KISSsoft 03/2012 – Instructions 072

Contact Analysis in the Cylindrical Gear Calculation

Ho 06.05.11, Update 11.10.2011 Ho; Update 16.09.2013 Ho

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

1 Initial Situation .......................................................................................................................................... 3

1.1 Work steps...................................................................................................................................... 3
2 Solution .................................................................................................................................................... 4
2.1 General notes ................................................................................................................................. 4
2.1.1 Step 1: Analyze the current situation .......................................................................................... 4
2.1.2 Step 2: Analyze the current situation, considering shaft deformation ........................................ 8
2.1.3 Step 3: Determine the necessary modifications for the tooth trace on the pinion and the gear 10
2.1.4 Step 4: Including modifications in the cylindrical gear calculation ............................................ 14
2.1.5 Step 5: Analyze the optimized situation taking into account the shaft deformation .................. 15
2.2 Summary ...................................................................................................................................... 17
3 Results ................................................................................................................................................... 17
3.1 Report of the contact analysis of the initial variant with main load stage ..................................... 17
3.2 Report of contact analysis of the end variant with main load stage .............................................. 28

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1 Initial Situation
Since the 2011 release it is now possible to include and take into account shaft deformation directly in
cylindrical gear analysis. If you do so, the deformation that occurs is determined on the basis of the shaft
dimensions and included directly in the cylindrical gear analysis. To illustrate this new functionality, KISSsoft
is providing a number of pre-defined example analyses for cylindrical gears and the shafts associated with
them. The relevant examples are highlighted in the figure below.

Figure 1.1-1: pre-defined calculation files for cylindrical gear pair and shaft analysis

1.1 Work steps

Work through the following steps with these examples:
Step 1: Analyze the current situation according to the relevant standard
Step 2: Analyze the current situation, taking into account the shaft deformation, with or without contact
analysis
Step 3: Determine the necessary modifications for the tooth trace on the pinion and the gear
Step 4: Include the modifications in the cylindrical gear calculation
Step 5: Analyze the optimized situation, taking into account the shaft deformation

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2 Solution
2.1 General notes
These work steps are designed to illustrate the basic procedure, to better identify and describe this new
functionality.
The face load factors take into account the effect of unequal load distribution across facewidth on flank
pressure KHß, on tooth root stress KFß and on scuffing stress KBß. The KISSsoft system has a number of
different ways in which you can input KHß:
 Input KHß directly, method A;
 Input deformation fsh and manufacture tolerance fma: The KISSsoft shaft analysis functions can
calculate the exact flank line variation due to deformation (torsion and bending) in the plane of
action, method B;
 An approximate analysis according to ISO6336 (or DIN 3990). To do this, input the bearing
distance l, the distance s of the pinion shaft, and the outside diameter of the pinion shaft,
method C.

2.1.1 Step 1: Analyze the current situation

Load the current cylindrical gear calculation file CylGearPair 6a.Z12 into the cylindrical gear pair module.
Compare the data inputs for the face load factor with the current dimensions taken from the shaft analysis
of the pinion. Change the settings and compare the determined face load factors for K Hß with the
subsequent analysis results from steps 2 through 5.

Figure 2.1-1: Pinion shaft dimensions and support

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Figure 2.1-2: Gear shaft dimensions and support

To define the inputs for the face load factor, go to “Factors” tab. In the “Face load factor” section, first select
“Calculation according calculation method” in the drop down list. Then click in the plus button on the right of
the section to define more inputs for the load face factor.

Figure 2.1-3: Defining the face load factor

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Figure 2.1-5: Inputs that take into account pinion dimensions (for method C)

The application factor KA must be set to 1 so that it can be compared with the results of the subsequent
analysis at a later point in time

Figure 2.1-6: Application factor

The following message appears when you run this calculation.

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Figure 2.1-7: Warning message stating that the face load coefficient is too high

Note:
Any face load factor calculated according to method C which have a value greater than 1.5 must be
checked in more detail. Method C is often very conservative. In other words, the calculated factor is too high
and therefore the calculated safeties are too low. The factor should therefore be calculated in greater detail.
You can do this by verifying the value more precisely. To do this, use the KISSsoft Shaft calculation module
or the shaft analysis functions integrated in contact analysis in the KISSsoft cylindrical gear calculation
functionality.

Figure 2.1-8: Calculation results according to the standard, method C, and taking into account the influence of pinion geometry

The result shows the calculation of KHß with the appropriate settings according to the standard. This
calculation only includes the dimensions of the pinion shaft. However, the gear shaft will also deform when
placed under load, and this method cannot take this effect (which is usually significantly smaller) into
account.

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 Pinion Gear
Figure 2.1-9: stress distribution calculated with KHß =2.18

2.1.2 Step 2: Analyze the current situation, considering shaft deformation

This calculation step determines the face load factor using the contact analysis in the KISSsoft cylindrical
gear calculation functionality. You can perform the calculation with a complete contact analysis. In this case,
the calculation will take significantly longer to run and the result for KHß is more accurate as it takes into
account the shafts deformation.

The necessary shaft calculation files have already been assigned correctly in the CylGearPair 6a (…).Z12
cylindrical gear calculation file supplied with the system.

Figure 2.1-10: Determining KHß with contact analysis

Note:
a) If you want to consider tooth trace or profile corrections in the calculation, you must enable these
modifications in the "Modifications" tab before running the contact analysis. If tooth trace corrections
have been entered, you must enable them for this calculation step in the contact analysis. You do not
need to enable profile corrections if only KHß is to be calculated
b) If the warning message does not appear, this means either that you have not input any modifications
or that the modifications are already enabled.

