KISSsoft Release 03/2013 Changes from Release 03/2012 to Release 03/2013 DRAFT KISSsoft AG Rosengartenstrasse 4 8608 Bubikon Switzerland Tel: +41 55 254 20 50 Fax: +41 55 254 20 51 info@kisssoft.ag www.kisssoft.ag
Contents General... 3 Base packages... 4 Base packages... 4 System modules... 7 KISSsys... 7 Expert Gears... 8 Cylindrical gears... 8 Configuration / Dimensioning... 8 Methods for strength calculation... 8 Contact analysis... 8 Bevel gears... 9 Worm gears (Globoid)... 9 Crossed helical gears or Worm gears (Cylindrical-Worm gear)... 10 Further gear specific modules... 10 Expert modules shafts and bearings... 10 Shafts... 10 Languages... 10 CAD Interfaces... 10 3D Export... 10 Highlights are marked in blue. 11.02.2013 2 / 10
General General Rules can be defined for parameters as i.e. limits for values or the ratio of two length parameters, which are checked and reported in separate displayed messages or even set back to allowed values. Exclusive opening for files possible so that no parallel modification of the same file is possible. Reports have new font style with proportional spacing. Export of Data from 3D diagrams as i.e. normal force curve are now possible, for further evaluation with other software. With the COM interface, suppressing of messages (silent mode) and generation of report is possible. Icons are reworked, for graphics the icon for properties has changed. Data Base Tool Modifications: the modifications for cylindrical gear as i.e. crowning etc. can be handled now in the database modifications, it is possible now to hide unwanted modification types. 11.02.2013 3 / 10
Base packages Base packages ZPK Cylindrical gear basic package Wear calculation: the calculation is done now with a more precise algorithm, considering also the K-factors. Tooth form calculation: The form circle for tool tip dfa0 is calculated with new, more precise formulae. Tolerance: When using the DIN 3961, the parameters total cumulative pitch deviation (Fp) and total tangential composite deviation (Fi ) can be referred to DIN 3962 resp. DIN 3963 (for these parameters the difference between DIN 3961 and DIN 3962/3963 are relatively high). The size factors ZX and YX for small gears can be determined analog to FVA 410II (to be activated under module specific settings ). Material data: plastic data are enhanced with 6 new or enhanced material data from SABIC; more S-N curves for root strength are available now. Tab Basic Data: for internal gears the geometry convention is available according to ISO 21771, using positive values for center distance and diameters (to be activated under module specific settings ). The main difference between DIN and ISO is, that in ISO all diameters of inner gear and the center distance have a positive sign; only the tooth number of the internal gear has to be introduced with a negative sign. As many engineers, for example in the USA, are used to this convention, we recommend considering to change to ISO 21771 convention, and save this as template. Tab Reference profile: the hob geometry has now a minimal radius (max. 0.1mm) as transition between protuberance and main cutting edge, to avoid numerical problems in many calculations. When working with pre-manufacturing, the generating tool (rack for external gears and pinion type cutter for internal gears) for final treatment is shown. For pinion type cutter (shaper) a conversion is now available for calculation of the profile shift coefficient. Also the definition of protuberance for pinion type cutter is now referred to the tool directly; this will result in more precise protuberance at the work piece than before. For constructed involute, protuberance and ramp can be defined too. For pre-manufacturing it is possible to give a tolerance for the grinding allowances. The tolerance is then considered in the corresponding tooth thickness values in the report (upper value / lower values with adding ½ of the tolerance). Tab Tolerances: a new serie of tooth thickness tolerance is implemented, which is able to consider the gear quality for the tooth thickness allowance (helpful feature for plastic gear calculation). Tab Modifications: when applying (parallel) helix angle modification, the tooth thickness measurement can optionally be reported using the exact manufactured helix angle (to be activated under module specific settings ). 11.02.2013 4 / 10
Tab Rating: the load spectra elements can contain individual oil temperatures now (to be activated under define Temperatures ). Tab Coefficient: the Y and Z factors as i.e. YR, YX, etc. can be entered manually now. Graphics: All graphics have identifier strings according to graphic type and can be added to a graphic list. The selected graphics are then added to the report (end of report). Graphics 2D geometry: the profile diagram is improved with several points to have a better readability. Also the selection of the tolerance range is added (constant tolerance range or AGMA 2001-A88). The gear and assembly drawing is improved, it was incomplete for internal gears before. Manufacturing drawing is available now. The user can define size and position of several graphics as i.e. drawing data, K-diagrams, etc. and export these as a single graphic with text for gear drawing documentation. Graphics 3D geometry: the handling in the 3D Graphics