Design/Development/Manufacturing. The Most Powerful Software for. The Most Powerful Software for. Transmission MASTA.

Transcription

1 MASTA The Most Powerful Software for The Most Powerful Software for Transmission Design/Development/Manufacturing SMT 2006 Slide 1

2 Mission of MASTA System 1. able to identify and fix Design Weakness as early as possible 2. able to reduce Development Tests as much as possible 3. able to identify design inherited Manufacturing Problems at design stage 4. able to fix Production Problems quickly 5. easy to use and no need for full time user Maximise Performance at Minimum Cost & Time SMT 2006 Slide 2

3 Versions Automotive Version: Complete System from Drive Line Compatibility to Gear Manufacturing From Passenger Car application to Heavy Duty Application Aerospace Version From Design to Gear Manufacturing Industrial Version From High Speed Application to Low Speed Application Design for Ultra-low low Noise Application SMT 2006 Slide 3

4 Modules of MASTA VPS Module (Vehicle Performance Simulation) Decide gear ratios to meet VP, cost & fuel consumption (Automotive version only) DLC Module (Drive Line Compatibility) Use existing transmission & axle due to compatibility (Automotive version only) Modify existing transmission & axle to achieve compatibility MASTA Design & Analysis Modules Design new transmission & axle to maximise the performance at minimum cost and time NVH Modules FMA --- Failure Mode Analysis for major components Gear Manufacturing Modules Achieve good gear quality at low cost SMT 2006 Slide 4

5 Technologies of MASTA System Technology Complete System Static Analysis (Non-Liner) System Dynamics Component Technology Leading gear technology Advanced shaft technology FEA based casing technology Latest bearing technology Unique Gear Manufacturing Technology For Hobbing/Shaping/Shaving process For Hobbing/Shaping/Grinding process For Spiral bevel and Hypoid gear manufacturing SMT 2006 Slide 5

6 Capability of MASTA 1. Vehicle Performance Simulation & Drive Line Compatibility Check (for Automotive version only) 2. Transmission Design 3. Transmission Analysis and Optimisation 4. Gear Design for Manufacturing 5. Hobbing,, Shaping, Shaving Cutter and Grinding Wheel Design for Cylindrical Gears 6. Cutter Design and Machine Setting for Bevel/Hypoid Gears 7. Simulation for Gear Manufactruing Process Hobbing/Shaping/Shaving and Hobbing/Shaping/Grinding Process SMT 2006 Slide 6

7 SMT 2006 Slide 7 VPS & DLC

8 P redicted Acceleration From R est Gearbox A Gearbox B Gearbox C Tim e (s) ECE R urban and extra urban cycles Spe e d (k m /h) Tim e (s) drive cycle SMT 2006 Slide 8 fuel economy clutch engine gearbox vehicle final drive % gradient Vehicle Speed (km /h) vehicle acceleration Model Structure wheel

9 Driveline Ratios 1 6 Gearbox A Gearbox B Gearbox C 1st 2nd 3rd 4th 5th Evaluation of different options SMT 2006 Slide 9 Inputs Drive line Ratio

10 Outputs Vehicle tractive effort and resistance Traction Diagram Case Study Engine (2 litre) Curves Torque (Nm) Power (kw) Torque Power Vehicle Speed (km/h) 1st 2nd 3rd 4th 5th Grade (0%) Grade (5%) Grade (10%) Grade (15%) Tractiv e Force (kn) Grade (20%) Grade (25%) Engine Speed (rpm) SMT 2006 Slide 10

11 Outputs Option C excluded as top speed too low Predicted Acceleration From Rest Gearbox A Gearbox B Gearbox C Vehicle Speed (km/h) Time (s) SMT 2006 Slide 11

12 Drive Cycle Simulation SMT 2006 Slide 12 Outputs

13 Engine Map SMT 2006 Slide 13 Outputs

14 Outputs Fuel Economy Fue l Econom y ove r ECE R 101 Urba n Drive Cycle Honda Ins ight (hy.) Toy ota Prius (hy.) Ford Fies ta (1.4) Peugeot 206 (1.4) Peugeot 206 (1.6) Ford Foc us (1.6) Toy ota Camry (2.4) Jaguar XJ6 (3.0) Maz da MPV (3.0) Land Rov er, Dis c ov ery, (4.0) Fue l Ec onom y (k m /litre ) SMT 2006 Slide 14

15 Outputs Acceleration Acceleration & Elasticity Performances , 5th , 5th , 4th Gearbox A Gearbox B Time (s) 50-80, 4th 50-80, 3rd Speeds km/h SMT 2006 Slide 15

