearings oil film or rolling elements Housing Thermal Distortion of Gear teeth gear blank shafts and housing Centrifugal Effects Centrifugal forces may cause misalignment for high speed gears External Effects Misalignment with coupled machines Gear tipping from external loads on shafts CHAPTER 12 AGMA 2001 2101 2 59 External thrust from shaft couplings 12 22 Dynamic factor The dynamic factor K accounts for internally generated gear tooth loads which are induced by non uniform meshing action transmission error of gear teeth If the actual dynamic tooth loads are known from a comprehensive dynamic analysis or are determined experimentally the dynamic factor may be calculated from Ky Wa W W where W Nominal transmitted tangential load and Wa Incremental dynamic tooth load due to the dynamic response of the gear pair to the transmission error excitation not including the transmitted tangential loads If the factor is calculated according AGMA the Transmission Accuracy Grade A is used A is calculated following formula 21 in AGMA2001 page 15 Therefore Anu is not alw
16. END FOR e Instead of i or f there can also be fixed numbers static FOR Loop FOR varname 0 TO 10 BY 1 DO END FOR CHAPTER 5 RESULTS AND REPORTS 1 29 e or intermingled FOR varname 5 TO i BY 1 DO Final value END FOR e Each FOR Loop has to be paired with a closing END FOR inc Semi colon Each defined counter variable varname inside the loop can be addressed with varname e You can choose negative steps for example 1 but never can you choose 0 The step width must always be defined e The varname condition can be used for the definition of a variable For example Number of teeth 3 2f ZR varname z e The varname condition can be used as a character for the issue of the variable value 0 is A 1 is B etc For example FOR quer 0 TO 8 BY 1 DO Cross section quer Squer 8 2f Qu quer sStatic END FOR Example of a Simple Loop FOR i 0 TO 10 BY 1 DO phase number Zi i END FOR his is issued as phase number 0 A phase number 1 B phase number 2 C phase number 3 D phase number 4 E phase number 5 F phase number 6 G phase number 7 H phase number 8 I phase number 9 J phase number 10 K CHAPTER 5 RESULTS AND REPORTS 1 30 Within a loop you can use any counter variables for all functions arrays included Chapter 6 Interfaces Available from Release 02 2007 1 31 Chapter 7 Program Settings Program Settings available from Release 02 2007 7 1 KISSini 7
17. RRR Bee Oe ew eR Bad 2 5 Maia Due d y oe aa ana erg 2 7 10 1 5 Reguired ration si 2x Se ars WR area E 2 7 1015 Puoble modileastion cuu o ed ee ERE 2 9 10 17 Stress cycle DiGi oo ar scs een ra Bw 2 9 10 1 8 Calculation of tooth form factor o o e seces sea 2 9 10 1 9 Reliability and The Reliability Factor 2 10 CONTENTS 10 1 10 Required safety factors 2 2 nenn 10 2 GEARCALC Pues uuo hog ara nen 1021 Material selection 2 22 422 54 222 4 8 R3 10 2 2 Quality according to AGMA 2000 AGMA 2015 1023 Fimmhing method 22224 amp bee hd be dws 10 3 GEARCALC page d iude d ARRA EEE es 10 3 1 Transmitted power nennen 1032 Pinion spend 4 2 2 5 aude au EO t EROR ERES 10 3 3 Required Design life 1134 Overload Beton lusor onm REG 10 3 5 Load distribution factor cns 10 3 6 Dynamic factor o o uos o san ae nie Mot DIVIDE oue g ai A EROR RS 10 3 8 Reversed bending a 10 3 9 Number of contacts per revolution 104 GEARCALC page 4 Kr soos RR 1041 Center distance 2 22 o o RR 1042 Pitch diameter piti n lt lt oro 2 n 10 4 3 Net face width 2 2 22s AG 10 4 4 Normal diametral pitch 104 5 Normoal modwe gt e has a a a oodd 10 5 GEARCALU BE das ER A 10 5 1 Bel overview o 22 2322 rue a 10 6 GEARCALC DEE ol ox oce x A aaa 10 6 1 Proposals for profile shift factors 10 6 2 Enter pinion profile shif
18. and alignment of the shaft bearings e Commercial This classification pertains to low speed enclosed gear units which employ gears that are through hardened and hobbed or shaped or hobbed or shaped and surface hardened and which are not subsequently finished by shaving or grinding e Precision This classification pertains to low or high speed enclosed CHAPTER 10 GEARCALC WIZARD 2 23 gear units which employ gears which are finished by shaving or grind ing e Extra Precision This classification pertains to high speed enclosed gear units which employ gears which are finished by grinding to high levels of accuracy The lead and profiles of the gear teeth are usually modified to compensate for load deflections and to improve the meshing characteristics Mesh alignment correction factor This selection can be used to account for improved corrective action after manufacturing for a better contact condition Some gearsets are adjusted to compensate for the no load shaft alignment error by means of adjustable bearings and or by re working the bearings or their housings to improve the alignment of the gear mesh Lapping is a finishing process used by some gear manufacturers to make small corrections in the gear tooth accuracy and gear mesh alignment Lapping is done by either running the gear in mesh with a gear shaped lapping tool or by running the two mating gears together while an abrasive lapping compound is added to the
19. e 2 62 CONTENTS 8 12 26 1 Material treatment 2 62 1220 2 Mater quality e ee uso REE EEE EG 2 64 12 26 3Own input of material data 2 65 12 27Calculation of tooth form factor 2 65 13 Lifetime Miner Rule 2 66 13 1 Calculating Lifetime according Miners rule 2 66 13 2 Define a lifetime calculation 2 68 13 2 1 Create a load spectrum element 2 68 12 2 2 Bunt ol Tone TAO ee besoa eso omo om 9 2 69 1515 Bey WER ee ee eae ee o es 2 69 1324 Reload spectrum oe ded gx aa 2 69 14 AGMA 925 Scoring 2 70 121 PE or lubrication e 13a depo ede eee Re eor ees 2 71 Corr A 2 71 14 3 Prole oca eu r o s s e coseno RUE REOR Wo o eS 2 71 144 hil temperate co era exo et 2 72 145 Tooth temperate lt occiso E ae d Rog 2 72 14 0 Seufimg temperature o el ee Bona a 2 73 14 7 Standard deviation of scuffing temperature 2 73 14 8 Dynamic viscoci n ab Ogg ee ee Hr ae o aoa 2 73 14 9 Coefficient for pressure viscocity 2 73 14 10Cogllicient of Tieton uus usos ana ge 2 74 14 11 Thermal contact eoefficlent 2 esor ee ee eee m 2 74 14 125url ce roughness o aaa nt 2 75 14 13 Pilter cut off of wavelength 2 a 2 cor be eo 2 75 CONTENTS III Appendix Bibliography and Index 3 1 Part I General Chapter 1 Elements of the KISSsoft user interface KISSsoft has been developed for Windows Regular Wi
20. e Double helical gears may be finished by grinding but this requires a large gap between the helices to allow runout of the grinding wheel Most high speed double helical gearsets are hobbed and shaved 10 1 4 Helix angle v is the standard or generating helix angle The helix angle of a gear varies with the diameter at which it is specified The standard helix angle is measured on the generating pitch cylinder For hobbed gears the helix angle may be freely chosen because the hobbing machine can be adjusted to cut any helix angle For pinion shaped gears the helix angle must correspond to the helical guides that are available for the gear shaping machine v deg Application 0 spur 10 20 single helical 20 40 double helical Low helix angle provides low thrust loads but results in fewer teeth in contact smaller face contact ratio mp and higher noise generation For the full benefit of helical action mr eg should be at least 2 0 If mp lt 1 0 the gear is a low contact ratio LACR helical gear and is rated as a spur gear Maximum bending strength is obtained with approximately 15 degree helix angles High helix angle provides smooth running quiet gearsets but results in higher thrust loads unless double helical gears are used to cancel internally generated thrust loads 10 1 5 Required ratio The gear ratio mg u of a gearset is defined as a number mg gt 1 0 and is the ratio of the tooth numbers of
21. for self aligning and compliance of the gears and mountings 10 3 2 Pinion speed The pinion is defined as the smaller of a pair of gears For planetary sun planet gearsets the sun is the pinion for mg gt 4 and the planet is the pinion for mg lt 4 For star sun planet gearsets the sun is the pinion CHAPTER 10 GEARCALC WIZARD 2 19 for Ma gt 3 and the planet is the pinion for mg lt 3 For planet internal gearsets the planet is always the pinion since it is smaller than the internal gear Epicyclic gearsets are analyzed using relative speeds The pinion and gear speeds are in proportion to the gear ratio mg np ng pinion speed gear speed 10 3 3 Required Design life A gearset s design life L is determined by the particular application Some gears such as hand tools are considered expendable and a short life is ac ceptable while others such as marine gears must be designed for long life Some applications have variable loads where the maximum loads occur for only a fraction of the total duty cycle In these cases the maximum load usually does the most fatigue damage and the gearset can be designed for the number of hours at which the maximum load occurs Typical design lives Application No Cycles Design Life L hr Vehicle 10 105 3000 Aerospace 106 10 4000 Industrial 101 50000 Marine 1019 150000 Petrochemical 10 10H 200000 The number of load cycles per gear i
22. gives a value for the variable sheave 0 d in the position f as a floating point with 6 decimal places Basic Calculations Output of Altered Variables In the report variables can be issued differently They can be multiplied or divided as well as factors can be added or subtracted This function is also valid in the arguments of the IF or FOR conditions Value of the variable multiplied 3 2f Var 2 0 Value of the variable divided 3 2f Var 2 0 Value of the variable added 3 2f Var 1 0 Value of the variable subtracted 3 2f Var 2 Similarly the two functions grad and rad are available for conversion into degree or radiant respectively angle 3 2f I grad angle CHAPTER 5 RESULTS AND REPORTS 1 26 Variables can be combined with each other like sheave 0 d sheave 1 d More than two variables can be used also Values with signs have to be put in brackets e g ZR 0 NL 1e 6 You can use the functions you find in table 5 2 5 5 3 4 Interrogation of Condition IF ELSE END The interrogation of condition enables you to issue certain values or text only if a certain condition is fulfilled The following conditions are supported Combination of Characters Meaning equal gt larger or equal lt smaller or equal unequal lt smaller gt larger This condition has to be written as follows IF Condition Var Case 1 ELSE Case 2 END Example IF i 0 Zst
23. in Degrees Minutes and Seconds 1 4 Report Viewer When a report is generated in KISSsoft a Report Viewer is opened for which entries in the Menu Report will be activated and the toolbar of the Report Viewer will be visible The Report Viewer is a text editor which contains the usual functions to save and print a text file The reports in KISSsoft can be saved in Rich Text Format rtf Portable Document Format pdf Microsoft Word Format doc and ANSII Text txt Further functions of the Report Viewer are Undo Redo Copy Cut and Paste with the usual Shortcuts The view can be zoomed and the report edited and properties such as text type size etc formatted To change the default settings of the report go to the main menu under Reports Settings CHAPTER 1 USER INTERFACE 1 9 KISSsoft Bolts according to VDI 2230 M04 Beispiel 1 VDI2230 M40 File Project View Calculation Report Graphics Extras Help o eae eB IU a sp Description KISSsoft Datensatz Changed by af on 01 11 2006 at 15 40 30 Bolts according to VDI 2230 M04 INPUTS Configuration Bolted connection under axial load single bolt Calculation using assembly temperature Assembly temperature C TM 20 00 Thread standard Standard thread Lable lead um Flank angle Reference diameter mm Flank diameter mm core mm Nominal cross section of thread mm Core cross section of the thread um Thread producti
24. included in the face width 2 The gear elements are mounted between bearings i e not overhung 3 Face widths up to 40 inches 4 Tooth contact extends across the full face width of the narrowest mem ber when loaded The input values used for the empirical method for the load distribution factor calculation can be found by pressing the plus button l beside the field Inputs for face load distribution factor Lead correction Factor Unmodified lead Pinion proportion modifier Large offset of pinion s1 s gt 0 175 Mesh alignment Factor Commercial enclosed gear units Mesh alignment correction Factor other conditions C Double helical gearing Figure 10 5 GEARCALC Face load distribution factor Lead Correction Factor The nominal setting Unmodified lead should be used when the machining quality is not known An option Lead properly modified by crowning or lead correction exists to define a well defined lead modification possible using high quality grinding machines CHAPTER 10 GEARCALC WIZARD 2 22 Lead modification helix correction is the tailoring of the lengthwise shape of the gear teeth to compensate for the deflection of the gear teeth due to load thermal or other effects Certain gear grinding machines have the capability to grind the helical lead to almost any specified curve Many high speed gears are through hardened hobbed and shaved Usually the gear member is shaved to improv
25. kXmnFlag Addendum modified no ELSE Addendum modified yes END If variable Zst kXmnFlag is 0 the first text is issued if it is not 0 the second Any amount of lines can stand between JF ELSE and END Every branch beginning on JF has to be closed by END Please note the semicolon after END The key word ELSE is optional it reverses the condition Branches can be interlaced up to level 9 Example of a Simple Branch IF i 1 ZP 0 Fuss ZFFmeth Calculation of the tooth form factor after method B END CHAPTER 5 RESULTS AND REPORTS 1 27 Function Meaning sin angle Sinus of angle in radians cos angle Cosinus of angle in radians tan angle Tangens of angle in radians asin val Arcussinus of val returns radians acos val Arcuscosinus of val returns radians atan val Arcustangens of val returns radians abs val val exp val e log val returns x in e val log10 val returns x in 10 val sqr val val sqrt val returns Vval pow x y returns z 1 if val gt 0 sgn val returns 0 if val 0 ifval lt 0 1 if val gt 0 sgn2 val returns l Aral c0 grad angle Conversion from radians to degree rad angle Conversion from degree to radians mm_in val celsius_f val min v 15 max v1 15 and v V2 Or 14 va xor v1 v3 AND v eg Vs OR 14 I V NOT val LESS 1 V EQUAL v V2 GREATER z V3 returns val 25 4 returns val 32 returns minimum of 1 returns
26. material data Using the plus button next to the material list the material values can be entered directly by the user You have to be careful choosing the values since they are not checked by the software Important for the calculation are the allowable stress numbers Sac O rim and Sat Ortim The youngs module is needed for the hertzian stress and the yield point for the static strength The hardness value is only used for documentation 12 27 Calculation of tooth form factor The point of force to be assumed by the calculation of tooth form factor for spur and LACR gears is defined here The drop down list allows the definition of force applied at tip or at the high point of single tooth contact HPSTO For low quality gears loading at the tip should be choosen because of the influence of pitch errors For high quality gears the single contact point can be choosen to consider load sharing between several pairs of teeth See AGMA 908 B89 Table 5 1 for limits of the load sharing For helical gears with an axial contact ratio mpeg gt 1 this input is not used Chapter 13 Lifetime Miner Rule 13 1 Calculating Lifetime according Miners rule The Palmgren Miner Linear cumulative fatigue damage theory Miner s Rule is used to calculate the resultant pitting or bending fatigue lives for gears that are subjected to loads which are not of constant magnitude but vary over a wide range According to Miner s Rule failure occurs when
27. maximum of 14 binary and function binary or function binary exclusive or function logical and function logical or function v5 v5 0 if val 40 ums 1 ifval f 0 returns DM cs 0 if L1 gt V2 1 if Vi V2 returns mn 4 vy returns es ue 0 if L1 V2 Table 5 2 Possible functions in for calculations in the report CHAPTER 5 RESULTS AND REPORTS If variable ZP 0 Fuss ZFFmeth is 1 a text is issued otherwise not Example of Interlacing Branches IF f lt 2 7 2092k vp periodical manual lubrication Text 1 ELSE IF f lt 12 2092k vp Lubrication with droplets 2 to 6 droplets per minute Text 2 ELSE IF f lt 34 2092k vp Lubrication with oil bath lubrication Text 3 ELSE Lubrication with circulation system lubrication Text 4 END END END 1 28 If variable 2092k vp is equal or smaller than 2 7 text 1 is issued If not the program checks whether z092k vp is smaller than 12 If this is true text 2 is issued If it is not true the program checks whether 2092k vp is smaller than 34 If this is true text 3 is issued otherwise text 4 5 5 3 5 Loops FOR In the KISSsoft report generator FOR loops can be entered too Within a FOR loop a counting variable is counted up and down You can employ up to 10 interlaced constructs A loop is constructed as follows FOR varname i TO i BY i DO Initial value Final value Step Access to variable with varname oder varname
