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 KISSsys 03/2014 Tutorial GPK 07/11/2014 10.11.20142 / 18 Foreword Thistutorialismeanttobeusedasastartinginstructionforcorrectworkingprocedurethroughgearbox design with GPK pre-made models. In this tutorial we will use a ThreeStageHelicalGearbox with Bearings as a basis. Similar procedure is to be used when working with any other GPK model. UsingtheGPKmodelsdoesntrequireanyprogrammingskillsormodelbuilding.Everycomponentand functionalityneededforworkingwiththemodelsisalreadyprogrammedinthemodels.Incasetheuser wantstoaddsomething(calculations,newcomponents...)tomeetownrequirements,itcanbeadded.In this case contact KISSsoft AG for more help. 10.11.20143 / 18 Contents 1.Sizing task ................................................................................................................................................ 4 1.1Input data ........................................................................................................................................ 4 1.2Purpose of this tutorial .................................................................................................................... 4 2.Preparations ............................................................................................................................................. 4 3.Sizing a gearbox ...................................................................................................................................... 4 3.1General notes ................................................................................................................................. 4 3.2Settings ........................................................................................................................................... 4 3.3PreSizing ........................................................................................................................................ 7 3.3.1Iteration for sizing ....................................................................................................................... 8 3.3.2Final sizing ............................................................................................................................... 10 3.3.3Gears ........................................................................................................................................ 10 3.3.4Shafts ....................................................................................................................................... 13 3.3.5Final notes of sizing .................................................................................................................. 15 4.Final Calculations ................................................................................................................................... 16 4.1UserInterface ................................................................................................................................ 16 4.2Strength calculation ...................................................................................................................... 16 4.3Torque capacity ............................................................................................................................ 17 4.4Reports ......................................................................................................................................... 17 10.11.20144 / 18 1.Sizing task 1.1Input data Design a three-stage helical gearbox with input speed of 3000rpm clockwise and a required output moment of 20000Nm. Total ratio 100 3 %. The Gearbox will be used in upright position so that input and outputs are on the same side of the gearbox and vertically on the same plane. Space between input and output is to be ~500mm. Table 1.1 Input data for gearbox sizing Input speed3000 rpm Required minimum output torque20000 Nm Ratio100 3 % Required lifetime10000 h OilGeneral type industrial oil Operating temperature70 C Required safetiesShafts 1.25, Gears SH = 1, SF = 1.4 1.2Purpose of this tutorial After completing this tutorial the user is able to use the GPK library models on his/her own. These readymademodelscanbeusedastemplatemodelstostartthecreationofowngearboxlayoutsand calculations.Thistutorialwillshowthecorrectworkingprocedurethroughthedesignprocedure.Notin every case all described steps are necessary and in other cases some more iterations or tuning is neededto get best possible solutions. 2.Preparations According to given data GPK model ThreeStageHelicalGearBox will be selected as a starting point. If you donthavethatmodel,pleasegotohttp://www.kisssoft.ch/english/downloads/gpkdownload.phpand download the correct file from there (ThreeStageHelicalGearBox.ks). Create a project folder and place that GPK library file into the folder. Open up KISSsys and select working directorytobethatnewlycreatedprojectfolder.GotoMenuFileOpenandselectthefile ThreeStageHelicalGearBox.ks. The GPK file is opened and ready for use. 3.Sizing a gearbox 3.1General notes All the operations described in here are made using the tables. The tables are created to ease the operation of the models. It is also possible to use the tree structure of the model to run the same functionalitiesand procedures. In general all the infomation, variables and functions are saved in the properties of the different elements. By use of the right-mouse click on the tree it is possible to view the menu for every element and have a look at the list of possible variables and functions and also to run the functions. 