To activate modifications in the "Modification” tab, enable the status as shown in the next figure.

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Figure 2.1-1: Enabling corrections in the "Modification" tab

Figure 2.1-11: Results overview for a complete contact analysis without tooth trace modifications

In contrast to the calculation performed according to the equation in the standard, as shown in Step 1, the
effective occurring face load factor changes to 1.79 in analysis step 2. This can now be used directly in the
calculation. The safeties determined in the calculation then change accordingly.

Pinion Gear
Figure 2.1-12: stress distribution calculated with KHß =1.79

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2.1.3 Step 3: Determine the necessary modifications for the tooth trace on the
pinion and the gear
To do this, load the file ‘Pinion shaft for CylGearPair 6a.W10’ into the Shaft calculation module.

Figure 2.1-13: Pinion shaft for CylGearPair 6a

Then open the "Tooth trace modification" tab as shown in the figure below.

Figure 2.1-14: Calculating the tooth trace modification

Run the calculation after this. The next figure shows the results determined for the pinion. The calculation
and modeling have been performed in such a way as to represent the counter gear as an idealized gear
with infinite stiffness.

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Figure 2.1-15: Results overview without tooth trace modification for the pinion

To reach an ideal modification, enter the helix angle modification CHb step-by-step. You can then check the
result, i.e. the correct input for the size and the sign. The deformation graphic shows an optimum proposed
value (shown here in gray). If values have been defined for the helix angle modification CHb, the graphic
also shows the defined correction (shown here in green). The value for KHb should be reduced (ideally to 1).
The current value is then displayed in the results window.

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Figure 2.1-16: Results overview with enhanced tooth trace modification for the pinion

Since 2012th version, the sizing button is also available for this calculation. It runs an internal
algorithm to get the optimum result. In the next image, it not possible to see the gray modification anymore
as the green defined is now above it. Notice that the value is very close to the one reached before when
trying step by step but there is also a small crowning to get is exact. Also the KHb is reduced to 1.0003.

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Figure 2.1-17: Results overview with optimum tooth trace modification for the pinion

The same should be done for the Gear. Load the file ‘Pinion shaft for CylGearPair 6a.W10’ and follow the
same steps as decribed for the pinion.

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Figure 2.1-2: Results overview with optimum tooth trace modification for the gear

2.1.4 Step 4: Including modifications in the cylindrical gear calculation

The Shaft Analysis report and the "Deformation" figure both state the tooth flank for which the modification
is to be performed. This is calculated from the direction of rotation and the direction of load. In this example,
the modification is performed for the right tooth flank for both the pinion and the gear.

Figure 2.1-19: Report note with optimum tooth trace correction for the pinion

Figure 2.1-20: Report note with optimum tooth trace modification for the gear

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Now open the "Modifications" tab in the cylindrical gear calculation and enter the corrections. You should
reduce the helix angle on the pinion and increase the helix angle on the gear.

Figure 2.1-21: Inputting a conical helix angle and crowning for the gear and pinion in the Cylindrical gear calculation:

The tip reliefs entered in Figure 2.1- are a good idea, but optional. They do not affect the result. The crowning
calculated before by the sizing button is too small to have a real influence, but the optimal value is reached
just if applying this modification. It was used also in the Cylindrial gear calculation, shown also in Figure 2.1-
to show how the process works.

2.1.5 Step 5: Analyze the optimized situation taking into account the shaft
deformation
The calculation of KHb in the "Contact analysis" tab now returns a much lower value than previously, due to
the flank line modification that has just been applied. Both shaft deformations (pinion and gear) are now
included here.

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Figure 2.1-22: Results overview with optimum tooth trace modification

Pinion Gear
Figure 2.1-23 stress distribution calculated with KHß =1.0027

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2.2 Summary
The table below contains an overview of the results.

Face load factors on

Step Pinion Gear Total Note
the
determined in accordance with
1 KHß 2.179 (1.332)
the standard
2 KHß 1.796 taking into account the shafts
without correction, calculated in
3 KHß 1.677 1.347
the shaft analysis
with correction, calculated in the
4 KHß 1.029 1.019
shaft analysis
With optimum correction,
4b KHß 1.0003 1.0001 calculated in the shaft analysis
by sizing button
with corrections, calculated in the
5 KHß 1.0029 cylindrical gear calculation, and
taking into account both shafts

3 Results
3.1 Report of the contact analysis of the initial variant with main
load stage
KISSsoft Release 03/2013
KISSsoft-Entwicklungs-Version KISSsoft AG CH-8608 BUBIKON
File
Name : CylGearPair 6a (shafts for contact analysis) (Helical DIN3990)
Description: KISSsoft example
Changed by: ho am: 23.09.2013 um: 16:24:40

Contact analysis
Mesh gear 1 - gear 2 (Right Tooth Flank)
Shaft file A: C:/KISSsoft 03-2013/example/Pinion shaft for CylGearPair 6a.W10, selected gear: Pinion from CylGearPair6 (gears
as masses and stiffness)
Shaft file B: C:/KISSsoft 03-2013/example/Gear shaft for CylGearPair 6a.W10, selected gear: Gear from CylGearPair6 (gears
as masses and stiffness)
(Partial load for calculation wt = 100 %)

Accuracy of calculation medium

Partial load for calculation 100.00 %
Center distance [a] 101.8450 mm
Single pitch deviation [fpt] 0.0000 µm
Coefficient of friction [µ] 0.1011
Torque [T1] 40.463 Nm
Torsion from shaft calculation
min max Δ µ σ
Transmission error (µm) -9.0579 -8.4042 0.6537 -8.7165 0.2070
Stiffness curve (N/mm/µm) 19.1317 21.4254 2.2937 20.5353 0.5876
Line load (N/mm) 0.0000 188.2982 188.2982 65.4500 36.1387
Torque Gear 1 (Nm) 40.4591 40.4671 0.0080 40.4624 0.0016