28. notches stress concentrations Damage during assembly or incorrect assembly Quality assurance inspection techniques e Material Properties CHAPTER 11 CALCULATION SETTINGS 2 39 Handbook values or test data for strengths Material procurement control Heat treatment control Quality assurance inspection techniques e Design Analysis Is gear rating verified with computer programs AGMA2001 and Scoring Will gears be tested before going into service e Service Conditions Environment thermal chemical etc Installation procedures Operation procedures Maintenance procedures Consider the need to conserve material weight space or costs Most impor tantly consider e Consequences of Failure Nature of failure modes Risk to human life Economic costs Environmental impact 11 3 1 Factor for minimal normal tooth thickness at tip This is the multiple of normal module which must exist at the tip This factor is used to warn against pointed tip designs CHAPTER 11 CALCULATION SETTINGS 2 40 11 4 AGMA 925 Settings GearCalc AGMA 2001 AGMA 925 Number of points For graphic 50 0000 Value for x axis Roll angle Figure 11 4 GEARCALC settings page AGMA 925 11 4 1 Number of points for graphics This cell can be used to determine the total number of points used in the graphics of the AGMA 925 calculation 11 4 2 X axis unit There are three optio
29. quiet gearsets but high thrust loads occur Double helical gears generate no thrust load but are more expensive The ratio should be entered as a positive value for an external gear set and as a negative value for an internal gear set The absolute value should be greater than or equal to one The setting for profile modification is required for the proposal of optimal profile shift shown on the last page of the wizard only The reliability the stress cycle factor and the required safety factors provide an influence on the strength of the proposed gear set 10 1 Figure 10 1 GEARCALC Wizard page 1 1 Description The Description field allows the design to be labelled with a code or brief description for reference purposes and documentation 2 4 CHAPTER 10 GEARCALC WIZARD 2 5 10 1 2 Normal pressure angle n an is the standard or generating pressure angle For hobbed or rack generated gears it is the pressure angle of the tool For helical gears amp is measured on the generating pitch cylinder in the normal plane is stan dardized to minimize tool inventory dn deg Application 14 5 Low Noise 17 5 20 General Purpose 22 5 25 High load Capacity Low pressure angle Requires more pinion teeth V 21 to avoid under cut Gives larger topland for same addendum modification coefficient High pressure angle Allows fewer pinion teeth without undercut Gives smaller topland for s
30. side of the field can be used to define the hand left or right of the helix Enter hand of helical gears Pinion right Gear left Pinion left Gear right Figure 12 2 AGMA 2001 2101 Helix angle CHAPTER 12 AGMA 2001 2101 2 44 12 5 Center distance The centre distance C a is the theoretical distance between the origins of the pinion and gear on assembly The plus button can be used to define an upper and lower tolerance for the centre distance The sizing button can be used to calculate an appropriate center distance based a given sum for the profile shift coefficients Tolerances for the centre distance can be defined using the next to the in put field Normally the tolerances are defined symmetrically so one is positive and the other is negative Set center distance tolerances Center distance C 3 6788 in Upper tolerance AC 0 0000 in Lower tolerance AC 0 0000 in Figure 12 3 AGMA 2001 2101 Center distance 12 6 Number of teeth The numbers Np z and Nafz2 represent the number of teeth on the pinion and gear respectively As a default the data of the pinion is input in the left column the data of the gear in the right column For spur gears you need a minimum number of 17 teeth to avoid undercut without any profile shift You can achive a smaller number of teeth with an appropriate profile shift factor or using helical gears 12 7 Face width The face width F b
31. tables to input data The Add Button joins a new line to the table The Remove Button removes a selected row from the table x The Clear Button deletes all entries in the table CHAPTER 1 USER INTERFACE 1 8 1 3 3 Toggle Units In KISSsoft the units of the value input field see 1 3 1 and in the tables see 1 3 2 can be changed To do this click on the unit with the right mouse button A context menu is opened which contains all possible units for this value If a different unit to that currently used is selected then KISSsoft converts the value in the input field to the appropriate value In order to toggle the default unit between metric and imperial use the main menu option Extras System of Units 1 3 4 Enter formulae and angles In some cases it is practical to define a value in terms of a small mathemati cal expression A formula editor is opened by clicking on the edit filed using the right mouse button A formula can be defined using the four basic oper ations x and Additionally all functions that are supported by the report generator can be used see Tables 5 2 Confirm the formula with the Enter Key sometimes called Carriage Return Key and the formula will be evaluated The formula itself will be lost if the formula editor is again opened the calculated value is seen and not the original formula For input fields which show an angle a dialog appears instead of the formula editor to input the value
32. the active project An indicator in the status bar see 1 6 shows whether the current calculation file is a part of the active project 3 4 File Storage Files that belong to project do not have to be saved in the project directory Files can therefore also belong to several projects simultaneously If an active project has been defined then KISSsoft proposes the active project directory for storage whenever a calculation file or a report is to be opened or saved If no project is active then the user directory see 2 3 will be proposed as the storage point 3 5 Projects and Default Files On loading a new file a default file will first be sought for the active project see 2 4 If no file exists then a general default file will be used In the project properties see 3 6 it can be seen whether a special default has been defined for a project 3 6 Project Properties The project properties for the selected project shown using the Action Project Properties or with the context menu see 1 1 Chapter 4 Calculations in KISSsoft 4 1 Current calculation of a Module The current calculation of a module is carried out by the Action Calculation Run Additionally the toolbar and function key F5 can be used for quick and easy access to this Action A Module can have one or more calculations In every case the calculation of the visible tab will be carried out 4 2 Messages A calculation sends various types of messages
33. the directory for the default files see 2 4 can be entered The new project is entered in the project tree navigator and set as the active project If an existing project is opened Project Open this will likewise be set in the project tree navigator and marked as the active project The currently selected project is closed using the Action Project Close This Action can also be found in the context menu see 1 1 of the project tree 3 2 Add and Remove Files Files can either be both added and removed using either the project proper ties see 3 6 or the context menu see 1 1 Not only calculation files from KISSsoft but also arbitrary external files can be added to the project 1 15 CHAPTER 3 PROJECT MANAGEMENT 1 16 Projects BY x FODO E MO10 E MOZO H moso Beispiel 1 VDI2230 Beispiel 2 YDI2230 Beispiel 3 YDI2230 Beispiel 4 YDI2230 Beispiel 5 YDI2230 Tutorial Schrauben nach YDI 2230 E M090 z011 Beispiel 1 2012 H 2014 H 2015 H 2016 Figure 3 1 The Project Tree of KISSsoft CHAPTER 3 PROJECT MANAGEMENT 1 17 3 3 The Active Project The project tree in the navigator shows all open projects but the active project must not necessarily be defined If the active project has been defined it will be displayed in bold text A project can be activated or deactivated using the Menu Project as well as the context menu The current calculation file must not necessarily belong to
34. the mating gears ma Ng N It is also the ratio of the speeds high low of the mating gears mg ny ng CHAPTER 10 GEARCALC WIZARD 2 8 For internal gearsets the gears rotate in the same direction instead of opposite directions As convention the tooth number of the internal gear is set to a negative value Therefore the ratio for an internal gear set is negative For an internal gearset the difference of the tooth numbers NG Np should not be too small to avoid interference between the tips of pinion and gear teeth For the sizings in GEARCALC Wizard the ratio for internal gear sets has to be below mg lt 2 For epicyclic gear trains the overall gear ratio is Moo Ze Zs for a star gear IZa Zs 1 for a planetary S where Za no of teeth in internal gear Zs no of teeth in sun gear Typical ranges for overall gear ratio MGo Application 1 5 offset gears 3 6 star gear epicyclic 4 7 planetary epicyclic For gear ratios larger than those shown in the table it is generally more economical to use multiple stages of gearing rather than a single gearset Star gear Epicyclic Ratios planet sun gear ratio for mg gt 3 ma Mco 1 2 planet sun gear ratio for mg lt 3 ma 2 mco 1 planet is the pinion internal planet gear ratio me 2 mco Meo 1 Note star gears cannot have ma 1 A reasonable minimum ratio is mq e CHAPTER 10 GEARCALC WIZARD 2 9 Pl
35. to the input window infor mation warnings and errors Information and warnings should be heeded in order to ensure safe results If an error occurs the calculation is automatically stopped Normally all messages are written to a message box in the message window see 1 2 4 The reporting of information and warnings in the message box can be changed see 7 using Extras Settings 4 3 Consistency The status of the calculation is consistent if it has been carried out without an error occurring As soon as any data has been changed in the input window 1 18 CHAPTER 4 CALCULATIONS IN KISSSOFT 1 19 the calculation becomes inconsistent i e the results of he calculation no longer match the current data set The current status of the calculation is indicated in the status bar see 1 6 Chapter 5 Results and Reports 5 1 Results of a calculation If a calculation has been carried out then the results window see 1 2 4 will show the results If no results are shown then the calculation has encountered an error In this case the MessageBox will notify the user of the error An indicator in the status bar see 1 6 shows whether the results are consistent i e whether the results apply to the current interface data set see 4 3 From Release 02 2007 it will be possible for the user to specify a template for the results in a similar way to the definition of report templates see 5 5 5 2 Calculation report The Action Rep
36. with the gear pair operating at a center diatance smaller than standard The sizing button at the side of this field allows the program to calculate coefficients suitable for a range of operating criteria e General purpose The profile shift factor is calculated according to a formula by Robert Errichello m u 1 zu for speed reducers X1 CHAPTER 12 AGMA 2001 2101 2 AT Xr p for speed increasers ucl e Balanced specific sliding The specific sliding at the beginning and the end of the contact has the same values on the root of the gears e Balanced sliding speed at tip The sliding velocity at the beginning and the end of the contact has the same values e Best strength against bending Choose x for the best bending strength e Best strength against scoring Choose x for the best scoring resis tance e Minimum zr without undercut or pointed tip Choose x so that no undercut occurs at the pinion and the minimal topland of the gear is still large enough e Maximum zr without undercut or pointed tip Choose x so that the minimal topland of the pinion is large enough and no undercut occurs for the gear 12 9 Thinning for backlash It is customary to ignore backlash when determining the addendum mod ification coefficients x and rs i e z and z gt are usually nominal values corresponding to zero backlash The small adjustments radial shifting of the generating rack for tooth thinning are indirectl
37. 1 0 depending on user preference C 1 0 suggested for general purposes The lower button allows the direct input of the ratio of face width F b to pitch diameter d m F b d This option activates the cell directly under the radio button The cells for factors C1 and C2 will be de activated and the cell for the definition of width to pitch diameter can be accessed to enter a fixed value 11 1 5 Tool addendum The user can specify an addendum A po of the tool for three given machin ing processes finish cutting shiving and grinding for a specified range of pressure angle designs The tool addendum is measured from the datum line CHAPTER 11 CALCULATION SETTINGS 2 35 with s 7 2 P 4 An associated radius pp can also be specified at this point The tool addendum form is defined as follows D Tool line Figure 11 2 This figure shows a normal plane view of a rack type generating tool hob rack cutter or generating grinding wheel 11 1 6 Use full radius calculated at run time This option implies that a radius is to be determined during the calculation at run time which will be the largest possible fitting to the defined tooth form tip CHAPTER 11 CALCULATION SETTINGS 2 36 11 2 AGMA 2001 2101 Settings GearCalc AGMA 2001 AGMA 925 C Don t use stock allowance and protuberance Definition of reference profile Use factors to module Use absolute values Manufac
38. 2222 ROO RUE RO ee 1 13 3 Project Management 1 15 3 1 Create open and close projects sn 1 15 32 Add and Remove Files 2 224 o ox sx X 1 15 Aa The Active REB uso bw oe we ee A RR Wa 1 17 De Pile MONE ea Se eS a ne ee Bc XD e 1 17 3 5 Projects and Default Files 2 64 4 4 4s xS 1 17 efr Project Properts o air ossea OX ee bU 1 17 4 Calculations in KISSsoft 1 18 4 1 Current calculation of a Module 1 18 LE NONEM lie X3 POE 4X C454 A A 1 18 A3 Consistency nt he ea Rex SE co eos 1 18 5 Results and Reports 1 20 wl Results al acalculation sc sos ke ae 1 20 ms Calculation repari 2222 9 quw A es 1 20 2o DESEA er a ara Nox gode RO ee eR E G 1 21 34d Report settings 22222499 OEE a Dan RR RS 1 21 oo Report templates 22522292 9x3 ER x exa 1 21 CONTENTS 4 5 5 1 Storage und Designations 1 21 5352 Scoopeo Reports occiso RE bea RO 1 22 A 22d REGE rear 1 23 6 Interfaces 1 31 7 Program Settings 1 32 TIL RSS 229805 ual en S koX web es cx a a we 1 32 T2 DOSES uou Ba scd a A a o ORE a 1 32 8 Additional KISSsoft Tools 1 33 Bl Liene Tool 3 sse poem ease eda Se ee ed ewe 1 33 22 Qosmio Tool s e soea saie a ME xD Eee on i 1 33 8 3 Database Tool and Table Interface 1 33 II GEARCALC 2 1 9 GEARCALC in general 2 2 10 GEARCALC Wizard 2 4 Mi GEABLALC pagel gt o era en 2 4 101 1 Deepen 2 25 433 25 2 ee ans 2 4 10 1 2 Normal pressure angle lt o 2 2 2 4 62256544 265 2 5 10 13 DMA ee
39. 40 to HB 654 for Nitralloy 135M and 2 596 chrome alloys The practical limit on case depth is about 0 025 in which limits the application of nitriding to pitches finer than approximately Bas e Induction hardened gear teeth are heated by electromagnetic induc tion from a coil or inductor and are immediately quenched Because only the surface layers of the gear teeth are hardened heat treat dis tortion is minimized Very tight controls of every step of the process are necessary for satisfactory results and it is best for high volume pro duction where the process can be optimized Several gears from each production run must be destructively inspected for case depth to ensure that the induction hardening is properly controlled Carbon content of induction hardened gears is usually 0 40 or 0 50 Plain carbon steels e g AISI 1050 may be used for small gears while alloys such as AISI 4350 may be used for large gears e Carburized gears are first cut then heated in a carbon atmosphere usually gas carburizing which causes carbon to diffuse into the sur face layers of the gear teeth The gears are either quenched from the carburizing temperature or cooled reheated and quenched later Most gears are tempered at 300 400 F after carburizing and quenching Car bon content of carburizing steels range from 0 15 to 0 2596 Low alloy steels e g AISI 8620 are used for small gears and moderate loads while high alloy steels e g AISI 4820 are