3.2Settings Start with giving correct global setting values for Settings table. 10.11.20145 / 18 Figure 3.1 Settings via table 1.Selectlubricantandlubricationmethod,aswellasthelubricationtemperature.Note!Ambient temperature has an effect only when using plastic gearing. 2. Define the mounting position and required lifetime for the gearbox 3.Definetheefficiencyforgearsmanuallyorlettheprogramcalculatetheefficiencywhilerunningthe kinematic calculation. Adjust KA to 1.25. 4. Select calculation methods for components. Use classical method (according to ISO 281) for bearings to consider also the lubrication. 5. Define materials for components. Pinion type gears will be gear1, gear3 and gear5 on shafts 1, 2 and 3, so materials for those shall be equal. 6. Double-click Update model to accept all changes. Use functions Model ID to give correct information tomodelandPricesettingstodefinepinionshaftsandpriceestimations.(Note!Approximatepricefor gearbox is calculated according to given base costs/kg. User needs to define these prices according to own knowledge) Figure 3.2 Model information dialog 1. 2. 3. 4. 5. 5. 6. 7. 8. 10.11.20146 / 18 Figure 3.3 Price setting dialogs for price calculations settings 7.UsethefunctionSetupI/OtodefinespeedfortheShaft1(Boundary1)andtorquefortheShaft4 (Boundary2).Torquecanalwaysbedefinedasinputoroutput,meaningthegearboxcanbeeasily calculated for both directions. Figure 3.4 Power definition dialog 8.Atthispointitisalsopossibletochangethebearingstosupportonly.Thiscanbedoneusingthe function Model Setup. Figure 3.5 Bearing settings 10.11.20147 / 18 3.3PreSizing Because no initial information about the gearbox size is given, the sizing of the gearbox can be started by giving a total required ratio for the gearbox. Type in the value of 100 for total ratio and give it a deviation of 3%.ThenclickonDivideratiotodividethistotalratiooverthethreereductions.Theratiosreachedare goodstartingvaluesandcanafterwardsbechangedifneeded.Whenthehelixanglerangeistobe modified, it can be done using the function Gear sizing param. Range can be selected here freely, e.g. Figure 3.6 Definition for the helix angle After the settings have been made it is possible to try the gear sizing function. Select initial sizing strategy i fixedfromthedrop-downlistandexecutesizingfunctions:Sizinggearpair1,Sizinggearpair2and Sizing gear pair 3 in this order. With this sizing method only the ratio is fixed for gears and all other values (helixangle,width,centredistance...)areselectedinordertohaveagoodoverallsolution.Afterthepre-sizing, gear geometries are proposed and an updated layout can be seen in 3DView. Then the same can be done for the bearings and the shafts. For Shaft and bearing sizing choose Use types defined below and select desired bearings from the list Types of bearing. Select how shaft ends are positioned from the list of Coupling side and Gear side in the first shaft. Initially we will use the Deep groove ball bearing (single row)becausetheyarethecheapestandmostcommontypeofbearings.Alsotypeintherequiredshaft safeties (fatigue = 1.25 and Static = 1.25). Then double-click on function Shaft and bearing sizing to make initial sizing for bearings and shafts. Figure 3.7 Sizing of gears and sizing of shafts and bearings

10.11.20148 / 18 If a Message for geometrical errors appears, we need to do some adjustments for the gearbox. Figure 3.8 Information of geometrical error during first pre-sizing Figure 3.9 Geometrical error and possible collision in 3DView 3.3.1Iteration for sizing Thefirstandlastgearpairsarecolliding.Thiscanbepreventedbyincreasingthecentredistanceofthe second gear pair. At the same time we can also adjust the centre distances of the other stages to achieve reasonableroundednumbers.Thiscanbedonebytypinginthenewvalues forPair1=200,Pair2=260 andPair3=300andbyselectingsizingstrategytobei,afixedandexecutinggearpairsizingagain. Finally the same should be done for the shaft and bearing sizing Function to get a new layout.Beforesizingofshaftsandbearingsyoucanalsoturnthegearboxinthecorrectworkingpositionby changingaxisanglestoconsiderallforcescorrectlyforeverybearing.Theremaybeseveralinternal layouts for the gearbox to achieve the required output shaft position. 10.11.20149 / 18 Figure 3.10 Gearbox positioning in space and new pre-sizing After the pre-sizing the 3DView can be also adjusted. By clicking on the icon in the top menu bar and changingthesettingsinthedialog.Toturnthehousinginvisibleinthe3DViewright-clickonHousingin the structure tree, choose SetColor and set transparency to 1. Figure 3.11 Color Settings for the housing