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Torque Gear 2 (Nm) 153.7548 154.2581 0.5032 153.9325 0.1490
Power loss (W) 140.0137 172.2304 32.2167 158.8077 9.4681
Flash temperature (°) 76.0159 154.1917 78.1758 93.1865 12.8547
Lubricating film (µm) 0.1074 0.7949 0.6875 0.2526 0.0982
Hertzian stress (N/mm²) 1468.9605 683.1111
Safety against micropitting 0.2994

Transverse contact ratio under load [εa'] 1.779

Overlap ratio under load [εb'] 0.811
Total contact ratio under load [εg'] 2.589
Efficiency [η] 98.73 %

KHβ Calculation - Gear 1 - Gear 2

Right flank

fma = 0.000 µm , fHβ = 0.000 µm

Result after i = 3 iterations of load distribution
Gear 1
Point in polar co-ordinates:
R = 20.991 mm , φ = 0.000 °
Displacement calculated in direction 111.425 °

y φ1.t f1.t f1.b f1.tot f1.C f1.tot+f1.C

1 40.323 mm -0.0001° 0.0266 µm 0.2677 µm 0.2943 µm 0.0000 µm 0.2943 µm
2 40.968 mm -0.0001° 0.0467 µm 0.4770 µm 0.5237 µm -0.1106 µm 0.4131 µm
3 41.613 mm -0.0002° 0.0659 µm 0.6853 µm 0.7512 µm -0.2212 µm 0.5300 µm
4 42.258 mm -0.0002° 0.0841 µm 0.8927 µm 0.9768 µm -0.3318 µm 0.6450 µm
5 42.903 mm -0.0003° 0.1013 µm 1.0992 µm 1.2005 µm -0.4424 µm 0.7581 µm
6 43.548 mm -0.0003° 0.1176 µm 1.3048 µm 1.4224 µm -0.5530 µm 0.8694 µm
7 44.194 mm -0.0004° 0.1330 µm 1.5095 µm 1.6425 µm -0.6636 µm 0.9789 µm
8 44.839 mm -0.0004° 0.1476 µm 1.7133 µm 1.8610 µm -0.7742 µm 1.0868 µm
9 45.484 mm -0.0005° 0.1614 µm 1.9163 µm 2.0777 µm -0.8848 µm 1.1929 µm
10 46.129 mm -0.0005° 0.1743 µm 2.1184 µm 2.2927 µm -0.9954 µm 1.2974 µm
11 46.774 mm -0.0005° 0.1865 µm 2.3197 µm 2.5062 µm -1.1060 µm 1.4002 µm
12 47.419 mm -0.0006° 0.1978 µm 2.5201 µm 2.7180 µm -1.2166 µm 1.5014 µm
13 48.065 mm -0.0006° 0.2085 µm 2.7197 µm 2.9282 µm -1.3272 µm 1.6010 µm
14 48.710 mm -0.0006° 0.2184 µm 2.9185 µm 3.1368 µm -1.4378 µm 1.6991 µm
15 49.355 mm -0.0007° 0.2275 µm 3.1164 µm 3.3440 µm -1.5484 µm 1.7956 µm
16 50.000 mm -0.0007° 0.2360 µm 3.3136 µm 3.5496 µm -1.6590 µm 1.8906 µm
17 50.645 mm -0.0007° 0.2438 µm 3.5099 µm 3.7537 µm -1.7696 µm 1.9841 µm
18 51.290 mm -0.0007° 0.2509 µm 3.7054 µm 3.9563 µm -1.8802 µm 2.0761 µm
19 51.935 mm -0.0008° 0.2574 µm 3.9002 µm 4.1576 µm -1.9908 µm 2.1668 µm
20 52.581 mm -0.0008° 0.2632 µm 4.0942 µm 4.3575 µm -2.1014 µm 2.2561 µm
21 53.226 mm -0.0008° 0.2685 µm 4.2875 µm 4.5560 µm -2.2120 µm 2.3440 µm
22 53.871 mm -0.0008° 0.2732 µm 4.4801 µm 4.7533 µm -2.3226 µm 2.4307 µm
23 54.516 mm -0.0008° 0.2774 µm 4.6719 µm 4.9493 µm -2.4332 µm 2.5161 µm
24 55.161 mm -0.0008° 0.2810 µm 4.8631 µm 5.1441 µm -2.5438 µm 2.6003 µm
25 55.806 mm -0.0008° 0.2841 µm 5.0535 µm 5.3376 µm -2.6544 µm 2.6833 µm
26 56.452 mm -0.0008° 0.2868 µm 5.2433 µm 5.5301 µm -2.7650 µm 2.7651 µm
27 57.097 mm -0.0008° 0.2889 µm 5.4325 µm 5.7213 µm -2.8756 µm 2.8458 µm
28 57.742 mm -0.0009° 0.2906 µm 5.6210 µm 5.9115 µm -2.9862 µm 2.9254 µm
29 58.387 mm -0.0009° 0.2918 µm 5.8088 µm 6.1006 µm -3.0968 µm 3.0039 µm
30 59.032 mm -0.0009° 0.2926 µm 5.9960 µm 6.2886 µm -3.2074 µm 3.0813 µm
31 59.677 mm -0.0009° 0.2930 µm 6.1827 µm 6.4756 µm -3.3180 µm 3.1577 µm