40. 8 Generate report 1 20 Graphics Windows 1 6 Hand of helix 2 43 Helical gearsets 2 6 Helix 2 5 Helix Angle 3 5 INDEX AGMA 2001 2101 2 43 Helix angle GEARCALC Wizard 2 7 Help Viewer 1 10 Index 1 6 Information 1 6 Information Window 1 6 Input Angle 1 8 Input Window 1 6 Input Formula 1 8 Interfaces 1 31 ISO 1328 2 34 2 37 2 52 ISO 54 2 42 KISSini 1 32 Lead correction factor 2 55 Licence Tool 1 33 Life AGMA 2001 2 53 GEARCALC Wizard 2 19 Lifetime 2 66 Create a load spectrum 2 68 3 6 AGMA 2001 2 64 GEARCALC Wizard 2 15 Material treatment AGMA 2001 2 62 GEARCALC Wizard 2 12 Menus 1 2 Mesh alignment correction factor 2 57 Mesh alignment factor 2 56 Messages 1 18 Message Window 1 5 Module Tree 1 4 Normal diametral pitch AGMA 2001 2 42 GEARCALC Wizard 2 28 Normal module AGMA 2001 2 42 GEARCALC Wizard 2 28 Normal Pressure Angle AGMA 2001 2 42 GEARCALC Wizard 2 5 Number of Teeth 2 44 Lifetime calculation input of 2 Open a project 1 15 68 Load Spectrum load 2 69 Load Spectrum save 2 69 Sum of time ratio 2 69 Lifetime calculation 2 66 Load distribution factor AGMA 2001 2 54 GEARCALC Wizard 2 21 Load sharing 2 65 Manufacturing tolerance 2 34 Manufacturing tolerances Settings 2 37 Material AGMA 2001 2 62 GEARCALC Wizard 2 12 Material quality Overload factor AGMA 2001 2 53 Overload factor GEARCALC Wizard 2 19
41. 99 o button Next Figure 10 7 GEARCALC Wizard page 5 10 5 1 Result overview This page is a tabluated form showing all solutions for the design manufa turing and operating conditions defined previously An appropriate solution must be chosen to progress to the next page Click the table on the row containing required option details to continue CHAPTER 10 GEARCALC WIZARD 2 30 10 6 GEARCALC page 6 GearCalc AGMA 2001 Lifetime Miner Rule AGMA 925 Description Select profile shift coefficient pren on The profile shift coefficient changes the tooth thickness and the tip and root diameters of the gear For general purpose Anz pe Therefore it has an influence on sliding conditions and For balanced specific sliding 0 5691 0 5055 on the strength of tha ga SIE addendum modification For best strength against bending 0 6250 0 4496 For a ratio from high to low speed often the solution B E for balanced specific sliding is recommended The For best strength against scoring 0 3600 0 7146 general purpose solution can be used for speed ER 3 increasers and decreasers Generally the selected Limit For undercut 0 0516 3 4578 profile shift coefficient should be above the limit For Limit For minimal topland 07948 24434 undercut and below the limit For minimum topland Enter pinion profile shift coefficient x 0 0000 Figure 10 8 GEARCALC Wizard page 6 This page allows the s
42. AGMA Steel Grade 2 HB400 AGMA Steel Grade 1 HRC50 Type A AGMA Steel Grade 1 HRC54 Type A AGMA Steel Grade 2 HRC50 Type A AGMA Steel Grade 2 HRCS4 Type A AGMA Label Steel Grade 2 HRC58 64 AGMA Steel Grade 1 HRCSO Type B AGMA E Steel Grade 1 HRC54 Type B AGMA Material type Case carburized steel v Material Be careful when you use this option You have to enter data in accordance with AGMA2001 or AGMA2101 GEARcalc does not check wether the material data entered is correct or not If you are not very experienced better use one of the preset material Steel Grade 2 HRC50 Type B AGMA Steel Grade 2 HRC54 Type B AGMA Type of treatment case hardened p v Steel Grade 1 HRCSS 64 AGMA Se Steel Grade 2 HRC58 64 AGMA Hardness 60 Steel Grade 2 3 HRC58 64 AGMA Steel Grade 3 HRCS8 64 AGMA Allowable contact stress 225000 00 Allowable bending stress 65000 00 Yield point 119221 0255 Youngs modulus 30000013 20 Poisson number 0 30 Density Figure 10 3 GEARCALC Material CHAPTER 10 GEARCALC WIZARD 2 14 Good tooth accuracy typically 10 acc AGMA2000 can be ob tained by hobbing the teeth after heat treatment eliminating heat treatment distortion from the generated tooth forms Hardenability must be adequate to obtain the required hardness at the root diame ter e Nitrided gears are quenched and tempere
43. GEARCALC User s manual OKISSsoft AG Uetzikon 4 CH 8634 Hombrechtikon Fon 41 55 25420 50 Fax 41 55 254 20 51 www KISSsoft ch info KISSsoft ch December 13 2006 Contents I General 1 1 1 User Interface 1 2 11 Menus Context Menus and Toolbar 1 2 L2 Dock Window ous ka ee Gb RE Rev eR EE SS ua 1 3 121 The Module Tres 2222222223 xx 1 4 1 22 Ihe Project Ties 24 3 sh ar rede 1 5 1 23 The Explorer auae oe OS ra 1 5 1 24 The Results Windows 2444 826244444465 1 5 1 2 5 The Message Window 1 5 1 2 6 The Information Window 1 6 LAT Contents and Index 2 2 2 2 o ees 1 6 122 Graphics Windows 2 2222 dega ta 1 6 1 3 loput Windom 22 sec a ara ea riet 1 6 131 Value Input Field o o 2 522254 2 24 844 244 1 6 132 Tabl 22 40 ko EROR A RUSO RR AR Rn d 1 7 13 3 Toggle Unite ei cc nagao ta RR 22 1 804 x3 1 8 1 3 4 Enter formulae and angles 1 8 1 4 Report AI 1 8 15 Help Viewer 22442 22 oom RR RR Rt x RR R 1 10 1 6 Tool Tips md Status DAP os e oko Re RS E GR Xo OES 1 10 CONTENTS 3 2 Setting Up KISSsoft 1 11 2 1 Language Settings 22222222949 OR RE 1 11 2 1 1 Language ofthe User Interface 1 11 2 1 2 Language of the Reports 1 11 2 13 Language for messages o a 1 12 22 pyem ol UNS co 24 AAA 1 12 2 3 User Directoy e a RRA RA AR 1 12 2 4 Definition of own Standard Files 1 13 2 5 Start 1
44. HD Oil Film Theory to Industrial Gear Drives Trans ASME J Eng Ind Vol 98 series B No 2 May 1976 pp 626 634 27 Winter H and Weiss T Some Factors Influencing the Pitting Micro Pitting Frosted Areas and Slow Speed Wear of Surface Hardened Gears ASME paper no 80 C2 DET 89 1980 Index Active project 1 17 Addendum modification factor AGMA 2001 2 45 Add a file 1 15 AGMA 925 2 70 AGMA 2000 2 52 GEARCALC Wizard 2 16 Settings 2 34 2 37 AGMA 2001 2 41 AGMA 2015 2 52 GEARCALC Wizard 2 16 Settings 2 34 2 37 AGMA 2101 2 41 Basic rack addendum 2 50 Calculate 1 18 Calculations 1 18 Center Distance AGMA 2001 2 44 Center distance GEARCALC Wizard 2 27 Centre distance tolerances 2 44 Change language 1 11 Close a project 1 15 Configuration Tool 1 33 Consistency 1 18 Contacts Per Revolution AGMA 2001 2 60 GEARCALC Wizard 2 26 Contents 1 6 Context Menus 1 3 Create a project 1 15 Database 1 33 Default Files 1 13 Definition of reference profile 2 36 Description GEARCALC Wizard 2 4 Design life GEARCALC Wizard 2 19 DIN 780 2 42 Dock Window 1 3 Double helical gearsets 2 6 Drawing data 1 21 Driving gear AGMA 2001 2 59 GEARCALC Wizard 2 25 Dynamic factor AGMA 2001 2 59 GEARCALC Wizard 2 24 Explorer 1 5 Face width AGMA 2001 2 44 Factor for minimal tooth thickness 2 39 Finishing Method 2 16 Full length teeth 2 33 GEARCALC Wizard 2 4 Net face width 2 2
45. LD0 RPT Rack german issue ZO14LDO RPT Planetary gear german issue Z015LDO0 RPT 3 gears german issue Z016LDO0 RPT 4 gears german issue English issue M040LEO0 RPT Thread calculation English issue American issue M040LAO0 RPT Thread calculation American issue 5 5 2 Scope of Reports The Scope e g length of the report can be defined in the Menu Report Settings on a scale from 1 to 9 where 9 represents the complete data set and 1 for a short summary In the report template there exists a digit at the beginning of each line between 1 and 9 This digit defines independently of the previously mentioned setting whether the line should be read or not CHAPTER 5 RESULTS AND REPORTS 1 23 Example If a report length of length 5 middle has been chosen then all lines of the report template with 1 2 3 4 or 5 at the beginning are read Lines with 6 7 8 and 9 are not read 5 5 3 Formatting Report templates as well as completed reports are text files containing Mi crosoft Windows labels Please process your reports only in Windows pro grams to avoid complications with symbols The following directions and key words are defined in the report format e Text that should be given out e Comment that should not be given out e Designations and formats of calculation variables e Conditional branches IF ELSE END e Repeatitions FOR Loop 5 5 3 1 Text formatting KISSsoft reports are normally generated in R
46. Pinion speed AGMA 2001 2 52 Pinion proportion modifier 2 56 Pinion speed GEARCALC Wizard 2 18 Pitch diameter GEARCALC Wizard 2 28 Power AGMA 2001 2 52 GEARCALC Wizard 2 18 Pre set Values 1 13 Profile modification INDEX GEARCALC Wizard 2 9 Profile shift coefficient AGMA 2001 2 45 Profile shift factor GEARCALC Wizard 2 31 Proposals in GEARCALC wiz ard 2 30 Program Settings 1 32 Project management 1 15 Project properties 1 17 Project Tree 1 5 Protuberance 2 51 Protuberance angle 2 51 Quality AGMA 2001 2 52 GEARCALC Wizard 2 16 ratio face width to pitch diameter 2 34 Registry 1 32 Reliability GEARCALC Wizard 2 10 Reliablility Settings 2 37 Remove a file 1 15 Report 1 20 Reporttemplate 1 21 FOR loop 1 28 Format 1 23 IF condition 1 26 Name 1 21 Scope 1 22 Variables 1 24 Report Viewer 1 8 Required design life 2 19 Required ratio 2 7 Required safety factors GEARCALC Wizard 2 10 Results 1 20 Results overview GEARCALC Wizard 2 29 Results Window 1 5 Reversed bending AGMA 2001 2 60 GEARCALC Wizard 2 25 Scoring 2 70 Coefficient for pressure viscosity 2 73 Coefficient of friction 2 74 Dynamic viscosity 2 73 Lubrication type 2 71 Oil type 2 71 Profile modification 2 71 Surface roughness 2 75 Temperature oil 2 72 Temperature scuffing 2 73 Temperature standard tion of scuffing 2 73 Temperature tooth 2 72 Thermal contact coefficient 2 74 Wavelengt
47. TF Format RTF recognises the following text formats Description Start Ende Under Score lt UL gt lt UL gt Strichen Through lt STRIKE gt lt STRIKE gt Bold lt BF gt lt BF gt Kursive lt IT gt lt IT gt Tiefgestellt lt SUB gt lt SUB gt Font Size lt FONTSIZE xx gt Enlarge Font lt INCFONTSIZE gt lt DECFONTSIZE gt Reduce Font lt DECFONTSIZE gt lt INCFONTSIZE gt Page break lt NEWPAGE gt Line break lt BR gt Text Color red lt RED gt lt BLACK gt Text Color green lt GREEN gt lt BLACK gt Text Color blue lt BLUE gt lt BLACK gt CHAPTER 5 RESULTS AND REPORTS 1 24 Space SPACE Figure lt IMAGE name WIDTH xx einf gen HEIGHT yy PARAM xyz gt 5 5 3 2 Comments Comment lines begin with Comments are ignored when generating a report Example I have changed the report text here on 13 12 95 hm Tip diameter mm 10 2f sheave 0 da In this case only the second line will be given out 5 5 3 3 Calculation variables No variables can be defined by the user other than those used for FOR Loop which can be named by the user and whose values can be entered see Chapter 5 5 3 5 Replacement character The file type and format of a variable is given by a Replacement character e i stands for a whole number f stands for a floating point number v vof stands for a formatted floating
48. TS 7 12 8 Profile shift coefiigient gt occo toota reie ta RR 2 45 12 8 1 Gears with standard addenda 2 45 12 8 2 Gears with addendum modification 2 46 129 Thinning for backlash o 5 2222 0 1 2 20 HG 2 47 1210St ck iu zoom a aa Rex mom bee 2 48 121lTool addendum iuo ee cada 2 48 15 121000 tip tadi s uus uox ane doe A e a di 2 50 12 13Basic rack addendum Tool dedendum 2 50 12 14Tool protuberance angle 2 51 1215100 protuberance 2 2 sauna orm om REG 2 51 12 16Quality according to AGMA cn 2 52 De es acocida noa Oe PS AAA LIRE 2 52 12 18 Pins pero 2 os los ee o ow eo Re Rm RO m RR 2 52 AA 222424 or Ro deck de De UR OR GEO CORR GEO dec PCR a 2 53 122200 verlond factor 2 222 o om man ed 2 53 1221Load distribution factor 222r oo RA 2 54 12 21 1 Lead correction factor Qu soo o 2 55 12 212 Pinion proportion modifier Cial 15 6 14 Maa m mn 2 56 12 21 3 Mesh alignment factor Cima rer 2 56 12 21 4 Mesh alignment correction factor Ce 2 57 12212 Double Ebel 2 oe bw des Oa oa gekenn 2 57 12 21 6 Transverse load distribution factor 2 57 ole lee oe ee eee A Oe ee 2 57 are rs es se ee ow Er ea ee we eS 2 59 o MM een Brig m QEON EN 2 59 1224Beversed bend lt s lt wok 9 oux XX hau na 2 60 12 25Number of contacts per revolution 2 60 19 BO Material lt 4 6545 48644 eee ew SEE ewe eb ee x
49. a given calculation must be defined Depending upon the complexity of a calculation the input window may be divided into several tabs In most cases a single side is sufficient to carry out the calculation Every input window uses the same control elements which will be described now in greater detail 1 3 1 Value Input Field As a rule for each value input field there is the variable name symbol the editing field and unit If the editing field is greyed out then the variable can CHAPTER 1 USER INTERFACE 1 7 not be edited and will be determined by the calculation Behind each input field there can be one or more of the following buttons Setting the Check Button fixes the entered value Setting the Radio Button you select which of the values in a group will be calculated and which will be fixed al The Size Button calculates an appropriate suggestion for the value S The Convert Button recalculates the value from depending data The Plus Button can be used to input further data related to the value m l The Info Button shows appropriate information in the information win dow see 1 2 6 1 3 2 Tables In some modules the data is displayed or entered in a table Double clicking on the end tab to the left of a row selects a complete entry while the data in a single cell can be edited by double clicking on the cell Tables often have extra information as Tool Tips see 1 6 The following buttons are as a rule provided with
50. ame addendum modification coefficient 10 1 3 Helix type You can design spur single helical and double helical gearsets Characteristics for spur gearsets are e Teeth are parallel to the gear axis e Theoretically spur gears impose only radial loads on their bearings In practice misalignment of the gear mesh may cause small thrust loads e Spur gears are noisier than helical gears because they have fewer teeth in contact Alternating one two pair tooth contact causes mesh stiffness variation and vibration Profile modification in the form of tip and root relief improves smoothness e Size for size spur gears have less load capacity than helical gears e Although some aircraft gas turbine spur gears run faster most spur gears are limited to pitch line velocities less than 10000 fpm e Spur gears may be cut by hobbing shaping or milling and finished by shaving or grinding CHAPTER 10 GEARCALC WIZARD 2 6 Characteristics for helical gearsets are e Teeth are inclined to the gear axis in the form of a helical screw e Single helical gears impose both radial and thrust loads on their bear ings Helix angles are usually held to less than 20 degrees to limit thrust loads e Single helical gears are quieter than spur gears because they have more teeth in contact with smaller variations in mesh stiffness e Size for size single helical gears have more load capacity than spur gears e Many industrial single helical gear
51. anetary Epicyclic Ratios planet sun gear ratio for mg gt 4 mg mgo 2 2 sun is the pinion planet sun gear ratio for Mg lt 4 ma 2 mq 2 planet is the pinion internal planet gear ratio mg 2 meo 1 Meao 2 Note planetary gears cannot have mg 2 A reasonable minimum ratio is MGo 2 2 10 1 6 Profile modification You can make corrections to the theoretical involute profile modification The type of profile modification has an impact on the calculation of the scoring safety The Distribution factor or Force Distribution factor XGam is calculated differently depending on the type of profile modification There is a significant difference between cases with and without profile correction The difference between profile correction for high load capacity gears and thise for smooth meshing however is not so important The calculation procedure requires that the C of the profile correction is sized according to the applied forces but does not indicate an exact value 10 1 7 Stress cycle factor The stress cycle factor can be determined dependent upon the expected ap plication The choice of critical service Yy gt 0 8 or general applications Yn gt 0 9 can be set from the drop down list 10 1 8 Calculation of tooth form factor The point of force to be assumed by the calculation of tooth form factor for spur and LACR gears is defined here The drop down list allows the definition of force applied at
52. at problematic because comprehen sive or generally applicable notes are missing in this area In particular there is no reference to the scuffing load load capacity specification according to the FZG test Oils with active EP additives therefore have a tendency to be undervalued 2 70 CHAPTER 14 AGMA 925 SCORING 2 71 GearCalc AGMA2001 Lifetime Miner Rule AGMA 925 Type of lubrication Oil bath lubrication v oil Mineral oil ISO VG 220 EP gear oil v Profile modification Unmodified v a Oil temperature 158 0000 F Tooth temperature Ou 189 8600 F O Scuffing temperature o 469 1809 F v Standard deviation of scuffing temperature g 65 5200 F O Dynamic viscosity at Bu Min 23 2597 mPas L1 Pressure viscosity coefficient a 0 000110 in2 lbF Coefficient of friction u 0 1000 O 2 Welding Factor Ku 1 0000 Thermal contact coefficient Bu 43 7619 43 7619 Ibf in s 9F Surface roughness R 24 8031 24 8031 uin O Filter cutoff of wavelength L 0 0315 in Figure 14 1 GEARCALC AGMA 925 14 1 Type of lubrication Grease or oil lubrication oil bath oil mist or oil injection process are the options in the list 14 2 Oil There are numerous oils and greases from which an appropriate option can be selected The data for this oil type will be used by the calculation 14 3 Profile modification You can make corrections to the t