16 Model for AMT shift quality SMT 2006 Slide 16 Outputs

17 Shift Simulation SMT 2006 Slide 17 Outputs

18 Transmission Design For any Arrangement SMT 2006 Slide 18

19 SMT 2006 Slide 19 Truck Applications Track Transmission with Planetary Range Change

20 SMT 2006 Slide 20 Truck Application Track Transmission with Range Change

21 Passenger Car Applications Front Drive Transmission SMT 2006 Slide 21

22 Passenger Car Applications Front Drive Transmission SMT 2006 Slide 22

23 SMT 2006 Slide 23 Complex Automatic Transmission

24 Simplified demonstration models, client confidentiality maintained SMT 2006 Slide 24 Aerospace Applications

25 SMT 2006 Slide 25 Track Applications

26 Marine Applications Very wide and big helix angle gear SMT 2006 Slide 26

27 Analysis For any Arrangement SMT 2006 Slide 27

28 SMT 2006 Slide 28 Analysis based on Actual Duty Cycle

29 Underlying Analysis Model Component Stiffness and Masses Shafts classic finite element beam model (or derived from full FE model for complex 3-D shape, e.g. to capture gear blank deflection) Bearings stiffness derived from non-linear loaddeflection models (use Herztian contact theory & bearing internal geometry, ref T. Harris) Gears mesh stiffness and line of action derived from gear geometry Housing & complex shafts reduced stiffness and mass derived from full FE models SMT 2006 Slide 29

30 Underlying Analysis Model Specialised Interface allows rapid modelling of geared systems Component libraries and databases Fully integrated analysis & results display SMT 2006 Slide 30

31 Underlying Analysis Model Powerflow analysis to calculate all component speeds, powers, torques System Finite Element Model created from Design Geometry System model retains all degrees of freedom, laterals, axial, tilt, torsional SMT 2006 Slide 31

32 Shaft Deflection Validation MASTA vs MSC.NASTRAN Transaxle Input Shaft Deflection (x) Nominal X Bending Stress Bending Stress (MPa) Displacement (um) Offse t (m m ) MSC-Nastran, spring model MASTA, full model M SC-Nastran, pinned MAS TA, pinned Offset (mm) MASTA X Bending Stress Nastran pt2 Bend Stress Nastran pt4 Bend Stress SMT 2006 Slide 32

33 Shaft Analysis MASTA Shaft Forces and Fatigue Analysis vs Curves Qualitative Behaviour of Stresses in A Rotating Shaft Qualitative Behaviour of Stresses in A Rotating Shaft Stress Stress Alternating Stress Mean Stress Yield Line (Langer) Soderberg Line Goodman Line Gerber Curve ASME Elliptic Curve Bagci Curve Goodman Diagram Time Bending Stress Axial + Torsional Stress Total Stress Time Equivalent Fully Reversing Stress SMT 2006 Slide 33

34 Fatigue/Lives/Scoring Input Gear Train\Wheel to Pinion: ISO 6336 Rating Report Load Case: Full Power In New Design State Description Symbol Wheel 2 Pinion Load Conditions & Inputs Description Symbol Wheel 2 Pinion Torque (Nm) T Speed (rpm) n Power (kw) P Duration (hr) Number of Cycles N L Contact Durability Results (ISO ) Description Symbol Wheel 2 Pinion Percentage Damage 0% 0% Factor Of Safety For Pitting S H Calculated Contact Stress (MPa) σ H Nominal Contact Stress (MPa) σ H Bending Durability Results (ISO ) Description Symbol Wheel 2 Pinion Gear ISO6336 Safety Factors Percentage Damage 0% 0% Factor Of Safety For Bending S F Tooth Root Stress (MPa) σ F Nominal Tooth-Root Stress (MPa) σ F Various rating and lifing methods Input Idler i/p Idler o/p PTO1 PTO2 Gen. Pump. Contact Bending Bearings, ISO + supplier Bearing Duty Cycle % Damages Gears, ISO/AGMA + experience/references/database Shafts, classic beam model fatigue or use full FE Hyd. Pump Left Hyd. Pump Right Gen. Left Gen. Right Idler Left Idler Right Input Right Input Left Upper PTO1 Left Upper PTO1 Right Upper PTO2 Left Upper PTO2 Right SMT 2006 Slide 34

35 System Deflection Calculation: Apply Input Torque Derived Gear Loads Calculate System Deflection (non-linear force/load balance) Results: Shaft loads and deflection Bearing loads, misalignments & life Gear misalignment & life SMT 2006 Slide 35 System Static Analysis Static deflection, zero to full load

36 System Deflections Gear Mesh Misalignment, FBetaX MASTA allows inclusion of housing flexibility via reduced stiffness imported from housing FE model Idler/Input Input/PTO1 PTO1/PTO2 IdlerOutput/Gen. Gen./Hyd. Pump Bearing Misalignment (mrad) Hyd. Pump Left Hyd. Pump Right Gen. Left Gen. Right Idler Left Idler Right Input Right Input Left Upper PTO1 Left Upper PTO1 Right Upper PTO2 Left Upper PTO2 Right For lightweight aerospace transmission it is important to include effects of housing/support flexibility on internals SMT 2006 Slide 36

37 System Dynamics Calculation: Static load condition provides system stiffness Add mass to give dynamic model Solve multi-shaft system modes (or single shaft if required) Forced excitation System Dynamic Mode, full load condition Results: Modal Map, Mode shapes, Forced Response to Excitation, Critical Speed Maps, Campbell Diagrams etc SMT 2006 Slide 37