Gear 2
Point in polar co-ordinates:

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R = 80.854 mm , φ = 180.000 °
Displacement calculated in direction 111.425 °

y φ2.t f2.t f2.b f2.tot f2.C f2.tot+f2.C

1 24.323 mm 0.0000° 0.0000 µm -0.0583 µm -0.0583 µm 0.0000 µm -0.0583 µm
2 24.968 mm 0.0000° 0.0001 µm -0.1748 µm -0.1747 µm 0.0000 µm -0.1747 µm
3 25.613 mm 0.0000° 0.0002 µm -0.2913 µm -0.2911 µm 0.0000 µm -0.2911 µm
4 26.258 mm 0.0000° 0.0004 µm -0.4077 µm -0.4073 µm 0.0000 µm -0.4073 µm
5 26.903 mm 0.0000° 0.0007 µm -0.5241 µm -0.5234 µm 0.0000 µm -0.5234 µm
6 27.548 mm 0.0000° 0.0010 µm -0.6405 µm -0.6395 µm 0.0000 µm -0.6395 µm
7 28.194 mm 0.0000° 0.0014 µm -0.7568 µm -0.7554 µm 0.0000 µm -0.7554 µm
8 28.839 mm 0.0000° 0.0018 µm -0.8730 µm -0.8712 µm 0.0000 µm -0.8712 µm
9 29.484 mm 0.0000° 0.0023 µm -0.9893 µm -0.9869 µm 0.0000 µm -0.9869 µm
10 30.129 mm 0.0000° 0.0029 µm -1.1054 µm -1.1026 µm 0.0000 µm -1.1026 µm
11 30.774 mm 0.0000° 0.0035 µm -1.2216 µm -1.2181 µm 0.0000 µm -1.2181 µm
12 31.419 mm 0.0000° 0.0041 µm -1.3377 µm -1.3336 µm 0.0000 µm -1.3336 µm
13 32.065 mm 0.0000° 0.0048 µm -1.4538 µm -1.4489 µm 0.0000 µm -1.4489 µm
14 32.710 mm 0.0000° 0.0056 µm -1.5698 µm -1.5642 µm 0.0000 µm -1.5642 µm
15 33.355 mm 0.0000° 0.0064 µm -1.6858 µm -1.6794 µm 0.0000 µm -1.6794 µm
16 34.000 mm 0.0000° 0.0072 µm -1.8018 µm -1.7945 µm 0.0000 µm -1.7945 µm
17 34.645 mm 0.0000° 0.0081 µm -1.9177 µm -1.9096 µm 0.0000 µm -1.9096 µm
18 35.290 mm 0.0000° 0.0091 µm -2.0336 µm -2.0245 µm 0.0000 µm -2.0245 µm
19 35.935 mm 0.0000° 0.0101 µm -2.1495 µm -2.1394 µm 0.0000 µm -2.1394 µm
20 36.581 mm 0.0000° 0.0111 µm -2.2653 µm -2.2542 µm 0.0000 µm -2.2542 µm
21 37.226 mm 0.0000° 0.0122 µm -2.3811 µm -2.3689 µm 0.0000 µm -2.3689 µm
22 37.871 mm 0.0000° 0.0133 µm -2.4969 µm -2.4836 µm 0.0000 µm -2.4836 µm
23 38.516 mm 0.0000° 0.0144 µm -2.6126 µm -2.5982 µm 0.0000 µm -2.5982 µm
24 39.161 mm 0.0000° 0.0156 µm -2.7283 µm -2.7128 µm 0.0000 µm -2.7128 µm
25 39.806 mm 0.0000° 0.0168 µm -2.8440 µm -2.8272 µm 0.0000 µm -2.8272 µm
26 40.452 mm 0.0000° 0.0181 µm -2.9597 µm -2.9416 µm 0.0000 µm -2.9416 µm
27 41.097 mm 0.0000° 0.0193 µm -3.0753 µm -3.0560 µm 0.0000 µm -3.0560 µm
28 41.742 mm 0.0000° 0.0206 µm -3.1909 µm -3.1703 µm 0.0000 µm -3.1703 µm
29 42.387 mm 0.0000° 0.0220 µm -3.3065 µm -3.2845 µm 0.0000 µm -3.2845 µm
30 43.032 mm 0.0000° 0.0234 µm -3.4221 µm -3.3987 µm 0.0000 µm -3.3987 µm
31 43.677 mm 0.0000° 0.0248 µm -3.5376 µm -3.5129 µm 0.0000 µm -3.5129 µm

Explanations:
y : Width
φ.t : Static torsion
f.t : Displacement due to torsion
f.b : Displacement due to bending
f.tot : Total displacement (f.b+f.t)
f.C : Change due to flank line modification

Load distribution
Contact stiffness = 19.491 N/mm/µm
Young's modulus = 206000.0/206000.0 N/mm2
y δ g w
1. 40.3226 mm 0.0000 µm 10.3956 µm 202.6245 N/mm
2. 40.9677 mm 0.2352 µm 10.1603 µm 198.0392 N/mm
3. 41.6129 mm 0.4685 µm 9.9270 µm 193.4925 N/mm
4. 42.2581 mm 0.6997 µm 9.6959 µm 188.9863 N/mm
5. 42.9032 mm 0.9289 µm 9.4666 µm 184.5183 N/mm
6. 43.5484 mm 1.1563 µm 9.2393 µm 180.0871 N/mm
7. 44.1935 mm 1.3818 µm 9.0138 µm 175.6921 N/mm
8. 44.8387 mm 1.6054 µm 8.7901 µm 171.3327 N/mm
9. 45.4839 mm 1.8273 µm 8.5683 µm 167.0083 N/mm
10. 46.1290 mm 2.0474 µm 8.3482 µm 162.7184 N/mm