53. ation The Action Drawing Data shows the drawing data see 5 3 of the selected element in the report viewer see 1 4 Under Settings the text size margins and scope of the reports can be changed The actions to save send and print are only active if a report is open The graphic window see 1 2 8 of a calculation module can be opened and closed in the main menu Graphic The 3D Export option accesses a CAD interface see 6 from KISSsoft Under Settings the CAD System can be chosen to which the selected element is to be exported Under Extras there is a licence tool see 8 1 the configuration tool see 8 2 as well as the database tool see 8 3 From the main menu the Windows calculator can be started and the Language see 2 1 or unit system see 2 2 changed General program settings see 7 such as formats for time and date can be changed under Settings KISSsoft help Help as with Windows convention is the last entry at the end of the menu toolbar and can be used to open and navigate the KISSsoft manual Under Info there is specific details of program version and support of KISSsoft In addition to the main menu KISSsoft uses context menus in many places Context menus offer access to Actions in a specific aspect or element of the software Context menus are normally accessed using the right mouse button The toolbar allows quicker access to those Actions in the Menu system which are used more frequently Note that there are T
54. ation of Concentrated Contacts NASA SP 237 1970 pp 153 248 16 Castellani G and Castelli V P Rating Gear Strength ASME paper no 80 C2 DET 88 1980 17 Dowson D and Higginson G R Elastohydrodynamic Lubrication The Fundamentals of Roller and Gear lubrication Pergamon Press Lon don 1966 18 Dowson D and Higginson G R New Roller Bearing Lubrication For mula Engineering London Vol 192 1961 pp 158 159 19 Dowson D Elastohydrodynamics Paper No 10 Proc Inst Mech En grs Vol 182 Pt 3A 1967 pp 151 167 20 Grubin A N Fundamentals of the Hydrodynamic Theory of Lubri cation of Heavily Loaded Cylindrical Surfaces in Russian Paper 2 Symp Investigation of the Contact of Machine Components Central Scientific Research Institute for Technology and Mechanical Engineer ing Moscow Book No 30 1949 pp 115 166 DSIR London Translation N0 337 21 Kelley B W A New Look at the Scoring Phenomena of Gears SAE Trans Vol 61 1953 pp 175 188 22 Kelley B W The Importance of Surface Temperature to Surface Dam age Chapter in Engineering Approach to Surface Damage Univ of Michigan Press Ann Arbor 1958 23 Mobile Oil Corporation Mobil EHL Guidebook 1979 24 Neale M J Tribology Handbook Butterwoths London 1973 BIBLIOGRAPHY 3 4 25 Shigley J E and Mitchell L D Mechanical Engineering Design McGraw Hill 4th ed 1983 26 Wellauer E J and Holloway G A Application of E
55. ations are often carried out the same values must be given in or selected KISSsoft makes this easier to achieve by means of default files For each calculation module there exits an internal default set of data A default file can be stored in which the data can be pre defined and appears on opening of the associated module or loading of a new file To define a default file simply open a calculation module and give in the re quired data The Action File Save as standard will store these values in the default files Default files can be defined for single modules or for entire projects see 3 5 If an active project is selected on saving the default values from this project only will be saved If there is no current project the default values are applied generally On loading a new file a default file will first be sought in the active project If it is not available the general default file internal preset settings for example will be used 2 5 Start Parameter The call of KISSsoft from the prompt can be done using the following start parameters Parameter Description INI Filename The initialisation file KISS INI is loaded from specified location A file name includ ing directory can be given START Module The given calculation module is started The module identification is for example M040 for the bolt calculation or Z012 for the spur helical calculation LOAD Filename The given calculation file will be loaded and t
56. ays identical but close to the gear quality CAUTION This factor has been redefined as the reciprocal of that used in previous AGMA standards It is now greater than 1 0 In earlier AGMA standards it was less than 1 0 12 23 Driving The software needs to know whether pinion or gear is driving when deter mining the optimum addenda modification for maximum scoring resistance The driving member influences load sharing between successive pairs of teeth and load distribution along the path of contact T his in turn influences the flash temperature and scoring resistance CHAPTER 12 AGMA 2001 2101 2 60 12 24 Reversed bending Usually a pair of gears rotate in one direction without torque reversals and the gear teeth are loaded on one side only For this case the gear teeth are subjected to one way bending or uni directional loading Some gears are loaded on both sides of the teeth and are subjected to reverse bending Examples are e idler gears e planet gears planetary or star gear systems e gearsets which have fully reversed torque loads In this case the strength of the gears is reduced 12 25 Number of contacts per revolution For a single pinion in mesh with a single gear each member has one contact per revolution Some gears have more than one cycle of load contact per revolution An epicyclic gearset planetary or star gear is shown below Sun Planet Annulus Sun The gear has Q contacts rev where Q n
57. ce hs 0 7303 0 7303 OK JI Cancel Figure 12 8 AGMA 2001 2101 Protuberance angle 12 15 Tool protuberance If the stock allowance has been activated under settings see 11 2 1 then the cells will appear to define the amount of protuberance o A cutting tool is provided with protuberance so that it will generate a relief in the tooth profile of the generated gear in the area of the tooth fillet See Fig 12 5 This relief allows the finishing shaving cutter or grinding wheel to run out without notching the root fillet The protuberance of the cutter is usually made somewhat larger than the amount of finishing stock i e CHAPTER 12 AGMA 2001 2101 2 52 do gt Us COS bn On 12 16 Quality according to AGMA The required quality for both the pinion and gear can be defined indepen dently The scale runs from 15 best to 3 worst according to AGMA 2000 or from 2 best to 11 worst according AGMA 2015 In ISO 1328 also the low numbers are for better quality like in AGMA 2015 Under settings see 11 1 3 the used tolerance standard can be choosen The actual quality achieved is dependent upon the manufacturing process used 12 17 Power P is the power transmitted per gear mesh For multiple power paths load sharing must be considered Branched offsets If the pinion meshes with two or more gears or the gear meshes with two or more pinions use the power of the more highly loaded branch Epicyclic Gearboxes Th
58. cified by assigning Sp gt 1 0 and or SH gt 1 0 Since pitting fatigue is slowly progressive and pitted gear teeth usually generate noise which warns the gearbox operator that a problem exists pitting failures are not usually catastrophic Bending fatigue frequently occurs without warning and the resulting damage may be catastrophic The safety factors should be chosen with regard to the uncertainties in the load and material data and the consequences of a failure Small safety factors can be used where the loads and material data are known with certainty and there are small economic risks and no risk to human life However if the loads and material data are not known with certainty and there are large economic risks or risks to human life larger safety factors should be used The bending fatigue safety factor is frequently chosen greater than the pitting safety factor Sp gt Sy since bending fatigue may be catastrophic However Sp should not be too large because it leads to coarse pitch teeth which may be noisy and prone to scoring failures Choosing a safety factor is a design decision that is the responsibility of the engineer It must be carefully selected accounting for the uncertainties in e External Loads Static or dynamic Load variation time history Transient overloads Loads from test data or service records e Component Geometry Dimensional tolerances Variation in fabrication Surface finish
59. controlled by pinion Required life H 132 h Actual life Heff 133 h Given Fid ratio was slightly changed D 141 to achieve required life g Center distance C 3 6788 in Pitch diameter pinion d 1 2263 in Net Face width F 1 0204 in Normal diametral pitch Pnd 12 5033 1fin O Previous Recalculate Next Figure 10 6 GEARCALC Wizard page 4 10 4 1 Center distance The standard center distance C a is dependent upon ratio tooth pitch and pressure angle Standard Center Distance A pair of gears may operate on modified or standard center distance The standard center distance is given by Csrp Na Np 2 Paa cos Ws For gears that operate on standard centers C Csrp CHAPTER 10 GEARCALC WIZARD 2 28 Modified Center Distance For gears that operate on modified centers the center distance modification is AC C C srp 10 4 2 Pitch diameter pinion The value for the pitch diameter of the pinion is normally calculated and entered here The value can be directly entered by checking the box by the side of the field 10 4 3 Net face width The net contacting face width F b excludes any face width that is non contacting because of chamfers or radii at the ends of the teeth For double helical gears the net face width equals the total face width minus the gap between the helices 10 4 4 Normal diametral pitch The normal diametral pitch is shown if US customary units are selected as a default see 1 3 3
60. d to obtain the desired core properties then the teeth are cut and finished followed by the nitrid ing process fle gears are placed in an ammonia gas atmosphere where nitrogen is absorbed into the surface bayers of the gear teeth and forms hard fron nitrides Because nitriding is performed at the relatively low temperature of 950 1050 F and there is no quench the distortion due to heat treatment is small Surface hardness ranges from HB 432 for alloys such as AISI 4340 to HB 654 for Nitralloy 135M and 2 5 chrome alloys The practical limit on case depth is about 0 025 in which limits the application of nitriding to pitches finer than approximately Pra 8 e Induction hardened gear teeth are heated by electromagnetic induc tion from a coil or inductor and are immediately quenched Because only the surface layers of the gear teeth are hardened heat treat dis tortion is minimized Very tight controls of every step of the process are necessary for satisfactory results and it is best for high volume pro duction where the process can be optimized Several gears from each production run must be destructively inspected for case depth to ensure that the induction hardening is properly controlled Carbon content of induction hardened gears is usually 0 40 or 0 50 Plain carbon steels e g AISI 1050 may be used for small gears while alloys such as AISI 4350 may be used for large gears Note ANSI AGMA 2001 D04 Figure 18 allows interp
61. e can be defined under settings The values in the left column are for the pinion the values on the right For the gear Figure 10 2 GEARCALC Wizard page 2 10 2 1 Material selection The material of the gears can be selected from the material database The strength is dependend of material type treatment and quality 10 2 1 1 Material treatment There are different possibilities for heat treatment through hardened ni trided induction hardened and case hardened materials e Through hardened annealed normalized or quenched and tempered Carbon content ranges from 0 30 to 0 50 Alloy content ranges from plain carbon steels e g MSI 1040 for tiny gears to Cr Ni Mo alloys e g AISI 4340 for large gears The best metallurgical properties are obtained with quenched and tempered steels Hardness ranges from HB 180 for lightly loaded gearsets to the limit of machinability approx imateby HB 360 for highly loaded gears CHAPTER 10 GEARCALC WIZARD 2 13 Material Own input Label Material type Type of treatment Hardness Steel Grade 1 HB250 AGMA Through hardened steel alloyed through hardened 250F Steel Grade 1 HB300 AGMA Through hardened steel alloyed through hardened 300F Steel Grade 1 HB350 AGMA hrough hardened lloyed through hardened 350 Steel Grade 1 HB400 AGMA Steel Grade 2 HB200 AGMA Steel Grade 2 HB250 AGMA Steel Grade 2 HB300 AGMA v Steel Grade 2 HB350
62. e degree of load sharing depends on the number of planets accuracy of the gears and mountings provisions for self aligning and compliance of the gears and mountings A load increasing because of shocks can be considered using the overload factor K see 12 20 The sizing button can be used to let the software calculate the maximum power that can be transmitted with the gear set so that the required safeties are reached see 11 3 12 18 Pinion speed Input the rotary speed of the pinion np as a positive number The pinion is the gear with the smaller number of teeth Here the values for the pinion are taken from the left columns of input data CHAPTER 12 AGMA 2001 2101 2 53 12 19 Life A gearset s design life L is determined by the particular application Some gears such as hand tools are considered expendable and a short life is ac ceptable while others such as marine gears must be designed for long life Some applications have variable loads where the maximum loads occur for only a fraction of the total duty cycle In these cases the maximum load usually does the most fatigue damage and the gearset can be designed for the number of hours at which the maximum load occurs Typical design lives Application No Cycles Design Life L hr Vehicle 10 105 3000 Aerospace 10 10 4000 Industrial 101 50000 Marine 1019 150000 Petrochemical 10 10H 200000 The number of load cycles per gea
63. e the surface finish profiles and spacing but the helix lead is not changed significantly The pinion and gear are then installed in the housing and a contact pattern is obtained by rolling the gears together under a light load with marking compound applied to the gear teeth Based on the contact pattern obtained from this test the pinion is shaved to match the lead of the gear The process is repeated until the desired no load contact pattern is obtained Pinion proportion modifier This setting allows consideration of the degree of alignment change as the pinion is offset under a defelction of the bearings The Cpm value alters the pinion proportion factor Cp based on the location of the pinion relative to its bearing center line Mesh alignment factor The mesh alignment factor Cma accounts for the misalignment of the axes of rotation of the pitch cylinders of the mating gear elements from all causes other than elastic deformation The factor is dependend on the face width and the follwing options e Open This type of gearing is used in such applications as rotary grinding mills kilns dryers lifting hoists and winches These gears are frequently of low accuracy because their large size limits the practicable manufacturing methods The gear shafts are usually supported by sep arate pedestal bearings with the gears covered by sheet metal shields The gear mesh alignnent is dependent on the skill and care exercised in the mounting
64. elections of a profile shift coefficient Several proposals are made by the software 10 6 1 Proposals for profile shift factors e General purpose The profile shift factor is calculated according to a formula by Robert Errichello _ de u l utd 3u ND util T for speed reducers 41 for speed increasers e Balanced specific sliding The specific sliding at the beginning and the end of the contact has the same values on the root of the gears e Best strength against bending Choose x for the best bending strength CHAPTER 10 GEARCALC WIZARD 2 31 e Best strength against scoring Choose x for the best scoring resis tance e Limit for undercut The profile shift factor should normally not be less than this value for the undercut boundary e Limit for minimal topland The profile shift factor should not be bigger than this value If you choose a bigger value the addendum has to be shortened to avoid a pointed tip 10 6 2 Enter pinion profile shift factor This field allows the user to enter the appropriate profile shift coefficient setting based on the above proposals Chapter 11 Calculation Settings 11 1 GEARCALC Settings GearCalc AGMA 2001 AGMA 925 Permissible deviation of ratio 5 0000 Option for tip shortening Standard working depth v Manufacturing tolerance according acma 2000 A88 v Use default equation for ratio width to pitch diameter b d Factor C1 spur and single helical