is improved; features as pan and zoom box are added. Module specific settings: setting for ISO 6336 corrigendum 2008, is removed, the corrigendum is now always considered. Reports: The tooth friction coefficient (Niemann) is enhanced with the Factor XL. Additionally to the backlash free center distance (acontrol) also start of active profile (in backlash free condition) and the reserve to the active flank is reported. WPK Shaft and bearing basic package Coaxial shafts: Warning messages are shown if speed inputs and connection types don t match. Elements-tree, outer contour: beams with I- and U-shape are updated to actual standards. Elements-tree, inner contour: sizing for the length of bore is added, to reach the end of the shaft. Element editor Roller bearing : The selectable tolerance class is now dependent on the bearing type. Shaft editor: the shaft is displayed now with shadows (can be deactivated under module specific settings ). The power flow is indicated by arrows, representing the torque input and output. The color of bearings is depending on the lifetime; critical bearings are shown with darker color. Module specific settings: for the shaft strength calculation it is possible now to distinguish between the number of load cycles between bending load and torsion load (available for limited life time calculation only). Bearing calculation: very high lifetime is shown with >1 000 000 h now. The exact value is documented in the report. Bearings: TIMKEN tapered roller bearing data are updated according to 2012. 11.02.2013 5 / 10
Bearings (classical method): Toroid roller bearings (CARB from SKF) are added in the database of Barrel roller bearings, the name is changed to barrel and toroidal roller bearings Bearing losses: sealing component is added to SKF 2004. The oil level is now referred to the left end of the shaft, and the oil level for each bearing is determined considering the tilting of the shaft (to be set up in tab basoc data ). Hence the bearing losses are calculated using the individual oil level (if oil bath lubrication is applied). Graphic equivalent stress : equivalent stress according to Tresca (SSH) is added. MPK Shaft-hub connections Cylindrical & conical interference fit: own input for surface roughness is possible now. Keys: strength calculation according to DIN 6892 is updated to edition 2012. Straight-sided spline: geometry standard DIN 5464 (heavy, for vehicles) is updated to edition 2010 Bolts and pins: for bolts with circular arrangement, additionally the maximum shear stress and minimum safety factor for the pin is calculated and reported. SPK Bolt calculation Tab Basic data : own input for surface roughness is possible now. The thread type UNF- Thread is added, to be selected under Define bolt. Washer type ISO 940 (DIN 125A/126) is removed. Tab Clamped parts : the sequence of the clamped parts can be changed now by the arrows up and down. Tab Position of bolt : the circle for outer head diameter is drawn now also in the graphic Preview. Report: additional plate load FPA is shown in the report now. RPK Belts and chains: The standard for chain types DIN ISO 606 is updated to edition 2012. LPK FKM guideline for proof of strength with local stress is updated to 6. Edition, 2012. 11.02.2013 6 / 10
System modules KISSsys SYS KISSsys has many new features as i.e. special tool bar for the elements, etc. Many short cuts are added for faster handling, as i.e ALT + E for the property window. Menu File: KISSsys example models and GPK models can be opened now directly under File. Also for the support it is now possible to add the KISSsys file directly into an email. Menu System: load spectra can be selected under System. The properties windows has now a second tab containing all functions of an element. This helps checking the functions. Also a new window is added to show all variables as an overview, i.e. for the dataflow KISSsoft <-> KISSsys, etc. A selection is provided to allow non-consistent KISSsoft calculations. Menu Insert: a wizard for planetary gear box is available which guides the user to setup a planetary model more easily (using coaxial shafts). It is possible now to insert predefined models and templates from a default template window, as i.e. for shift gear functionality, etc. Furthermore, the user can add own templates into the template window. Menu Extras: in the Configuration tool, setting of the naming for the elements can be defined now for all elements at the same time. Sizing functionalities: for bevel, worm and crossed helical gear pair, the sizing functionalities are added (analogue to gear pair sizing). Elements: new element ksysecentricalload is available. Function: new function is available which allows the transfer of the inner geometry from KISSsoft to KISSsys. GPK Gearbox calculation package: planetary gearboxes are now additionally available with coaxial shaft. 11.02.2013 7 / 10