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11. 46.7742 mm 2.2657 µm 8.1298 µm 158.4622 N/mm
12. 47.4194 mm 2.4824 µm 7.9132 µm 154.2393 N/mm
13. 48.0645 mm 2.6974 µm 7.6982 µm 150.0489 N/mm
14. 48.7097 mm 2.9107 µm 7.4848 µm 145.8905 N/mm
15. 49.3548 mm 3.1225 µm 7.2731 µm 141.7634 N/mm
16. 50.0000 mm 3.3326 µm 7.0629 µm 137.6669 N/mm
17. 50.6452 mm 3.5411 µm 6.8544 µm 133.6031 N/mm
18. 51.2903 mm 3.7481 µm 6.6474 µm 129.5685 N/mm
19. 51.9355 mm 3.9536 µm 6.4419 µm 125.5625 N/mm
20. 52.5806 mm 4.1577 µm 6.2378 µm 121.5844 N/mm
21. 53.2258 mm 4.3604 µm 6.0351 µm 117.6335 N/mm
22. 53.8710 mm 4.5618 µm 5.8338 µm 113.7092 N/mm
23. 54.5161 mm 4.7618 µm 5.6338 µm 109.8108 N/mm
24. 55.1613 mm 4.9605 µm 5.4351 µm 105.9376 N/mm
25. 55.8065 mm 5.1579 µm 5.2376 µm 102.0890 N/mm
26. 56.4516 mm 5.3542 µm 5.0414 µm 98.2642 N/mm
27. 57.0968 mm 5.5492 µm 4.8464 µm 94.4627 N/mm
28. 57.7419 mm 5.7431 µm 4.6525 µm 90.6836 N/mm
29. 58.3871 mm 5.9358 µm 4.4597 µm 86.9268 N/mm
30. 59.0323 mm 6.1274 µm 4.2681 µm 83.1924 N/mm
31. 59.6774 mm 6.3180 µm 4.0776 µm 79.4783 N/mm

Explanations:
δ : Gap
g : Flank overlap
w : Line load

Force application point, Y direction: y = 47.808 mm (F = 2777.5 N)

wmax = 202.624 N/mm, wm = 138.873 N/mm

wm = Kv * KA * Kγ * (Ft/b) / cos(αwt)
Kv = 1.067, KA = 1.250, Kγ = 1.000
KHβ = wmax/wm = 1.4591 (Calculation according to ISO 6336-1, Appendix E)

Notice: The influence of the exceeding facewidth is not taken into account in the calculation of KHbeta.

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da1 = 45.6874 mm, df1 = 38.8180 mm, As1 = -0.0540 mmda2 = 163.9684 mm, df2 = 156.9589 mm, As2 = -0.1050 mm
Figure: Path of contact

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank

Figure: Transmission error

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1st Harmonic frequency [1/s] : 1327.500000Harmonics Amplitude [µm]1. 0.2831592. 0.0633833.
0.0108044. 0.0114765. 0.0065096. 0.0053527. 0.0034938. 0.0017659. 0.00400110
Figure: Amplitude spectrum of transmission error

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank

Figure: Stiffness curve

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1st Harmonic frequency [1/s] : 1327.500000Harmonics Amplitude [N/mm/µm]1. 0.7471052. 0.2267753. 0.2198174.
Figure: Amplitude spectrum of contact stiffness

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank

Figure: Normal force curve (Line load)

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank
Figure: Stress curve

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flankMaximum sliding velocity: 1.758 m/s
Figure: Kinematics

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Displaying power losses per mm facewidthWorking flank: Right flank
Figure: Specific Power Loss

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.107the0il = 70.0 °C, theM = 76.0 °C, etaM = 25.88 mPa*sWorking flank:
Right flank
Figure: Flash temperature (ISO TR 15144)

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.107the0il = 70.0 °C, theM = 76.0 °C, etaM = 25.88 mPa*shMini(ISO) = 0.107
µm, Ra = 3.000 µmWorking flank: Right flank
Figure: Lubricating film (ISO TR 15144)

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.107the0il = 70.0 °C, theM = 76.0 °C, etaM = 25.88 mPa*shMini(ISO) = 0.107
µm, Ra = 3.000 µm, lamGFmin = 0.036Working flank: Right flank
Figure: Specific film thickness (ISO TR 15144)

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.107the0il = 70.0 °C, theM = 76.0 °C, etaM = 25.88 mPa*sSlam(ISO) = 0.299,
Ra = 3.000 µmWorking flank: Right flank
Figure: Safety against micropitting (ISO TR 15144)
Remark:
The report contains only the important graphics.
The other graphics can be found in menu 'Graphics' -> 'Contact analysis'.