65. ence line with a different tooth thickness snt Set addendum of tool Tool line Definition of reference profile Use factors to module Use absolute values Addendum gear 1 Tool tooth thickness 1 5708 1 4000 0 9941 in O Tool addendum Root diameter Addendum gear 2 2 5 7929 in U Tool tooth thickness 1 5708 Tool addendum 1 4000 Root diameter Figure 12 6 AGMA 2001 2101 Addendum of tool CHAPTER 12 AGMA 2001 2101 2 50 Where Snt normal tooth thickness of the tool at the tool line This thickness is usually equal to 7 2 in terms of Pnd 1 0 for gears that are not subse quently finished by shaving grinding skiving etc For gears that are finished by one of the above mentioned finishing methods the tooth thickness of the rack type cutting tool is sometimes made thinner than 7 2 to provide stock allowance for finishing i e Sn m 2 2 u hapo addendum of tool measured from the tool datum line Papo tip radius of tool o protuberance of tool The tool addendum can also be calculated by a given root diameter using the convert button 12 12 Tool tip radius A tool tip radius p po is added to the design is used to remove stress raisers in the finished gear root A value can be entered for the gear and pinion individually directly into the cells provided The sizing button to the side of the cells can be usd to calculate the maximum radius that can be used
66. erature controls the operating viscosity of the lubricant which is entrained into the gear tooth contact The entrained lubricant is in thermal equilibrium with the surfaces ot the gear teeth and its viscosity determines the thickness of the EHD oil film lt is therefore imperative that an accurate value of gear bulk temperature be used as input to Scoring In some cases the equilibrium gear bulk temperature may be significantly higher than the temperature of the oil supplied to the gear mesh For example reference tested high speed single helical gears typical of gears used in the turbo machinery of the petro chemical industry With oil nozzles supplying lubricant to the outgoing side of the gear mesh the temperature of the pinion teeth was 180 deg F 76 deg F rise over the inlet oil temperature at a pitch line velocity of v 20 000 fpm and 275 deg F 171 deg F rise at v 40 000 fpm For the mating gear the temperature was 138 deg F 34 deg F rise at V 20 000 fpm and 208 deg F 104 deg F rise at v 40 000 fpm CHAPTER 14 AGMA 925 SCORING 2 13 This example indicates that the bulk temperature of ultra high speed gears may be significantly higher than the temperature of the oil supply 171 deg F rise at v 40 000 fpm and that the pinion can be very much hotter than the gear 67 deg F difference at v 40 000 fpm 14 6 Scuffing temperature In the list can the user to select from three options for determining the sc
67. fts and housing Centrifugal Effects Centrifugal forces may cause misalignment for high speed gears External Effects Misalignment with coupled machines Gear tipping from external loads on shafts External thrust from shaft couplings 10 3 6 Dynamic factor The dynamic factor accounts for internally generated gear tooth loads which are induced by non uniform meshing action transmission error of gear teeth If the actual dynamic tooth loads are known from a comprehensive dynamic analysis or are determined experimentally the dynamic factor may be cal culated from CHAPTER 10 GEARCALC WIZARD 2 25 K Wa W W where W Nominal transmitted tangential load and Wa Incremental dynamic tooth load due to the dynamic response of the gear pair to the transmission error excitation not including the transmitted tangential loads If the factor is calculated according AGMA the Transmission Accuracy Grade Anu is used Anu is calculated following formula 21 in AGMA2001 page 15 Therefore Anu is not always identical but close to the gear quality CAUTION This factor has been redefined as the reciprocal of that used in previous AGMA standards It is now greater than 1 0 In earlier AGMA standards it was less than 1 0 10 3 7 Driving GEARCALC needs to know whether pinion or gear is driving when deter mining the optimum addenda modification for maximum scoring resistance The driving member influences load sharing between succes
68. g to AGMA925 14 11 Thermal contact coefficient The thermal contact coefficient Bm accounts for the influence of the material properties of pinion and gear Bm YAm Dui CM1 Bm Anz PM2 CM2 For martensitic steels the range of heat conductivity Am is 41 to 52 N sK and the product of density times the specific heat per unit mass py Cm is about 3 8N mm K so that the use of the average value By 13 6N mms K for such steels will not introduce a large error when the thermal contact coefficient is unknown CHAPTER 14 AGMA 925 SCORING 2 75 14 12 Surface roughness The initial as manufactured surface roughness R of the working profiles of gear teeth depends primarily on the manufacturing method The surface roughness to be used as input data for Scoring should be the surface rough ness micro in rms of the gear tooth profiles after they are run in The degree of improvement in surface roughness depends on the surface hardness of the gear teeth the initial as manufactured surface roughness and the operating conditions of load speed and lubrication regime The surtace roughness of slow speed low hardness gears with an initial surface roughness of 80 micro in rms might have up to a 4 1 improvement by running in to 20 micro in rms Medium hard medium speed gears commonly have 2 1 improvements by running in from say 60 micro in rms to 30 micro in rms while the sur faces of high speed carburized gears may improve f
69. gear mesh to promote removal of the high points of the gear tooth working surface Double Helical For double helical gears the mesh alignment factor is calculated based on one helix one half of the net face width NOTES It usually is not possible to obtain a perfectly uniform distribution of load across the entire face width of an industrial gearset Misalignment between the mating gear teeth causes the load and stress distribution to be non uniform along the tooth length The load distribution factor is used to ac count for the effects of the non uniform loading It is defined as the ratio of the maximum load intensity along the face width to the nominal load intensity 1 e Km Cm Maximum Load Intensity W F Variations in the load distribution can be influenced by Design Factors Ratio of face width to pinion diameter CHAPTER 10 GEARCALC WIZARD 2 24 Bearing arrangement and spacing Internal bearing clearance Geometry and symmetry of gear blanks Material hardness of gear teeth Manufacturing Accuracy Gear housing machining errors shaft axes not parallel Tooth errors lead profile spacing amp runout Gear blank and shaft errors runout unbalance Eccentricity between bearing bores and outside diameter Elastic Deflection of Gear tooth bending Gear tooth hertzian Pinion shaft bending and torsional Bearings oil film or rolling elements Housing Thermal Distortion of Gear teeth gear blank sha
70. guage for messages Messages are either in the same language as the user interface or as in the reports The setting for this is in the KISS ini file in section SETUP in the line MESSAGELANG 0 represents the language of the messaging language of report while 1 represents the language of the messaging language of user interface 2 2 System of Units KISSsoft recognises two unit systems metric and imperial US Customary Units If the value in line UNITS in section SETUP of the KISS ini file is 0 then KISSsoft uses the metric system while 1 will indicate that the imperial system should be used Using Extras System of Units the unit system can be toggled This setting will be recorded in your personal Registry see 7 2 but not in the KISSini see 7 1 2 3 User Directory If a calculation file or report needs to be opened or saved KISSsoft will suggest your personal user directory as the location This trait saves time by avoiding searching through the entire directory structure of the computer system The user directory can be defined in the AKJSS ini file in section SETUP in the line USERDIR see 7 1 By default this is the directory USR in the installation directory The user directory is ignored if an active working project has been chosen see 3 3 In this case KISSsoft first suggests the project directory CHAPTER 2 SETTING UP KISSSOFT 1 13 2 4 Definition of own Standard Files If the same or similar calcul
71. h filter 2 75 Settings 2 32 GEARCALC Wizard 2 32 Graphics number of points 2 40 Graphics X axis unit 2 40 Ratio permissible deviation 2 33 Setting AGMA 2001 2 36 Setting AGMA 925 2 40 Settings choosing factors 2 38 Stress cycle factors 2 37 Tooth form factor calculation 2 Sr Spur Gearsets 2 5 Standard tip to root clearance 2 33 Standard working depth 2 33 Start parameter 1 13 Status Bar 1 10 Stock allowance 2 48 Settings 2 36 Stress cycle factor devia INDEX 3 8 GEARCALC Wizard 2 9 System of Units 1 12 Tables 1 7 Thinning for backlash 2 47 Tip radius of tool 2 50 Tip shortening 2 33 Toggle Units 1 8 Toolbar 1 3 Tool Addendum Settings 2 34 Tool addendum 2 48 Tool Tips 1 10 Tool tip radius 2 50 Tooth form factor AGMA 2001 2 65 GEARCALC Wizard 2 9 Tooth thickness tolerances 2 47 Type of Helix 2 5 User Directory 1 12 User Interface 1 2 Using full radius GEARCALC Wizard 2 35 Value Input Field 1 6
72. he associated calculation module started If a name is given without a path the file will be loaded from a pre defined directory loca tion CHAPTER 2 SETTING UP KISSSOFT 1 14 LANGUAGE Integer KISSsoft starts with given language for user interfaces and reports 0 German 1 En glish 2 French 3 Italian 4 Spanish 11 English with imperial units DEBUG Filename A file with debug information will be writ ten which can be helpful in the identification of errors It is recommended to give the file name complete with path in order to easily locate the log file Filename The calculation module relating to the file is started and the file loaded A link from KISSsoft with the corresponding file ending in Windows is also possible Start of KISS soft by double clicking on a calculation file Chapter 3 Project Management KISSsoft has its own project management system which supports the user in helping to order multiple calculation modules and associated external files The major part of the management system is the project tree see 1 2 2 Here can be seen which projects are opened i e active in the workspace and all information about the files which belong to an individual project 3 1 Create open and close projects A new project is created using Project New This opens a Dialog in which the name of the project the directory descriptions and comments as well as
73. heoretical involute profile modification The type of profile modification has an impact on the calculation of the scoring safety The Distribution factor or Force Distribution factor XGam is calculated differently depending on the type of profile modification There is a significant difference between cases with and without profile correction CHAPTER 14 AGMA 925 SCORING 2 72 The difference between profile correction for high load capacity gears and thise for smooth meshing however is not so important The calculation procedure requires that the C of the profile correction is sized according to the applied forces but does not indicate an exact value 14 4 Oil temperature The Oil Temperature Oog is the input required for the calculation of the effective oil viscosity 14 5 Tooth temperature The tooth temperature bulk temperature O y that is relevant to the anal ysis of flash temperature and film thickness is the bulk temperature of the surfaces of the gear teeth just before they engage The gear tooth bulk tem perature is an important component of the total temperature that occurs during engagement of the gear teeth which consists of the bulk temperature plus the instantaneous flash teruperature rise i e Op Ou Of It is the total contact temperature O p which controls the scoring scuffing mode of gear tooth failure Besides being an important contributor to the gear tooth total temperature the bulk temp
74. ile name and directory required for storage 13 2 4 Reload spectrum An existing table containing a saved load spectrum can be reloaded using the button indicated A directory window opens to allow the user to select the file required Chapter 14 AGMA 925 Scoring The AGMA925 A03 Effect of Lubrication on Gear Surface Distress is currently the only standard that calculates the conditions in the lubrication gap over the tooth contact AGMA925 describes the calculation of the height of the lubrication gap taking into account the curvature of the flanks proper ties of the lubricant sliding speed and the local stress load On this basis the standard calculates the probability of wear by means of metallic contact by the surfaces if the lubrication gap is too small The standard itself does not provide any notes on protection against micropitting It is known however from literature and research results that there is a direct correlation between the minimum lubrication gap size and the occurrence of micropitting The calculation method can therefore be used when gearing is to be optimized to resist micropitting The probability of the occurrence of scuffing is also determined in accor dance with AGMA925 This calculation has the same basis Blok s equation as the calculation of scuffing in accordance with the flash temperature cri teria under DIN3990 part 4 The determination of the permitted scuffing temperature under AGMA925 is somewh
75. ing into service e Service Conditions Environment thermal chemical etc Installation procedures Operation procedures Maintenance procedures Consider the need to conserve material weight space or costs Most impor tantly consider e Consequences of Failure Nature of failure modes Risk to human life Economic costs Environmental impact CHAPTER 10 GEARCALC WIZARD 2 12 10 2 GEARCALC page 2 GearCalc AGMA 2001 Lifetime Miner Rule AGMA 925 Des pon Select material data Material pinion steel Grade 2 HRC58 64 AGMA v The strength of the material is dependend on material type surface hardness heat treatment and material grade Grade 1 corresponds to general Material Steel Grade 2 HRC58 64 AGMA wl commercial quality steel grade 2 high quality steel un eee with a proper process control and grade 3 for the best quality for example for aircraft use Case carburized steel case hardened Case carburized steel case hardened r Quality AGMA 2000 intl eu ES The quality is dependend on the manufacturing process better quality corresponds to a higher Finishing method Ground v Ground w value in AGMA 2000 and a lower value in AGMA 2015 Proposals AGMA 2000 AGMA 2015 Grinding 11 las Hobbing B as The selected finishing method has an influence on the reference profile used This reference profil
76. ing method 1 Finish cut Many gears are not shaved or ground Accuracy and surface roughness of as cut gear teeth depend on the condition of the cutting machine the accuracy and rigidity of the fixtures which hold the gear the quality of the gear blank and the quality of the cutter For gears that are cut only the most accurate are through hardened gears whose teeth are cut after the gear blanks are heat treated Carburized gears are cut and then heat treated and usually must be finished by grinding to remove the distortion due to the heat treatment Nitrided and induction hardened gears usually are not ground because they have low distortion due to heat treatment The shallow case depth of nitrided gears makes CHAPTER 10 GEARCALC WIZARD 2 17 grinding risky Sometimes nitrided gears are shaved or ground before nitriding to obtain good surface finish and accuracy 2 Shaving A finishing process which uses a pinion shaped shaving cutter with hardened steel helical teeth that have radial gashes which act as cut ting edges The shaving cutter is run in tight mesh with the gear to be shaved with the axes of cutter and gear skewed Axial sliding removes small amounts of material Shaving is frequently used as a final finish ing operation on through hardened gears and sometimes as a finishing operation before nitriding It can be applied to both external and in ternal spur and helical gears Shaving can produce profile modification e g