38 System Dynamics Fully Coupled Gearbox Modal Frequencies for Cruise Condition Frequency Fully Coupled Gearbox Model Critical Speed Map 3 Mode # 2.5 Frequency Mode 2: torsional driveline E E E E E E+11 Brg/Support Stiffness Mode1 Mode 2 Mode 3 Mode 4 Mode 5 Mode 6 Mode 7 Mode 8 MASTA can run full coupled gearbox or shafts in isolation Mode 4: shaft bending mode Check excitations from shaft and gear rotation speeds do not coincide with modal frequencies SMT 2006 Slide 38

39 Advanced System Deflection Example showing use of MASTA & FE for complex shaft shapes. A truck planet carrier shaft. Complex geometry done in industry standard CAD tools SMT 2006 Slide 39

40 Advanced System Deflection Example showing use of MASTA & FE for complex shaft shapes. A truck planet carrier shaft. Complex FEA done in industry standard tools, e.g. NASTRAN or ANSYS SMT 2006 Slide 40

41 Advanced System Deflection MASTA interface to NASTRAN & ANSYS FE SMT 2006 Slide 41

42 Advanced System Deflection MASTA interface to NASTRAN & ANSYS FE SMT 2006 Slide 42

43 SMT 2006 Slide 43 Gear Optimisation for High Performance and Low Cost

44 Very Accurate Gear Rating for Life Internal dynamic factor: method B & C Face load factor: Method A & B Nominal tooth-root stress: Method B & C All other factors: Method B SMT 2006 Slide 44

45 SMT 2006 Slide 45 Gear Rating to Scuffing

46 Gear Micro Modification Define Micro Geometry Profile Lead Total Bias SMT 2006 Slide 46

47 Gear Micro Modification Transmission Error & Contact Pattern (Predicted) T.E. for all Load Case 100% Load 50% Load 10% Load SMT 2006 Slide 47

48 LTCA for Ultra-low low Noise Gear High contact ratio: Industrial Gear-set SMT 2006 Slide 48

49 Minimise Manufacturing Cost SMT 2006 Slide 49

50 Failure Mode Analysis for Major Components Sort the major components by design lives to guide the investment t of manufacturing process SMT 2006 Slide 50

51 SMT 2006 Slide 51 Design Gears for existing Hobs/Shapers

52 Gear Hob/Shaper Design Maximise gear bending strength by optimising cutter tip SMT 2006 Slide 52

53 Hobbing Cutter Simulation Gear rating based on the actual gear fillet generated by the hobs SMT 2006 Slide 53

54 Shaping Cutter Simulation Gear rating based on the actual gear fillet generated by the shapers SMT 2006 Slide 54

55 Shaping/Hobbing Process Profile Lead Pitch Rapidly identify root causes and solutions to poor Shaping/Hobbing quality SMT 2006 Slide 55

56 Plunge Shaving Dynamics Simulation To find out if the gear is difficult to shave and also provide solution if there is difficulty at gear design stage Good dynamics: no difficulty in shaving SMT 2006 Slide 56

57 Plunge Shaving Dynamics Simulation To find out if the gear is difficult to shave and also provide solution if there is difficulty at gear design stage Very bad dynamics, hence very poor shaving quality SMT 2006 Slide 57

58 Shaving cutter micro modification Profile Lead A powerful tool for gear micro modification and heat treatment distortion compensation SMT 2006 Slide 58

59 Spiral/Hypoid Gear Contact pattern Contact pattern after assembly Contact pattern in-service Predict the contact pattern for given machine setting SMT 2006 Slide 59

60 Spiral/Hypoid Gear Ease off Predict the actual gear tooth topology accurately SMT 2006 Slide 60

61 Spiral/Hypoid Pinion Finish Stock Distribution Even finish stock distribution makes cutter life longer, connection between rough/finish fillet smoother, and SMT 2006 Slide 61

62 Heat Treatment Distortion compensation Pinion flank is designed based on heat treated wheel SMT 2006 Slide 62

63 3D Simulation of Pinion cutting Connection between rough root and finish filet Check the gears before starting any machining SMT 2006 Slide 63

64 Summary MASTA has been used to Maximise/Upgrade the ratio=load/volume of transmission at minimum cost and time cycle Improve Gear Contact Pattern and System Response to Improve Noise/Vibration Optimise Major Component Design to Maximise Life and Performance Minimise Manufacturing Cost Design gears using existing hobs and Shapers Predict failure modes of the major components at design stage Predict and fix potential gear manufacturing problems at design stage Optimise gear cutter design at design stage (for cylindrical and bevel/hypoid gears) Simulate Manufacturing Process to identify and fix the root causes of Gear quality in no time (for cylindrical and bevel/hypoid gears) SMT 2006 Slide 64

65 How to contact us? s: Website: SMT 2006 Slide 65 SMT Limited 14 Regent Street Nottingham NG1 5BQ Tel: +44 (0) Fax: +44 (0)