End of Report lines: 199

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3.2 Report of contact analysis of the end variant with main load
stage
KISSsoft Release 03/2013
KISSsoft-Entwicklungs-Version KISSsoft AG CH-8608 BUBIKON
File
Name : CylGearPair 6a (shafts for contact analysis) (Helical DIN3990)
Description: KISSsoft example
Changed by: ho am: 23.09.2013 um: 16:57:23

Contact analysis
Mesh gear 1 - gear 2 (Right Tooth Flank)
Shaft file A: C:/KISSsoft 03-2013/example/Pinion shaft for CylGearPair 6a.W10, selected gear: Pinion from CylGearPair6 (gears
as masses and stiffness)
Shaft file B: C:/KISSsoft 03-2013/example/Gear shaft for CylGearPair 6a.W10, selected gear: Gear from CylGearPair6 (gears
as masses and stiffness)
(Partial load for calculation wt = 100 %)

Accuracy of calculation medium

Partial load for calculation 100.00 %
Center distance [a] 101.8450 mm
Single pitch deviation [fpt] 0.0000 µm
Coefficient of friction [µ] 0.1011
Torque [T1] 40.463 Nm
Torsion from shaft calculation
min max Δ µ σ
Transmission error (µm) -5.6249 -5.5004 0.1245 -5.5652 0.0417
Stiffness curve (N/mm/µm) 19.9252 20.8398 0.9146 20.3570 0.2159
Line load (N/mm) 0.0000 102.4541 102.4541 66.6563 21.3582
Torque Gear 1 (Nm) 40.4591 40.4670 0.0079 40.4630 0.0020
Torque Gear 2 (Nm) 153.9835 154.1090 0.1256 154.0489 0.0320
Power loss (W) 143.2836 153.7558 10.4722 149.0376 3.2240
Flash temperature (°) 73.1639 111.9055 38.7416 88.7234 9.7977
Lubricating film (µm) 0.1427 0.9937 0.8510 0.2831 0.1508
Hertzian stress (N/mm²) 1201.1029 717.5320
Safety against micropitting 0.3977

Transverse contact ratio under load [εa'] 1.642

Overlap ratio under load [εb'] 0.989
Total contact ratio under load [εg'] 2.632
Efficiency [η] 98.81 %

KHβ Calculation - Gear 1 - Gear 2

Right flank

fma = 0.000 µm , fHβ = 0.000 µm

Result after i = 2 iterations of load distribution
Gear 1
Point in polar co-ordinates:
R = 20.991 mm , φ = 0.000 °
Displacement calculated in direction 111.425 °

y φ1.t f1.t f1.b f1.tot f1.C f1.tot+f1.C

1 40.323 mm -0.0001° 0.0267 µm 0.2901 µm 0.3167 µm 0.0000 µm 0.3167 µm
2 40.968 mm -0.0001° 0.0471 µm 0.5170 µm 0.5641 µm -0.2475 µm 0.3165 µm

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 3 41.613 mm -0.0002° 0.0669 µm 0.7431 µm 0.8100 µm -0.4937 µm 0.3164 µm
4 42.258 mm -0.0003° 0.0859 µm 0.9686 µm 1.0545 µm -0.7384 µm 0.3161 µm
5 42.903 mm -0.0003° 0.1043 µm 1.1932 µm 1.2975 µm -0.9816 µm 0.3159 µm
6 43.548 mm -0.0004° 0.1220 µm 1.4172 µm 1.5391 µm -1.2235 µm 0.3156 µm
7 44.194 mm -0.0004° 0.1390 µm 1.6403 µm 1.7793 µm -1.4640 µm 0.3153 µm
8 44.839 mm -0.0005° 0.1553 µm 1.8627 µm 2.0181 µm -1.7032 µm 0.3149 µm
9 45.484 mm -0.0005° 0.1710 µm 2.0844 µm 2.2554 µm -1.9409 µm 0.3145 µm
10 46.129 mm -0.0005° 0.1860 µm 2.3053 µm 2.4913 µm -2.1773 µm 0.3140 µm
11 46.774 mm -0.0006° 0.2003 µm 2.5254 µm 2.7257 µm -2.4123 µm 0.3134 µm
12 47.419 mm -0.0006° 0.2139 µm 2.7447 µm 2.9586 µm -2.6459 µm 0.3127 µm
13 48.065 mm -0.0007° 0.2269 µm 2.9632 µm 3.1901 µm -2.8781 µm 0.3120 µm
14 48.710 mm -0.0007° 0.2392 µm 3.1810 µm 3.4201 µm -3.1090 µm 0.3111 µm
15 49.355 mm -0.0007° 0.2508 µm 3.3979 µm 3.6487 µm -3.3385 µm 0.3102 µm
16 50.000 mm -0.0008° 0.2617 µm 3.6140 µm 3.8757 µm -3.5666 µm 0.3092 µm
17 50.645 mm -0.0008° 0.2719 µm 3.8293 µm 4.1012 µm -3.7931 µm 0.3080 µm
18 51.290 mm -0.0008° 0.2814 µm 4.0437 µm 4.3251 µm -4.0184 µm 0.3068 µm
19 51.935 mm -0.0009° 0.2903 µm 4.2573 µm 4.5476 µm -4.2422 µm 0.3054 µm
20 52.581 mm -0.0009° 0.2984 µm 4.4701 µm 4.7686 µm -4.4646 µm 0.3039 µm
21 53.226 mm -0.0009° 0.3059 µm 4.6821 µm 4.9881 µm -4.6857 µm 0.3024 µm
22 53.871 mm -0.0009° 0.3127 µm 4.8933 µm 5.2061 µm -4.9054 µm 0.3007 µm
23 54.516 mm -0.0009° 0.3189 µm 5.1037 µm 5.4226 µm -5.1237 µm 0.2989 µm
24 55.161 mm -0.0010° 0.3244 µm 5.3133 µm 5.6376 µm -5.3406 µm 0.2970 µm
25 55.806 mm -0.0010° 0.3291 µm 5.5220 µm 5.8512 µm -5.5562 µm 0.2950 µm
26 56.452 mm -0.0010° 0.3333 µm 5.7299 µm 6.0632 µm -5.7704 µm 0.2928 µm
27 57.097 mm -0.0010° 0.3367 µm 5.9371 µm 6.2738 µm -5.9832 µm 0.2906 µm
28 57.742 mm -0.0010° 0.3395 µm 6.1434 µm 6.4829 µm -6.1946 µm 0.2883 µm
29 58.387 mm -0.0010° 0.3415 µm 6.3489 µm 6.6904 µm -6.4046 µm 0.2858 µm
30 59.032 mm -0.0010° 0.3429 µm 6.5535 µm 6.8964 µm -6.6131 µm 0.2833 µm
31 59.677 mm -0.0010° 0.3435 µm 6.7574 µm 7.1010 µm -6.8203 µm 0.2807 µm