77. ion For crit ical service Yy gt 0 8 is used while Yy gt 0 9 is used for general applications The option Yy gt 1 0 and Zy gt 1 0 is not recommended by AGMA and could be used for optimum contitions Note Yy for flanc induction hardened steel see chapter 10 2 1 1 11 2 5 Calculation of tooth form factor This options allows consideration of the tooth form which may concentrate loading on a specific area of the tooth Consideration of loading expected at the tip or at HPSTC can be specified This setting has only an influence on spur and LACR gears 11 2 6 Reliability The reliability factor Kpr accounts for the statistical distribution of fatigue failures found in materials testing The required design life and reliability varies considerably with the gear application Some gears are expendable and a high risk of failure and a short design life are acceptable Other applications such as marine gears or gears for power generation require high reliability and very long life Special cases such as manned space vehicles demand very high reliability combined with a short design life Reliability R Application Failure Frequency 0 9 Expendable gears Motor vehicles 1 in 10 0 99 Usual gear design 1 in 100 0 999 Critical gears Aerospace vehicles 1 in 1000 0 9999 Seldom used 1 in 10000 CHAPTER 11 CALCULATION SETTINGS 2 38 11 3 Choosing Bending Pitting safety fac tors An extra margin of safety can be spe
78. ion engine with many cylinders e Medium shock Multi cylinder internal combustion engine with few cylinders e Heavy shock Single cylinder internal combustion engine Examples of operating characteristics of driving machines e Uniform Generator centrifugal compressor pure liquid mixer e Light shock Lobe type blower variable density liquid mixer e Medium shock Machine tool main drive multi cylinder compressor or pump liquid 4 solid mixer e Heavy shock Ore crusher rolling mill power shovel single cylinder compressor or pump punch press Operating Characteristics of Driven Machine Operating Characteristics of Driving Machine uniform light shock medium shock heavy shock uniform 1 00 1 25 1 50 1 75 light shock 1 10 1 35 1 60 1 85 medium shock 1 25 1 50 1 75 2 00 heavy shock 1 50 1 75 2 00 2 25 CHAPTER 10 GEARCALC WIZARD 2 21 10 3 5 Load distribution factor The factor allows for the variation in contact brought about by differing man ufacturing processes operating conditions and mounting error on assembly The load distribution factor can either be defined directly or calculated by the empirical method of AGMA 2001 2101 This empirical method is rec ommended for normal relatively stiff gear designs which meet the following requirements 1 Net face width to pinion pitch diameter ratios less than or equal to 2 0 For double helical gears the gap is not
79. l Grade 2 HB200 AGMA Steel Grade 2 HB250 AGMA Steel Grade 2 HB300 AGMA v Own input Steel Grade 2 HB350 AGMA Steel Grade 2 HB400 AGMA Steel Grade 1 HRC50 Type A AGMA Steel Grade 1 HRCS4 Type A AGMA Steel Grade 2 HRC50 Type A AGMA Material Be careful when you use this option You have to enter data in accordance with AGMA2001 or AGMA2101 GEARcalc does not check wether the material data entered is correct or not IF you are not very experienced better use one of the preset material Steel Grade 2 HRC54 Type A AGMA Label Steel Grade 2 HRC58 64 AGMA Steel Grade 1 HRCSO Type B AGMA Steel Grade 1 HRC54 Type B AGMA Material type Case carburized steel Steel Grade 2 HRCSO Type B AGMA pu Steel Grade 2 HRC54 Type B AGMA Type of treatment case hardened Steel Grade 1 HRCSS 64 AGMA Steel Grade 2 HRCS8 64 AGMA Steel Grade 2 3 HRCS8 64 AGMA Steel Grade 3 HRCS8 64 AGMA amp Allowable contact stress 225000 00 IbF in2 Hardness 60 HRE vw Allowable bending stress 65000 00 IbFfin Yield point 5 119221 0255 lbffin2 Youngs modulus 30000013 20 IbFfin Poisson number 0 30 Density 488 81 lb ft gt Figure 12 10 AGMA 2001 2101 Material The material of the gears can be selected from the material database The strength is dependend of material type treatment and q
80. nal gear in a planetary gearset is fixed it is analyzed as if it were rotating at the planet carrier speed star gear train the internal gear has Q contacts per revolution of the internal gear where Q number of planets An example of a split power train branched gearset is shown below gear pinion gear CHAPTER 10 GEARCALC WIZARD 2 27 In this example if the pinion is the driver or is driven it has 2 contacts rev If the pinion is an idler it has 1 contact per revolution and reversed bending The mating gears each have 1 contact rev 10 4 GEARCALC page 4 GearCalc AGMA 2001 Lifetime Miner Rule AGMA 925 Description Select solution Presize case 1 A first solution is shown Operating center distance c 3 6788 in Pinion operating pitch diameter d 1 2263 in The solution can be modified by constraining center Net Face width F 1 0204 in distance pitch diameter of pinion diametral pitch or Normal diametral pitch Pad 12 5033 1fin face width Axial Face contact ratio mF 0 Please press Recalculate after changing one of these Solid rotor volume Y 31 3343 in values Pitch line velocity vtw 404 238 ft min Transmitted tangential load Ft 833 6418 lbf If you are satisfied with the solution accept it with the Contact load Factor For pitting resistance K 782 0762 bf in Next button Unit load factor For bending strength UL 9992 5 Ibf Jin Surface durability controlled by pinion Bending strength
81. ndows users will recog nise common elements of the interface such as Menus docking windows di alog boxes Tool tips and status bars As the development has heeded inter nationally recognised style guide lines the windows user will quickly become familiar with the operation of KISSsoft 1 1 Menus Context Menus and Toolbar In the main menu using File the calculation files can be opened saved sent as e mail file properties examined and KISSsoft ended The project management see 3 in KISSsoft is operated using the main menu Project as well as the project tree see 1 2 2 Projects can be opened closed and activated or files either added or removed from a project and project properties examined The single dock windows see 1 2 of the user interface can be hidden or shown using the options in the main menu View If the report facility or Help Viewer has been activated then the Action Input Window see 1 3 can be used to return to the data entry tab for the calculation module The main menu options Calculation Report and Graphic are only active if a calculation option is open The Actions of these menus depend partly on the current calculation module In the menu Calculation the current calculation can be carried out see 4 and the module specific settings changed 1 2 CHAPTER 1 USER INTERFACE 1 3 In the main menu Report there is an Action to build and open a report The report will always be produced for the current calcul
82. ng machines e Uniform Electric motor steam turbine gas turbine e Light shock Multi cylinder internal combustion engine with many cylinders e Medium shock Multi cylinder internal combustion engine with few cylinders e Heavy shock Single cylinder internal combustion engine Examples of operating characteristics of driving machines e Uniform Generator centrifugal compressor pure liquid mixer e Light shock Lobe type blower variable density liquid mixer e Medium shock Machine tool main drive multi cylinder compressor or pump liquid 4 solid mixer e Heavy shock Ore crusher rolling mill power shovel single cylinder compressor or pump punch press Operating Characteristics Operating Characteristics of Driven Machine of Driving Machine uniform light shock medium shock heavy shock uniform 1 00 1 25 1 50 1 75 light shock 1 10 1 35 1 60 1 85 medium shock 1 25 1 50 1 75 2 00 heavy shock 1 50 1 75 2 00 2 25 12 21 Load distribution factor This factor allows for the variation in contact brought about by differing man ufacturing processes operating conditions and mounting error on assembly The load distribution factor Km can either be defined directly or calculated CHAPTER 12 AGMA 2001 2101 2 55 by the empirical method of AGMA 2001 2101 This empirical method is rec ommended for normal relatively stiff gear designs which meet the following re
83. not yet been read Normally all messages will be shown in the Message Window and also in a message box The display of information and warnings in a message box can be changed using Extras Settings see 7 CHAPTER 1 USER INTERFACE 1 6 1 2 6 The Information Window The Information Window shows information opened by the user via an Info Button of the calculation module see 1 3 1 Using a context menu see 1 1 the information can be zoomed and printed 1 2 7 Contents and Index Contents and index of the manual are also available as dock window If a list entry is selected using a double click the Help Viewer see 1 5 is opened and the required chapter is show 1 2 8 Graphics Windows Any number of graphics windows can be opened simultaneously in KISSsoft which can also be docked to the sides of the software In this way all of the relevant graphics and diagrams for the calculation are in view at all times Graphics windows have their own toolbar which can be used to save print or zoom the current graphic Using the Action Lock in the toolbar the current data in the window is frozen The window is then prevented from updating by subsequent calculations The lock capability enables the retention of results and therefore a direct comparison with the current settings of the calculation 1 3 Input Window The most significant region of the KISSsoft workspace is occupied by input for the calculation In this region all the data for
84. ns available in the drop down list to plot X axis unit values These are in terms of roll angle length of path of contact and diam eter Chapter 12 AGMA 2001 2101 GearCalc AGMA 2001 Lifetime Miner Rule AGMA 925 Normal diametral pitch Pressure angle Helix angle Center distance No of teeth Face width Profile shift coefficient Thinning For backlash x As Stock allow for Finishing per sid u Tool addendum Tool tip radius Basic rack addendum Tool protuberance angle Tool protuberance Quality AGMA 2000 If metric units mm N kW are selected AGMA 2101 D04 is used for the calculation while AGMA 2001 D04 is used for the selection of US Customary units in Ibf hp For US Customary units also diametral pitch Pnd is used has Pare hy a P 12 5033 1 in p 20 0000 m 0 0000 2 E 3 6788 in m 15 0000 75 0000 1 0205 1 0205 i 0 0000 1 0746 m 0 0019 0 0019 i 0 0662 0 0662 1 4000 1 4000 3 0 4718 0 4718 m 0 9223 0 9223 3 10 0000 10 0000 29 0 0672 0 0672 11 0000 11 0000 Power Pinion speed Life Overload Factor Load distribution Factor Dynamic Factor Driving Reversed bending Number of contacts per revolution Material pinion Material gear P 6 8288 hp n 1260 0000 rpm L 131 8822 h Ko 1 0000
85. olation of Yn for through hardened gears However no guidance is given for flame induction hardened gears In lieu of guidance from AGMA for flame induction hardened gears the same Yy curve for carburized and flame induction hardened gears e Carburized gears are first cut then heated in a carbon atmosphere usually gas carburizing which causes carbon to diffuse into the sur face layers of the gear teeth The gears are either quenched from the carburizing temperature or cooled reheated and quenched later Most gears are tempered at 300 400 F after carburizing and quenching Car bon content of carburizing steels range from 0 15 to 0 25 Low alloy steels e g AISI 8620 are used for small gears and moderate loads while CHAPTER 10 GEARCALC WIZARD 2 15 high alloy steels e g AISI 4820 are used for large gears and high loads Minimum surface hardness ranges from HB 615 to HB 654 Be cause carburized gears are subjected to a drastic quench from a high temperature the distortion is large and grinding is usually required to obtain acceptable accuracy 10 2 1 2 Material quality Material quality strongly influences pitting resistance and bending strength For high quality material the following metallurgical variables must be care fully controlled e Chemical coposition e Hardenability e Toughness e Surface and core hardness e Surface and core microstructure e Cleanliness inclusions e Surface defects flanks and roo
86. on Surface roughness um Necessary clamping force For shearing force transmission N For sealing N Tightening procedure According own definition Tightening factor niz P Final heat treated Rz 16 Ker N KerfD alpha Minim tightening factor scattering coef of friction Force input between gap and support alphelfin 1 beta 60 3 12 a2 10 33 9 AN 113 243 76 CONSISTENT NOT IN THE PROJECT Figure 1 3 The KISSsoft Report Viewer CHAPTER 1 USER INTERFACE 1 10 1 5 Help Viewer The KISSsoft Manual is shown in HTML Format in the Help Viewer Open the Manual using the contents or the index see 1 2 7 or by pressing F1 to open the Manual at a position showing information relevant to the current state of the program 1 6 Tool Tips and Status bar Wherever it is appropriate in KISSsoft Tool Tips have been added which provide concise informative messages describing the program elements Tool Tips appear automatically if the mouse is moved slowly over the program element More detailed information appears in the status bar for all Actions in the menus as soon as the mouse is moved over the menu item In the right region of the status bar the current status of the calculation is shown The second region from the right shows CONSISTENT when the results are current and INCONSISTENT when the calculation should be carried out again after one or more data edi
87. on top of the tool It is dependend on the pressure angle and the addendum of the tool 12 13 Basic rack addendum Tool dedendum The gear addendum is created by the tool dedendum for a topping tool Since topping tools which are also cutting the tip diameter are usual only for very small gears the dedendum of the tool is often bigger than the addendum of the basic rack hip So the basic rack addendum 7p is defining the outside diameter of the gear The outside diameter of the gear is d z cos 2 2 2 hip Pra Alternatively the input values for the basic rack addendum can be calculated from the outside diameters by pressing the convert button beside the field CHAPTER 12 AGMA 2001 2101 2 51 Calculate basis rack addendum Tip diameter gear 1 do 1 3472 in Tip diameter gear 2 Do 6 3178 in Figure 12 7 AGMA 2001 2101 Basic rack addendum The sizing button will set the values of the basic rack addendum to the values needed for constant tip clearance see 11 1 2 12 14 Tool protuberance angle If the stock allowance has been activated under settings see 11 2 1 then the cells will appear to define the protuberance angle a The convert button E at the side of the field can be used to enter a height value hy for the protuberance The protuberance angle is automatically adjusted for the new values on returning to the main dialog after pressing OK Calculate protuberance angle from height E Height of protuberan
88. ool Tips which give informa tion on the Actions in the toolbar as well as further explanation in the status bar see 1 6 1 2 Dock Window As well as the menu bar tool bar and status bar the dock windows are im portant elements of the KISSsoft user interface Dock windows are windows that are displayed either free floating or arranged to the sides of the appli cation Dock windows can be arranged one over the other a tab bar will be added in this case A dock window can be released by a double click on the title bar at the top A window can be shifted by clicking and holding the mouse button while CHAPTER 1 USER INTERFACE 1 4 Modules x Cylindrical gears 1 Connections Shaft Hub Connections E Interference f connections Zylindrischer Press Sitz MO1a Konischer Press Sitz MO1b Passfeder MO2a Keilwelle MO2b Zahnwelle MO2c P Polygon MO2d Scheibenfeder M02e be Bolzen und Stifte MO3a Bolts M040 1 Schweissverbindungen M080 Kleb und L tverbindungen M090 B ub E Various Figure 1 1 Calculation modules of KISSsoft over the title bar and then moving the mouse If the windows is close to the main window the new position for the window will be indicated Release the mouse button in order to set the window down in this position The customised arrangement of the windows will be saved in the Registry see 7 2 Dock windows can be hidden or shown using the menu View see 1 1
89. ort Generate is used to write a report for the calculation In addition the toolbar and function keys F6 provide quick and convenient access to this Action A module can have one or more reports The report relevant to the currently selecvted tab will be generated As a rule a report should only be generated if the calculation is consistent see 4 3 If this is not the case the report will be written with the current status strongly indicated This can be useful if it is only required to print a data set 1 20 CHAPTER 5 RESULTS AND REPORTS 1 21 In generating a report a RTF File is produced with the designation of the module as a file name The file will be stored in tmp Directory which is defined in the KISS ini File in section SETUP row TMPDIR see 7 1 The report will be shown in the KISSsoft report viewer as standard see 1 4 From Release 02 2007 other editors e g Windows Word can also be selected The report viewer can also be used to change save and print the report Important If the user returns to the input window from the report viewer then the report is lost In order to have the report for a longer period this must be saved with a user defined name 5 3 Drawing data Depending on the calculation module the Action Report Drawing data can be used to generate a report which can be used as a drawing ready for printing 5 4 Report settings Under Report Settings the automatic generation of the rep