Figure 3.12 Gearbox layout after pre-sizing 10.11.201410 / 18 3.3.2Final sizing After pre-sizing, the final sizing for gears, shafts and bearings must be done. Also the correct geometry for shafts should be entered, because after pre sizing shaft geometry is only estimated. Figure 3.13 Definition of shaft1 after pre-sizing While final sizing please remember to use the function Update model in the right hand side upper corner of the tab UserInterface to update all the changes made. 3.3.3GearsMake the final sizing for all gears individually using the according gear pair mask found in the structure tree onthelefthandside.Youmayadjuste.g.thereferenceprofile,modifications,toothform,theprofileshift coefficient,facewidthoranyothervariablethatmaybecomenecessary.Inthisexamplewewillchange gear widths to be reasonable values. 10.11.201411 / 18 Figure 3.14 Structure tree with gear pair mask The type of profile modification is set for high load capacity under Rating - Details and Optimal tip relief (micropitting,scuffing)willbecheckedtogetbetterloaddistributionforthegears.Thiswillbedonefor every gear. Figure 3.15 GearPair details of strength For specific modifications, the modifications tab can be activated from the Calculation menu on top of the screen 10.11.201412 / 18 Figure 3.16 GearPair sizing modifications After setting values for all the gears. The GearPairResults should like this: Figure 3.17 Geometry after final sizing of all the gears 10.11.201413 / 18 3.3.4Shafts Definecorrectshaftdataforeveryshaft.Startbydeletinginitialshaftgeometryandtheninputnew geometryviashaftgraphicalinputwindow.Bearingsandforceelementscanbealsorepositionedand correctbearingscanbeselectedtosupporttheshafts.Ifyouright-clickabearingyoucanalsochoose sizing which opens a dialog with a choice of pre-specified bearings and the corresponding service life.Figure 3.18 Detailed geometry for shaft1 after input in graphical shaft editor Definenewshaftgeometryandinsertnotchfactors.Ifbearinglifetimewillgettoohighortoolowwith selectedshaftdiametersyoumayhavetoexecutesomeiterationsbeforeyoufindfittingshaft measurements. It is also possible to change bearing type into a more loads carrying type of bearing if shaft diameter gets too big. You can also define a new cross section to calculate. This can be done e.g. automatically using the sizing functionfromtheshafttree.Firstremovethecurrentcrosssectionsthencreatecrosssectionswherethe shaft strength is to be calculated. Proceed the same way with the other shafts. For shafts 2, 3 and 4 it is also possible to add a notch effect of key way or pressure fit, depending on how loose the gear is fixed on the shaft. These notch effects can be addedbyright-clickingontheshaftandchoosingtheappropriateoptionfromtheadd-menuwhilein graphical shaft editor. 10.11.201414 / 18 Figure 3.1918 Final geometry for shaft2 with key way notch effect Figure 3.20 Shaft3 after defining final geometry 10.11.201415 / 18 Figure 3.21 Shaft4 after defining final geometry Thebearingsareselectedusinggraphicalshaftinterfaces.Thelistofselectedbearingsisshownas follows: Figure 3.22 Selected bearings for the gearbox 3.3.5Final notes of sizing InthisexampleDeepgrooveballbearings(singlerow)andCylindricalrollerbearings(singlerow)are used. This selection is made because when loads get quite big due to high torque, bearing size will have to increase as well. This effect is amplified if deep groove ball bearings are used on each shaft. That may lead toanover-sizingofshafts.InthiscasebearingtypesarechangedtoCylindricalrollerbearingsthree shafts. This type of bearing has a higher load carrying capacity and therefore shaft size can be kept low and safetyfactorsforshaftsareinreasonablelevel.Deepgrooveballbearingsarelow-costbearingssoitis advised to keep the detailed analysis of total price in mind when changing the bearing type. 10.11.201416 / 18 4.Final Calculations 4.1UserInterface UsefunctionUpdateModelandCalculateKinematicsinUserInterface-tabbeforefinalstrength calculation to make sure that all changes in components are updated before calculation. Figure4.1Use"Updatemodel"and"CalculateKinematics"beforefinalcalculationstoactualizeevery component after changes 4.2Strength calculation After every component has been selected and adjusted do final strength calculation. That can be done via UserInterface with function Calculate Strength. After calculation is performed you should see a message that strength has been calculated. Figure 4.2 Message after strength calculation, indicating the calculation was a "success" 1. 2. 3. 10.11.201417 / 18 4.3Torque capacity Are you also interested to know what the torque capacity of your gearbox with defined components is? That can be easily checked with function Calculate Torque Capacity in UserInterface. The function will iterate input torque until some of the required criteria will fail. The result will be given asmaximum torque for the gearbox. Figure 4.3 Information about the requirements to be fulfilled Figure 4.4 Limiting calculation and max. torque is displayed after torque capacity calculation Limitingcalculationisthesecondgearpair.Themaximumappliedtorqueoutputforthatgearpairis 20226.577Nmwithgivenefficiencies.Initially20000Nmasoutputtorquerequirementwasgivenforthe gearbox. This means after the gearbox dimensioning the required lifetime and torque can be achieved. 4.4Reports After all calculations are done the last step is to create the necessary documentation for the gearbox. That can be done with the function Reports from UserInterface Figure 4.5 Report selection dialog 10.11.201418 / 18 SelectthedesiredreportfromthelistandselectOk.Allavailablereportsaresavedautomaticallytothe project folder and can be accessed later. The General report is a short summary of most important results e.g. to be given for customer. KISSsoft reports are a full documentation of all results in one file according toKISSsoftprotocols.Bearingforceswillcreateafileconsistingofglobalcoordinatesofeverybearing with bearing force components, e.g. to be used in housing FEM analysis.