Gear 2
Point in polar co-ordinates:
R = 80.854 mm , φ = 180.000 °
Displacement calculated in direction 111.425 °

y φ2.t f2.t f2.b f2.tot f2.C f2.tot+f2.C

1 24.323 mm 0.0000° 0.0000 µm -0.0589 µm -0.0589 µm 0.0000 µm -0.0589 µm
2 24.968 mm 0.0000° 0.0001 µm -0.1767 µm -0.1767 µm 0.1172 µm -0.0594 µm
3 25.613 mm 0.0000° 0.0002 µm -0.2945 µm -0.2943 µm 0.2344 µm -0.0600 µm
4 26.258 mm 0.0000° 0.0003 µm -0.4122 µm -0.4119 µm 0.3514 µm -0.0605 µm
5 26.903 mm 0.0000° 0.0005 µm -0.5299 µm -0.5295 µm 0.4684 µm -0.0611 µm
6 27.548 mm 0.0000° 0.0007 µm -0.6476 µm -0.6469 µm 0.5853 µm -0.0616 µm
7 28.194 mm 0.0000° 0.0010 µm -0.7653 µm -0.7643 µm 0.7022 µm -0.0621 µm
8 28.839 mm 0.0000° 0.0013 µm -0.8829 µm -0.8816 µm 0.8189 µm -0.0626 µm
9 29.484 mm 0.0000° 0.0017 µm -1.0004 µm -0.9988 µm 0.9356 µm -0.0631 µm
10 30.129 mm 0.0000° 0.0021 µm -1.1180 µm -1.1159 µm 1.0522 µm -0.0637 µm
11 30.774 mm 0.0000° 0.0025 µm -1.2355 µm -1.2330 µm 1.1688 µm -0.0642 µm
12 31.419 mm 0.0000° 0.0030 µm -1.3530 µm -1.3499 µm 1.2853 µm -0.0647 µm
13 32.065 mm 0.0000° 0.0036 µm -1.4704 µm -1.4668 µm 1.4016 µm -0.0652 µm
14 32.710 mm 0.0000° 0.0042 µm -1.5878 µm -1.5836 µm 1.5180 µm -0.0657 µm
15 33.355 mm 0.0000° 0.0048 µm -1.7052 µm -1.7004 µm 1.6342 µm -0.0661 µm
16 34.000 mm 0.0000° 0.0055 µm -1.8225 µm -1.8170 µm 1.7504 µm -0.0666 µm
17 34.645 mm 0.0000° 0.0062 µm -1.9398 µm -1.9336 µm 1.8665 µm -0.0671 µm
18 35.290 mm 0.0000° 0.0070 µm -2.0571 µm -2.0501 µm 1.9825 µm -0.0676 µm
19 35.935 mm 0.0000° 0.0079 µm -2.1743 µm -2.1665 µm 2.0984 µm -0.0681 µm
20 36.581 mm 0.0000° 0.0087 µm -2.2915 µm -2.2828 µm 2.2143 µm -0.0685 µm
21 37.226 mm 0.0000° 0.0096 µm -2.4087 µm -2.3991 µm 2.3301 µm -0.0690 µm
22 37.871 mm 0.0000° 0.0106 µm -2.5258 µm -2.5152 µm 2.4458 µm -0.0694 µm

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 23 38.516 mm 0.0000° 0.0116 µm -2.6429 µm -2.6313 µm 2.5614 µm -0.0699 µm
24 39.161 mm 0.0000° 0.0127 µm -2.7600 µm -2.7473 µm 2.6770 µm -0.0703 µm
25 39.806 mm 0.0000° 0.0138 µm -2.8770 µm -2.8632 µm 2.7925 µm -0.0707 µm
26 40.452 mm 0.0000° 0.0149 µm -2.9940 µm -2.9791 µm 2.9079 µm -0.0712 µm
27 41.097 mm 0.0000° 0.0161 µm -3.1110 µm -3.0948 µm 3.0233 µm -0.0716 µm
28 41.742 mm 0.0000° 0.0174 µm -3.2279 µm -3.2105 µm 3.1385 µm -0.0720 µm
29 42.387 mm 0.0000° 0.0186 µm -3.3448 µm -3.3261 µm 3.2537 µm -0.0724 µm
30 43.032 mm 0.0000° 0.0200 µm -3.4616 µm -3.4416 µm 3.3688 µm -0.0728 µm
31 43.677 mm 0.0000° 0.0213 µm -3.5784 µm -3.5571 µm 3.4839 µm -0.0732 µm

Explanations:
y : Width
φ.t : Static torsion
f.t : Displacement due to torsion
f.b : Displacement due to bending
f.tot : Total displacement (f.b+f.t)
f.C : Change due to flank line modification