90. orted by sep arate pedestal bearings with the gears covered by sheet metal shields The gear mesh alignnent is dependent on the skill and care exercised in the mounting and alignment of the shaft bearings e Commercial This classification pertains to low speed enclosed gear units which employ gears that are through hardened and hobbed or shaped or hobbed or shaped and surface hardened and which are not subsequently finished by shaving or grinding e Precision This classification pertains to low or high speed enclosed gear units which employ gears which are finished by shaving or grind ing CHAPTER 12 AGMA 2001 2101 2 57 e Extra Precision This classification pertains to high speed enclosed gear units which employ gears which are finished by grinding to high levels of accuracy The lead and profiles of the gear teeth are usually modified to compensate for load deflections and to improve the meshing characteristics 12 21 4 Mesh alignment correction factor Ce This selection can be used to account for improved corrective action after manufacturing for a better contact condition Some gearsets are adjusted to compensate for the no load shaft alignment error by means of adjustable bearings and or by re working the bearings or their housings to improve the alignment of the gear mesh Lapping is a finishing process used by some gear manufacturers to make small corrections in the gear tooth accuracy and gear mesh alignment
91. orts can be adjusted This Action will be available from Release 02 2007 5 5 Report templates KISSsoft has a template for each calculation module in which the form and content are already assigned These templates can be changed using any Text Editor or with the KISSsoft Report Viewer In this way every calculation can be formatted and output customised to a specific user requirements 5 5 1 Storage und Designations Every report template is stored in directory lt KISSDIR gt User specified des ignations have the Structure MMM Mlsz rpt that summarise the following dimensions CHAPTER 5 RESULTS AND REPORTS 1 22 MMMM Designation of module e g M040 l historical allways I S Language of report s d german e english f french i italian s spanish a english imperial z historical always 0 rpt Designation Reports of calculations templates of reports end on rtf Examples Bolted joints calculation MOJOLDO RPT M040USER RPT german issue standard issue over interface becomes file M040USER OUT Spur gear calculation Z012LD0 RPT Z012USER RPT ZIOGEAR1 RPT spur gear pair german issue standard issue over interface becomes file ZOIOUSER OUT print out over interface contains only data of gear 1 becomes file ZOIOGEAR1 OUT ZIOGEAR2 RPT issued over interface contains only data of gear 2 becomes file ZO10GEAR2 OUT ZO11LDO RPT Single gear german issue Z013
92. point number with 1 places in total inc digits and decimals and 12 decimal places s stands for a left justified character string Text ns stands for a right justified character string in a n symbol long field n is a whole number The data types must match the data types used in the program The value will be given out exactly in the position where the replacement character stands The Syntax of the formatting corresponds to the C C Standard Examples CHAPTER 5 RESULTS AND REPORTS 1 25 e 10 2f is a right justified floating point number with 10 places in the field and 2 decimal places e i is a whole unformatted number e 30s is a right justified character string in a 30 symbol long field if the number 30 was to be removed the string would be left justified Counter Example e 8 2i is an invalid format because a whole number has no decimal places e 10f2 gives a floating point with 10 positions in its field but the 2 decimal places are ignored and the number 2 is given as text Floating point numbers are normally given to 6 decimal places Variables The variable which should be actually given must be behind the replacement character in the same line The variable is marked in curly brackets If these brackets are removed then the variable name will be given as normal text Important The number of the replacement characters must match the num ber of bracket pairings Example f sheave O d
93. quirements 1 Net face width to pinion pitch diameter ratios less than or equal to 2 0 For double helical gears the gap is not included in the face width 2 The gear elements are mounted between bearings i e not overhung 3 Face widths up to 40 inches 4 Tooth contact extends across the full face width of the narrowest mem ber when loaded The input values used for the empirical method for the load distribution factor calculation can be found by pressing the plus button beside the field Inputs for face load distribution factor Lead correction Factor Unmodified lead Pinion proportion modifier Large offset of pinion s1 s gt 0 175 Mesh alignment Factor Commercial enclosed gear units Mesh alignment correction Factor other conditions C Double helical gearing Figure 12 9 AGMA 2001 2101 Face load distribution factor 12 21 1 Lead correction factor Cmc The nominal setting Unmodified lead should be used when the machining quality is not known An option Lead properly modified by crowning or lead correction exists to define a well defined lead modification possible using high quality grinding machines Lead modification helix correction is the tailoring of the lengthwise shape of the gear teeth to compensate for the deflection of the gear teeth due to load thermal or other effects Certain gear grinding machines have the capability to grind the helical lead to almost any specified curve
94. r is calculated from the required life L the speed n and the number of contacts per revolution q N 060 L n q The sizing button can be used to calculate the lifetime where the required safety factors see 11 3 are reached 12 20 Overload factor The overload factor K makes allowance for the externally applied loads which are in excess of the nominal tangential load W Overload factors can only be established after considerable field experience is gained in a particu lar application For an overload factor of unity this rating mehtod includes the capacity to sustain a limited number of up to 200 momentary overload cycles typically less than four starts 8 hours with a peak not exceeding one second duration Higher or more frequent momentary overloads shall be considered separately In determining the overload factor consideration should be given to the fact that many prime movers and driven equipment individually or in combination develop momentarypeak torques appreciably greater than those determined by the nominal ratings of either the prime CHAPTER 12 AGMA 2001 2101 2 54 mover or the driven equipment There are many possible sources of overload which should be considered Some of these are system vibrations accelera tion torques overspeeds varitions in system operation split path load shar ing among multiple prime movers and changes in process load conditions Examples of operating characteristics of drivi
95. re Small safety factors can be used where the loads and material data are known with certainty and there are small economic risks and no risk to human life However if the loads and material data are not known with certainty and there are large economic risks or risks to human life larger safety factors should be used The bending fatigue safety factor is frequently chosen greater than the pitting safety factor Sp gt Sy since bending fatigue may be catastrophic However Sp should not be too large because it leads to coarse pitch teeth which may be noisy and prone to scoring failures Choosing a safety factor is a design decision that is the engineer s responsi bility It must be carefully selected accounting for the uncertainties in e External Loads Static or dynamic CHAPTER 10 GEARCALC WIZARD 2 11 Load variation time history Transient overloads Loads from test data or service records e Component Geometry Dimensional tolerances Variation in fabrication Surface finish notches stress concentrations Damage during assembly or incorrect assembly Quality assurance inspection techniques e Material Properties Handbook values or test data for strengths Material procurement control Heat treatment control Quality assurance inspection techniques e Design Analysis Is gear rating verified with computer programs AGMA2001 and Scoring Will gears be tested before go
96. rom 25 micro in rms to 17 micro in rms by running in Users should obtain data for the surface roughness after run in from tests on their particular gears In lieu of this data the following table gives typical values of surface roughness before and after run in Surface Roughing micro in rms Gear Tooth Manufacturing Method As Manufactured After run in Milling 64 125 32 64 Shaping 32 125 25 50 Hobbing 30 80 20 45 Lapping 20 100 20 40 Shaving 10 40 10 25 Grinding 10 40 10 25 Honing 6 20 5 15 14 13 Filter cut off of wavelength This setting can be used to define the wave length limit L for the surface roughness calculation No wavelength with an amplitude above this value will be considered Standard values are shown in the following table CHAPTER 14 AGMA 925 SCORING in 0 08 0 25 0 80 2 50 8 00 0 003149606 0 009842520 0 031496063 0 098425197 0 314960630 2 76 Part Ill Appendix Bibliography and Index Bibliography 11 i ADAMS J H and Godfrey D Borate Gear Lubricant EP Film Analysis and Performance Lubricant Engineer Vol 37 No 1 Jan 1981 pp 16 21 ANSI AGMA 110 04 AGMA STANDARD Nomenclature of Gear Tooth Failure Modes Aug 1980 AGMA 217 01 AGMA Information Sheet Gear Scoring Design Guide for Aerospace Spur and Helical Power Gears Oct 1965 AGMA 218 01 AGMA STANDARD Rating the Pitting Resi
97. s calculated from the required life L the speed n and the number of contacts per revolution q N 60 L n q 10 3 4 Overload factor The overload factor K makes allowance for the externally applied loads which are in excess of the nominal tangential load W Overload factors can only be established after considerable field experience is gained in a particu lar application For an overload factor of unity this rating mehtod includes the capacity to sustain a limited number of up to 200 momentary overload cycles typically less than four starts 8 hours with a peak not exceeding one second duration Higher or more frequent momentary overloads shall be considered separately In determining the overload factor consideration CHAPTER 10 GEARCALC WIZARD 2 20 should be given to the fact that many prime movers and driven equipment individually or in combination develop momentarypeak torques appreciably greater than those determined by the nominal ratings of either the prime mover or the driven equipment There are many possible sources of overload which should be considered Some of these are system vibrations accelera tion torques overspeeds varitions in system operation split path load shar ing among multiple prime movers and changes in process load conditions Examples of operating characteristics of driving machines e Uniform Electric motor steam turbine gas turbine e Light shock Multi cylinder internal combust
98. sets run at pitch line velocities up to 20 000 fpm Special units have reached 40 000 fpm e Single helical gears are usually cut by hobbing or shaping and may be finished by shaving or grinding Characteristics for double helical gearset are e Double helical gears share all the advantages of single helical gears while cancelling internally generated thrust loads This means smaller thrust bearings may be used especially important to reduce power losses in high speed units Helix angles up to 35 degrees are typical e One member of a double helical gearset must be free to float axially to share tooth loads between the two helices and to balance the internally generated thrust loads However external thrust loads on the floating shaft disturb the balance by unloading one helix while overloading the other helix All shaft couplings generate large thrust loads if not prop erly aligned and lubricated Elastomeric and steel diaphragm couplings with high axial stiffness may be used to reduce external thrust loads e Because the two helices cannot be perfectly matched the floating mem ber will continualiy shift axially in response to unequal thrust loads This shifting can cause axial vibration if tooth geometric errors are excessive e Double helical gears allow larger F d ratios than spur or single helical gears because the floating member shifts axially and compensates for some of the alignment errors CHAPTER 10 GEARCALC WIZARD 2 7
99. sive pairs of teeth and load distribution along the path of contact T his in turn influences the flash temperature and scoring resistance 10 3 8 Reversed bending Usually a pair of gears rotate in one direction without torque reversals and the gear teeth are loaded on one side only For this case the gear teeth are subjected to one way bending or uni directional loading Some gears are loaded on both sides of the teeth and are subjected to reverse bending Examples are e idler gears e planet gears planetary or star gear systems e gearsets which have fully reversed torque loads CHAPTER 10 GEARCALC WIZARD 2 26 10 3 9 Number of contacts per revolution For a single pinion in mesh with a single gear each member has one contact per revolution Some gears have more than one cycle of load contact per revolution An epicyclic gearset planetary or star gear is shown below Sun Planet Annulus Annulus Sun Planet Annulus The gear has Q contacts rev where Q number of planets For the example shown the sun gear has 3 contacts rev The planet gear has 1 contact rev because the loads from the sun gear and ring gear occur on opposite sides of the planet gear teeth The reverse bending that occurs on the planet gear teeth is accounted for with the flag for reversed bending see chapter 10 3 8 planetary gear train The internal gear has Q contacts per revolution where Q number of planets Although the inter
100. sses in the pinion and gear or to vary the relative amounts of approach and recess action For external gears with increased addendum there is a corresponding reduction in dedendum i e the teeth are moved outward from the center of the gear This profile shift as it is called in newer standards is expressed in terms of a profile shift coefficient or an addendum modification coefficient x where x is the proportionate distance in terms of unity normal diametral pitch by which the datum line of the generating rack e g hob and the generating pitch circle of the gear are separated The profile shift x is positive when the addendum is increased the tooth thickness is also increased by shifting the generating rack outward of the material of the generated gear Existing conventions vary for internal gears for AGMA2001 we define xa as positive when the reference generating rack is shifted out of the material of the gear resulting in an increased tooth thickness of the gear teeth The sum of the addendum modification coefficients is given by Xr T1 m Gear pairs with modified addenda may operate on the same standard center distance as unmodified gears if the addendum modification coefficients are chosen as follows Ta 431 Then Xx 0 and the gear pair may operate on standard centers Alternatively ia may be a positive number with the gear pair operating at a center distance larger than standard or Xx may be a negative number
101. stance and Bending Strength of Spur and Helical Involute Gear Teeth Dec 1982 AGMA 250 04 AGMA STANDARD Specification Lubrication of In dustrial Enclosed Gear Drives Sept 1981 AGMA 390 03 AGMA Gear Handbook Volume 1 Gear Classification Materials and Measuring Methods for Unassembled Gears Jan 1973 AGMA 420 04 Practice for Enclosed Speed Reducers or Increasers Using Spur Helical Herringbone and Spiral Bevel Gears Dec 1975 AGMA 421 06 AGMA STANDARD Practice for High Speed Helical amp Herringbone Gear Units Jan 1969 AGMA 925 A03 AGMA Gear Manufacturers Association Effect of Lubricantion on Gear Surface Distress Mar 2003 ANSI AGMA 2001 D04 AGMA STANDARD Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth 2004 ANSI AGMA 2101 D04 AGMA STANDARD Metric Edition of AGMA ANSI 2001 D04 2004 3 2 BIBLIOGRAPHY 3 3 12 Akazewa M Tejima T and Narita T Full Scale Test of High Speed High Powered Gear Unit Helical Gears of 25000 PS at 200 m s PLV ASME Paper No 80 C2 DET 4 1980 13 Benedict G H and Kelley B W Instantaneous Coefficient of Gear Tooth Friction ASLE Trans Vol 4 1961 pp 59 70 14 Blok H Les Temperatures de Surface dans les Conditions de Graissage Sons Pression Extreme Second World Petroleum Congress Paris June 1937 15 Blok H The Postulate About The Constancy of Scoring Temperature Interdisciplinary Approach to the Lubric