Expert Gears Cylindrical gears Configuration / Dimensioning ZA1 ZA4 Planetary gears, three gears, four gears: in the tab modification for planetary gears a sizing proposition for tooth trace modification (helix angle modification and crowning) is added, so that equal load distributions between the meshing of sun-planet and planetinternal gear are achieved. Export of gear pairs sun - planet and planet - internal ring as gear pair files possible. Fine sizing: For planetary gears the ratio z3/z1 can be selected alternatively to the nominal ratio. The peak-to-peak value of torque of the driven gear can be evaluated now (if using the contact analysis). Methods for strength calculation ZA10 ZA17 Running-in value ya only depending on pitch deviation, in accordance to discussion with other ISO gear experts. Plastic gears: New guideline VDI 2736:2013 (Draft) for plastic gear is available. ZA19 DNV 41.2 is updated to edition May 2012, spiral angle factor is adopted to ISO 6336. ZA20 AGMA special standards: the calculation method API613 is added (special purpose Gear Units for petroleum, chemical and Gas industry services, 2003). Contact analysis ZA30 The contact analysis is modified according to research and comparison between several calculation programs through KISSsoft. Hence the settings possibilities for tooth stiffness are more detailed now (see module specific settings). The correction factor Cm is replaced by CHcorr which influences the hertzian stiffness only, with 1 the results are as before, and the recommended value is 0.5. The tooth stiffness is now selectable between Weber/Banaschek (as before), ISO 6336 or own input. The contact analysis is accelerated with several improvements of algorithm. Graphics / Evaluations: The graphic for single contact stiffness and stiffness curve are enhanced with a specific hertzian stiffness gear curve and tangent resp. secant gear pair stiffness curves. The transmission error can be displayed alternatively in angular units (under module specific settings ) The contact analyses for manufacturing is deactivated, for single gears, the contact analyses is removed. Planetary system: Axis alignment is possible now with individual definition and connected to shaft calculation. A faster contact analysis is available now, assuming that Kgamma = 1. FFT evaluation is added. 11.02.2013 8 / 10
Module specific settings: old contact analysis (2011) is not available anymore. ZA33 ZA35 Optimiziation of tooth trace and profile modification: The optimization of micro geometry is improved in many points: number of steps of partial load factor is introduced; graphical evaluations as i.e. spider diagram are added, etc. Additionally to the contact analysis under load, the standard strength calculation is done as well, considering the improved KHbeta values using the modifications. The peak-to-peak value of torque of the driven gear can be evaluated now. The optimization is also available now for planetary gears. KHbeta calculation: Input for minimum required KHbeta value is possible now (under module specific settings ). Also the topological modification are now considered for KHbeta calculation (line load at middle of tooth height is evaluated). For planetary systems, axis alignment is possible now with individual definition and connected to shaft calculation. This allows an exact contact simulation, analogue to gear pair calculation. Bevel gears ZC1 Bevel gears: Losses calculation acc. to Wech is added. In the module specific settings the user can select between Niemann or Wech calculation. Names of parameters are adopted to nomination in geometry standard ISO23509. Graphics 2D: the drawing is enhanced with tip alteration and inner diameter. ZC2 ZC5&6 ZC9 Bevel gears, ISO 10300: Updated calculation method ISO/DIS 10300:2012 (Draft International Standard) for bevel gears. Klingelnberg bevel and hypoid gears: Sizing of tip reduction for constant tip width at inner side (toe side) is possible according to Klingelnberg standard. Hypoid gears, ISO 10300: Updated calculation method ISO/DIS 10300:2012 (Draft International Standard) for hypoid gears. ZC11 DNV 41.2: Calculation method is updated to edition May 2012. Worm gears (Globoid) ZD10 Generation of 3D models is enhanced: the user can define the number of points on cutting edge and on root area. This influences the spline generation. The cutter tool can be modified with shaft angle adjustment of cutter, pressure angle modification for worm wheel cutter to improve the contact pattern. Also the tooth form for worm wheel cutter can be selected according to shapes as i.e. ZA, etc. ZD3 DIN 3996 is adopted to version 2012. ZD5 Fine sizing added for optimization of macro geometry. 11.02.2013 9 / 10
Crossed helical gears or Worm gears (Cylindrical-Worm gear) ZE5 ZE6 Plastic gears: New guideline VDI 2736:2012 (Draft) for plastic crossed helical gears is available. Fine sizing added for optimization of macro geometry. Further gear specific modules ZZ3 Backlash calculation: Value for run out error can be entered manually now. Expert modules shafts and bearings Shafts WA2 WA6 Tooth trace modification: Improved diagram for tooth trace modification. DIN 743 is updated to edition 2012, E-DIN 2008 is removed. WA7 FKM guideline is updated to 6. Edition, 2012. Languages LA6 Russian language is available now. CAD Interfaces 3D Export CB1 CB2 CB3 CB4 CB7 CB10 Export of 3D Models in STEP format: COM interface added for export of 3D model in remote mode (for cylindrical gears and bevel gears). Interface to Solid Edge ST5 is implemented. Interface to Solid Works 2013 is implemented. Interface to Inventor 2014 is implemented. Interface to Siemens NX 8.5 is implemented. Interface to KOMPASS is added. 11.02.2013 10 / 10