Load distribution
Contact stiffness = 19.491 N/mm/µm
Young's modulus = 206000.0/206000.0 N/mm2
y δ g w
1. 40.3226 mm 0.0217 µm 7.0971 µm 138.3327 N/mm
2. 40.9677 mm 0.0221 µm 7.0967 µm 138.3258 N/mm
3. 41.6129 mm 0.0224 µm 7.0964 µm 138.3191 N/mm
4. 42.2581 mm 0.0228 µm 7.0961 µm 138.3129 N/mm
5. 42.9032 mm 0.0231 µm 7.0958 µm 138.3072 N/mm
6. 43.5484 mm 0.0233 µm 7.0955 µm 138.3023 N/mm
7. 44.1935 mm 0.0235 µm 7.0953 µm 138.2984 N/mm
8. 44.8387 mm 0.0237 µm 7.0952 µm 138.2956 N/mm
9. 45.4839 mm 0.0237 µm 7.0951 µm 138.2941 N/mm
10. 46.1290 mm 0.0237 µm 7.0951 µm 138.2940 N/mm
11. 46.7742 mm 0.0237 µm 7.0952 µm 138.2954 N/mm
12. 47.4194 mm 0.0235 µm 7.0953 µm 138.2985 N/mm
13. 48.0645 mm 0.0233 µm 7.0956 µm 138.3034 N/mm
14. 48.7097 mm 0.0229 µm 7.0959 µm 138.3101 N/mm
15. 49.3548 mm 0.0225 µm 7.0964 µm 138.3188 N/mm
16. 50.0000 mm 0.0219 µm 7.0969 µm 138.3295 N/mm
17. 50.6452 mm 0.0212 µm 7.0976 µm 138.3425 N/mm
18. 51.2903 mm 0.0205 µm 7.0984 µm 138.3577 N/mm
19. 51.9355 mm 0.0196 µm 7.0993 µm 138.3750 N/mm
20. 52.5806 mm 0.0186 µm 7.1003 µm 138.3946 N/mm
21. 53.2258 mm 0.0174 µm 7.1014 µm 138.4165 N/mm
22. 53.8710 mm 0.0162 µm 7.1026 µm 138.4406 N/mm
23. 54.5161 mm 0.0149 µm 7.1040 µm 138.4670 N/mm
24. 55.1613 mm 0.0134 µm 7.1055 µm 138.4956 N/mm
25. 55.8065 mm 0.0118 µm 7.1070 µm 138.5265 N/mm
26. 56.4516 mm 0.0101 µm 7.1087 µm 138.5596 N/mm
27. 57.0968 mm 0.0083 µm 7.1105 µm 138.5948 N/mm
28. 57.7419 mm 0.0064 µm 7.1125 µm 138.6322 N/mm
29. 58.3871 mm 0.0044 µm 7.1145 µm 138.6717 N/mm
30. 59.0323 mm 0.0022 µm 7.1166 µm 138.7132 N/mm
31. 59.6774 mm 0.0000 µm 7.1188 µm 138.7566 N/mm

Explanations:
δ : Gap
g : Flank overlap
w : Line load

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Force application point, Y direction: y = 50.007 mm (F = 2768.2 N)

wmax = 138.757 N/mm, wm = 138.409 N/mm

wm = Kv * KA * Kγ * (Ft/b) / cos(αwt)
Kv = 1.063, KA = 1.250, Kγ = 1.000
KHβ = wmax/wm = 1.0025 (Calculation according to ISO 6336-1, Appendix E)

Notice: The influence of the exceeding facewidth is not taken into account in the calculation of KHbeta.

da1 = 45.6874 mm, df1 = 38.8180 mm, As1 = -0.0540 mmda2 = 163.9684 mm, df2 = 156.9589 mm, As2 = -0.1050 mm
Figure: Path of contact

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank
Figure: Transmission error

1st Harmonic frequency [1/s] : 1327.500000Harmonics Amplitude [µm]1. 0.0562442. 0.0133453.

0.0106724. 0.0021435. 0.0033786. 0.0014957. 0.0003798. 0.0010179. 0.00260310
Figure: Amplitude spectrum of transmission error

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank
Figure: Stiffness curve

1st Harmonic frequency [1/s] : 1327.500000Harmonics Amplitude [N/mm/µm]1. 0.1991012. 0.0761093. 0.0311604.
Figure: Amplitude spectrum of contact stiffness

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank
Figure: Normal force curve (Line load)

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flank

Figure: Stress curve

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Working flank: Right flankMaximum sliding velocity: 1.683 m/s
Figure: Kinematics

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101Displaying power losses per mm facewidthWorking flank: Right flank
Figure: Specific Power Loss

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101the0il = 70.0 °C, theM = 73.2 °C, etaM = 28.70 mPa*sWorking flank:
Right flank
Figure: Flash temperature (ISO TR 15144)

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101the0il = 70.0 °C, theM = 73.2 °C, etaM = 28.70 mPa*shMini(ISO) = 0.143
µm, Ra = 3.000 µmWorking flank: Right flank
Figure: Lubricating film (ISO TR 15144)

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wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101the0il = 70.0 °C, theM = 73.2 °C, etaM = 28.70 mPa*shMini(ISO) = 0.143
µm, Ra = 3.000 µm, lamGFmin = 0.048Working flank: Right flank
Figure: Specific film thickness (ISO TR 15144)

wt = 100 %, a = 101.845 mm,fpt = 0.000 µm,µ = 0.101the0il = 70.0 °C, theM = 73.2 °C, etaM = 28.70 mPa*sSlam(ISO) = 0.398,
Ra = 3.000 µmWorking flank: Right flank
Figure: Safety against micropitting (ISO TR 15144)
Remark:
The report contains only the important graphics.
The other graphics can be found in menu 'Graphics' -> 'Contact analysis'.

End of Report lines: 199

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