102. t factor CONTENTS 6 11 Calculation Settings 2 32 ILI GEARCALG 2a ARA Ri ed 2 32 11 1 1 Permissible deviation of ratio 2 33 11 12 Tipehorlenihg 2 22 2422 2 ewm ms 2 33 11 1 3 Manufacturing tolerance 2 34 11 1 4 Calculate ratio face width to pitch diameter 2 34 11 15 Tola ddendoa ee Sos 4 33x RR RR ke 2 34 11 1 6 Use full radius calculated at run time 2 35 12 AGMA 2001723101 e es 38220 eee ae 2 36 11 2 1 Don t use stock allowance and protuberance 2 36 11 2 2 Definition of reference profile 2 36 11 2 3 Manufacturing tolerance according to standard 2 37 11 24 Stress cycle factors o 2 cac 2 24 ooo o RS 2 37 11 2 5 Calculation of tooth form factor 2 97 1120 Bean p 4e we RUE RR PR Reno na 2 37 11 3 Choosing Bending Pitting safety factors 2 38 11 3 1 Factor for minimal normal tooth thickness at tip 2 39 114 AGMA Q95 soriana BR a ORE XX 2 40 11 4 1 Number of points for graphics 2 40 11013 ABE ER es ces iia dara 2 40 12 AGMA 2001 2101 2 41 121 Nomus module 2 425222 3x6 eR aaa 2 42 122 Moral diametral piel 22 249 ee eee ees ae 2 42 12 3 Normal pressure angle cuoco on o na as 2 42 I HS SES anne nen rd ne nen 2 43 12 5 Center defene con go som oc Ro o mo Dr a ad 2 44 126 Number of tech cec ede bee hee REED EEE YG 2 44 ELT Pub E hk hee he e X Rp RA AIRE E ES EG de d 2 44 CONTEN
103. t flllets e Grain size and structure e Residual stress pattern e Internal defects seams or voids e Microcracks e Carbide network e hetained austenite e Intergranular oxidation e Decarburization There are three basic grades of material CHAPTER 10 GEARCALC WIZARD 2 16 Grade 1 Commercial quality typical of that obtained from experienced gear manufacturers doing good work Modest level of control of the met allurgical variables Grade 2 High quality typical of aircraft quality steel with cleanliness certifled per AMS 2301 or ASTM A534 Close control of critical metallurgical variables Grade 3 Premium quality typical of premium aircraft quality with cleanliness certified per AMS 2300 or ASTM A535 Absolute control of all metal lurgical variables 10 2 1 3 Own input of material data Using the plus button next to the material list the material values can be entered directly by the user You have to be careful choosing the values since they are not checked by the software Important for the calculation are the allowable stress numbers Sac 0 rim and Sar O ri The youngs module is needed for the hertzian stress and the yield point for the static strength The hardness value is only used for documentation 10 2 2 Quality according to AGMA 2000 AGMA 2015 The quality for both the pinion and gear can be defined independently The actual quality achieved is dependent upon the manufacturing process used 10 2 3 Finish
104. three pages So you can get a geometry and strength report a report for the lifetime calculation and also a report for AGMA 925 calculation AGMA 2001 is used if US customary units are selected while AGMA2101 metric edition of AGMA 2001 is used if metric units are selected The formula signs in this manual are given as in AGMA 2001 and in brackets behind you will find the symbols as used in the metric system 2 2 CHAPTER 9 GEARCALC IN GENERAL 2 3 AGMA2001 AGMA2101 Description See Symbol Units Symbol Units C in a mm Operating center distance 12 5 Ce IK inne Mesh alignment correction factor 12 21 4 Oma I ina Mesh alignment factor Tala Grae Kime Lead correction factor 1221 1 Gag Kurs Face load distribution factor 12 21 Cmt Kya Transverse load distribution factor 12 216 Cpm K Hpm Pinion proportion modifier 12212 Cy Zw Hardness ratio factor for pitting resistance Km Ky Load distribution factor Tal Ko Ko Overload factor 12 20 Ky Dynamic factor 1222 Kr Yz Reliability factor 11 2 6 F in b mm Net face width TT L hours L hours Life 12 19 Ma u Gear ratio gt 1 Mp Ea Transverse contact ratio mp g Axial contact ratio Np 21 Number of teeth in pinion 12 6 Na 29 Number of teeth in gear 12 6 np rpm Wy rpm Pinion speed 12
105. tip and root relief and lengthwise helix modification Shaved gears are usually cut with a protuberance cutter followed by shaving of the tooth flanks only 3 Grinding Gear teeth may be ground by either the form grinding or generating grinding method Either method is capable of producing the highest accuracies of any finishing method Both spur and helical gears can be ground Most grinders finish only external gears some can grind internal gears Some gear grinders can produce profile and helix mod ification Grinding is used where high accuracy is required and most often used for finishing carburized gears to remove the distortions due to heat treatment The strongest gear teeth are cut with a protuber ance cutter and ground on the tooth flanks only leaving the root fillets unground Comparison of tooth finishing methods Gear Tooth Accuracy Surface Brinell Finishing Quality Roughness Hardness Method No Qn pin rms Limit HB Milling lt 6 64 125 360 Shaping 6 10 32 125 360 Hobbing 7 11 30 80 360 Shaving 10 13 10 40 360 Grinding 11 15 10 40 None The finishing method has an influence on the selected tool addendum ac cording to the GEARCALC setting see 11 1 5 CHAPTER 10 GEARCALC WIZARD 2 18 10 3 GEARCALC page 3 GearCalc AGMA2001 Lifetime Miner Rule acma 925 Description Enter load Transmitted Power P 10 0000 hp The overload factor considers variation of load
106. tip or at the high point of single tooth contact HPSTC CHAPTER 10 GEARCALC WIZARD 2 10 10 1 9 Reliability and The Reliability Factor The reliability factor Kg accounts for the statistical distribution of fatigue failures found in materials testing The required design life and reliability varies considerably with the gear application Some gears are expendable and a high risk of failure and a short design life are acceptable Other applications such as marine gears or gears for power generation require high reliability and very long life Special cases such as manned space vehicles demand very high reliability combined with a short design life Reliability R Application Failure Frequency 0 9 Expendable gears Motor vehicles 1 in 10 0 99 Usual gear design 1 in 100 0 999 Critical gears Aerospace vehicles 1 in 1000 0 9999 Seldom used 1 in 10000 10 1 10 Required safety factors An extra margin of safety can be specified by assigning Sp gt 1 0 for the bending stress and Sy gt 1 0 for the pitting Since pitting fatigue is slowly progressive and pitted gear teeth usually generate noise which warns the gearbox operator that a problem exists pitting failures are not usually catas trophic Bending fatigue frequently occurs without warning and the resulting damage may be catastrophic The safety factors should be chosen with regard to the uncertainties in the load and material data and the consequences of a failu
107. ts see 4 3 The area Project Members at the far right of the Status bar indicates whether the current calculation file belongs to the current working project see 3 Chapter 2 Setting Up KISSsoft 2 1 Language Settings KISSsoft is available in five languages German English French Italian and Spanish The choice of language will change the text in the user interface and the reports It is also possible to operate KISSsoft in one language and produce reports in another 2 1 1 Language of the User Interface Normally KISSsoft starts using the language that is defined in KI S ini file in section SETUP in the line DISPLAYLANGUAGE Here the value 0 is for German 1 English 2 French 3 Italian and 4 Spanish The language of the user interface can be changed using the program un der Extras Language This setting will be carried out in your personal Registry see 7 2 not in KISSini see 7 1 2 1 2 Language of the Reports The language of the reports is defined in the KIS5 ini file in section SETUP in the line LANGUAGE Here the value 0 is for German 1 English 2 French 3 Italian and 4 Spanish A special case here is the value 11 which represents English with imperial units 1 11 CHAPTER 2 SETTING UP KISSSOFT 1 12 The language used for the reports can be changed using the program under Protokolle Settings This setting will be carried out in your personal Registry see 7 2 not in KISSini see 7 1 2 1 3 Lan
108. turing tolerance according AGMA 2000 488 Stress cycle Factor Critical service YN gt 0 80 2N gt 0 68 Reliability 99 Required safety factor pitting 1 0000 Required safety Factor bending 1 0000 Factor for minimal normal tooth thickness at tip 0 2000 OK Cancel Figure 11 3 GEARCALC settings page AGMA 2001 11 2 1 Don t use stock allowance and protuberance The standard calculation procedure will use both stock allowance and protru berence defined on the tool profile The check box on the General tab sheet will prevent this during the calculation 11 2 2 Definition of reference profile The reference profile dimensions such as addendum and dedendum can be defined in dimensionless multiples of module instead of mm or inch values using this setting Normally the reference profile is given in factors of module or 1 P 4 CHAPTER 11 CALCULATION SETTINGS 2 37 11 2 3 Manufacturing tolerance according to standard The tolerance method can be defined for the calculation A choice of AGMA 2000 A88 or AGMA 2015 1 A01 is available from the drop down menu The scale runs from 15 best to 3 worst according to AGMA 2000 or from 2 best to 11 worst according AGMA 2015 In ISO 1328 also the low numbers are for better quality like in AGMA 2015 11 2 4 Stress cycle factors Three options are available to define stress cycle factors Yy for bending strength and Zy for pitting resistance based upon the applicat
109. uality 12 26 1 Material treatment There are different possibilities for heat treatment through hardened ni trided induction hardened and case hardened materials e Through hardened annealed normalized or quenched and tempered Carbon content ranges from 0 30 to 0 5096 Alloy content ranges from plain carbon steels e g MSI 1040 for tiny gears to Cr Ni Mo alloys e g AISI 4340 for large gears The best metallurgical properties are obtained with quenched and tempered steels Hardness ranges from HB 180 for lightly loaded gearsets to the limit of machinability approx imateby HB 360 for highly loaded gears CHAPTER 12 AGMA 2001 2101 2 63 Good tooth accuracy typically 10 acc AGMA2000 can be ob tained by hobbing the teeth after heat treatment eliminating heat treatment distortion from the generated tooth forms Hardenability must be adequate to obtain the required hardness at the root diame ter e Nitrided gears are quenched and tempered to obtain the desired core properties then the teeth are cut and finished followed by the nitrid ing process fle gears are placed in an ammonia gas atmosphere where nitrogen is absorbed into the surface bayers of the gear teeth and forms hard fron nitrides Because nitriding is performed at the relatively low temperature of 950 1050 F and there is no quench the distortion due to heat treatment is small Surface hardness ranges from HB 432 for alloys such as AISI 43
110. uffing temperature Os 1 Own input 2 Calculation according to AGMA925 equations 94 95 3 Calculation according to ISO TR 13989 1 2000 14 7 Standard deviation of scuffing tempera ture This is a statistical measure defining the variation in scuffing temperature Oy 14 8 Dynamic viscocity at Oy This is the viscocity nm of the oil expected at the bulk temperature achieved during operation 14 9 Coefficient for pressure viscocity The coefficients k and s are used to determine the pressure viscocity coeffi cient a The k value is a linear multiple while the s value is an exponen tial power for the dynamic viscocity nm These coefficients are found under Lubricant Data in the report CHAPTER 14 AGMA 925 SCORING 2 74 14 10 Coefficient of friction There are three options for determining the coefficient of friction ju e Own input of constant value e Constant value calculated according to AGMA925 equation 85 e Constant value calculated according to AGMA925 equation 88 Select method for calculation of friction x Constant value calculated according AGMA 925 eq 85 v Figure 14 2 AGMA 925 Calculation of friction The value for the coefficient of friction can be entered directly by checking the box at the side of the field or accept the program default for a constant value Alternatively the user may request a variable coefficient of friction in which case Scoring calculates accordin
111. umber of planets For the example shown the sun gear has 3 contacts rev CHAPTER 12 AGMA 2001 2101 2 61 Planet The planet gear has 1 contact rev because the loads from the sun gear and ring gear occur on opposite sides of the planet gear teeth The reverse bending that occurs on the planet gear teeth is accounted for with the Loading type Code See chapter 12 24 Annulus planetary gear train The internal gear has Q contacts per revolution where Q number of planets Although the internal gear in a planetary gearset is fixed it is analyzed as if it were rotating at the planet carrier speed Annulus star gear train the internal gear has Q contacts per revolution of the internal gear where Q number of planets An example of a split power train branched gearset is shown below gear pinion gear In this example if the pinion is the driver or is driven it has 2 contacts rev If the pinion is an idler it has 1 contact per revolution and reversed bending The mating gears each have 1 contact rev CHAPTER 12 AGMA 2001 2101 2 62 12 26 Material Material C Own input Label Material type Type of treatment Hardness Steel Grade 1 HB250 AGMA Through hardened steel alloyed through hardened 250F Steel Grade 1 HB300 AGMA Through hardened steel alloyed through hardened 300F Steel Grade 1 HB350 AGMA Through hardened steel alloyed through hardened 350F Steel Grade 1 HB400 AGMA Stee
112. used for large gears and high loads Minimum surface hardness ranges from HB 615 to HB 654 Be cause carburized gears are subjected to a drastic quench from a high temperature the distortion is large and grinding is usually required to obtain acceptable accuracy CHAPTER 12 AGMA 2001 2101 2 64 12 26 2 Material quality Material quality strongly influences pitting resistance and bending strength For high quality material the following metallurgical variables must be care fully controlled Chemical coposition Hardenability Toughness Surface and core hardness Surface and core microstructure Cleanliness inclusions Surface defects flanks and root fillets Grain size and structure Residual stress pattern Internal defects seams or voids Microcracks Carbide network Retained austenite Intergranular oxidation Decarburization There are three basic grades of material Grade 1 Grade 2 Commercial quality typical of that obtained from experienced gear manufacturers doing good work Modest level of control of the met allurgical variables High quality typical of aircraft quality steel with cleanliness certifled per AMS 2301 or ASTM A534 Close control of critical metallurgical variables CHAPTER 12 AGMA 2001 2101 2 65 Grade 3 Premium quality typical of premium aircraft quality with cleanliness certified per AMS 2300 or ASTM A535 Absolute control of all metal lurgical variables 12 26 3 Own input of
113. y defined by specifying the amount the pinion and gear teeth are thinned for backlash As and As With this convention the outside diameters of the gears are indepen dent of the tooth thinning for backlash and are based solely on the addendum modification coefficients x and x2 The root diameters will be changed with the tooth thinning sinze the tool is moved further into the material Tolerances for the maximum and minimum values can be entered using the plus button al at the side of the field CHAPTER 12 AGMA 2001 2101 2 48 Set tooth thickness tolerances Thinning For backlash pinion gear As 0 0019 0 0019 in Tolerance For thinning additional thinning 0 0000 0 0000 in Figure 12 4 AGMA 2001 2101 Tooth thickness tolerance 12 10 Stock allowance If the stock allowance u has been activated under settings see 11 2 1 then the cells will appear to define the amount of stock to be given on both gear and pinion The stock allowance is given per side of the gear and in circumferial direction 12 11 Tool addendum The tool addendum A py is defined from the datum line with the tooth thick ness 7 2P as follows CHAPTER 12 AGMA 2001 2101 2 49 Figure 12 5 This figure shows a normal plane view of a rack type generating tool hob rack cutter or generating grinding wheel Using the convert button e the tool addendum A po can also be calculated from an addendum h measured from a refer

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